Roadster 2023 Ryker - Service Manual - Sm61y023 - en

Vehicle Service Manual
Includes Safety, Use and Maintenance

Information
2023 Ryker Series
Version A
WARNING
Disregarding any of the safety precautions and instructions contained in this service manual
could cause injury including the possibility of death.
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 Cali-
fornia 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 ve-
hicle. For more information go to
www.p65warnings.ca.gov/products/passenger-vehicle.
All rights reserved. No parts of this Manual may be reproduced in any form without the prior written per-
mission of Bombardier Recreational Products Inc.
©Bombardier Recreational Products Inc. (BRP) 2022
™®Trademarks of BRP or its affiliates.

This document contains the trademarks of the following companies:
TABLE OF CONTENTS
01 S A F E T Y N O T I C E ....................................................................................................................... 1
S A F E T Y N O T I C E . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . . 2
IMPORTANT SAFETY PRECAUTIONS ................................................................................. 3
02 I N T R O D U C T I O N ........................................................................................................................ 5
G E N E R A L I N F O R M A T I O N . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . . 6
V E H I C L E I N F O R M A T I O N . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . . 7
VEHICLE IDENTIFICATION NUMBER (V.I.N.)....................................................................... 7
ENGINE IDENTIFICATION NUMBER (EIN) ........................................................................... 7
EPA COMPLIANCE LABEL (NORTH AMERICAN MODELS)................................................ 7
COMPLIANCE LABELS (AUSTRALIAN MODELS)................................................................ 8
L I F T I N G A N D S U P P O R T I N G T H E V E H I C L E . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 1 0
FRONT OF VEHICLE ............................................................................................................ 10
REAR OF VEHICLE............................................................................................................... 10
M A N U A L I N F O R M A T I O N . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 1 1
MANUAL PROCEDURES...................................................................................................... 11
TIGHTENING TORQUES ...................................................................................................... 11
F A S T E N E R I N F O R M A T I O N . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 1 3
SELF-LOCKING FASTENERS PROCEDURE ..................................................................... 13
LOCTITE® APPLICATION PROCEDURE............................................................................. 13
THREADLOCKER APPLICATION FOR UNCOVERED HOLES (BOLTS AND NUTS) ........................... 13
THREADLOCKER APPLICATION FOR BLIND HOLES .................................................................. 13
THREADLOCKER APPLICATION FOR STUD INSTALLATION IN BLIND HOLES ............................... 14
THREADLOCKER APPLICATION FOR PRE-ASSEMBLED PARTS ................................................. 14
THREADLOCKER APPLICATION FOR AN ADJUSTMENT SCREW................................................. 14
APPLICATION FOR STRIPPED THREAD REPAIR ....................................................................... 14
GASKET COMPOUND APPLICATION ....................................................................................... 15
THREADLOCKER APPLICATION FOR MOUNTING ON A SHAFT................................................... 15
THREADLOCKER APPLICATION FOR CASE-IN COMPONENTS (METALLIC GASKETS) ................... 16
03 M A I N T E N A N C E ....................................................................................................................... 1 7
P E R I O D I C M A I N T E N A N C E S C H E D U L E . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 1 8
MAINTENANCE ..................................................................................................................... 18
SEVERE DUSTY CONDITIONS ................................................................................................ 18
PRE-RIDE INSPECTION ......................................................................................................... 19
MAINTENANCE SCHEDULE .................................................................................................... 19
S T O R A G E P R O C E D U R E . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 2 3
GENERAL .............................................................................................................................. 23
PROCEDURES...................................................................................................................... 23
FUEL SYSTEM ...................................................................................................................... 23
ENGINE ............................................................................................................................... 23
COOLING SYSTEM ................................................................................................................ 23
ELECTRICAL SYSTEM ........................................................................................................... 24
WHEELS AND TIRES ............................................................................................................. 24
BRAKE SYSTEM.................................................................................................................... 24
VEHICLE .............................................................................................................................. 24
P R E S E A S O N P R E P A R A T I O N . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 2 5
PROCEDURES...................................................................................................................... 25
VEHICLE PREPARED AS PER STORAGE PROCEDURE.............................................................. 25
VEHICLE NOT PREPARED AS PER STORAGE PROCEDURE....................................................... 25
III
TABLE OF CONTENTS
0 4 E N G I N E ..................................................................................................................................... 2 7
E N G I N E R E M O V A L A N D I N S T A L L A T I O N . . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 2 8
GENERAL .............................................................................................................................. 30
PROCEDURES...................................................................................................................... 30
ENGINE ............................................................................................................................... 30
ENGINE MOUNTS.................................................................................................................. 32
A I R I N T A K E S Y S T E M . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 3 3
GENERAL .............................................................................................................................. 34
PROCEDURES...................................................................................................................... 34
AIR FILTER........................................................................................................................... 34
AIR INTAKE SILENCER .......................................................................................................... 34
E X H A U S T S Y S T E M .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 6
GENERAL .............................................................................................................................. 37
INSPECTION ......................................................................................................................... 37
PROCEDURES...................................................................................................................... 37
HEATED OXYGEN SENSOR (HO2S) ......................................................................................... 37
MUFFLER............................................................................................................................. 39
CATALYTIC CONVERTER....................................................................................................... 40
EXHAUST PIPE GASKET ........................................................................................................ 40
EXHAUST MANIFOLD ............................................................................................................ 40
C O O L I N G S Y S T E M - V E H I C L E C O M P O N E N T S . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 4 3
GENERAL .............................................................................................................................. 45
SYSTEM DESCRIPTION ......................................................................................................... 45
MAINTENANCE ..................................................................................................................... 45
ENGINE COOLANT ................................................................................................................ 45
INSPECTION ......................................................................................................................... 47
COOLING SYSTEM LEAK TEST ............................................................................................... 47
TROUBLESHOOTING........................................................................................................... 47
TROUBLESHOOTING............................................................................................................. 48
PROCEDURES...................................................................................................................... 48
COOLANT TEMPERATURE SENSOR (CTS)............................................................................... 48
PRESSURE CAP ................................................................................................................... 49
CLAMPS .............................................................................................................................. 49
RADIATOR ........................................................................................................................... 50
RADIATOR COOLING FAN ...................................................................................................... 50
0 5 E L E C T R O N I C M A N A G E M E N T S Y S T E M S .......................................................................... 5 3
E N G I N E M A N A G E M E N T S Y S T E M .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 5 4
GENERAL .............................................................................................................................. 54
ENGINE MANAGEMENT SYSTEM (EMS)................................................................................... 55
VEHICLE STABILITY SYSTEM (VSS) ........................................................................................ 57
C O N T R O L L E R A R E A N E T W O R K ( C A N ) . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 5 8
GENERAL .............................................................................................................................. 58
C O M M U N I C A T I O N T O O L S .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 5 9
REQUIRED COMMUNICATION TOOLS .............................................................................. 59
MULTI-PURPOSE INTERFACE CARD (MPI-2 OR MPI-3) .............................................................. 59
DIAGNOSTIC CONNECTOR LOCATION............................................................................. 59
DIAGNOSTIC TIPS................................................................................................................. 59
D I A G N O S T I C A N D F A U L T C O D E S ( P R E M I U M G A U G E ) . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 6 1
GENERAL .............................................................................................................................. 61
MONITORING SYSTEM .......................................................................................................... 61
IV
TABLE OF CONTENTS
FAULT CODES ...................................................................................................................... 62

SPECIFIC FAULTS................................................................................................................. 65
06 F U E L S Y S T E M ......................................................................................................................... 6 7
F U E L T A N K A N D F U E L P U M P . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 6 8
GENERAL .............................................................................................................................. 69
INSPECTION ......................................................................................................................... 70
DEPRESSURIZING FUEL SYSTEM........................................................................................... 70
TESTING THE FUEL SYSTEM FOR LEAKS ................................................................................ 70
TESTING THE FUEL SYSTEM PRESSURE ................................................................................ 71
VENT VALVE / ROLLOVER VALVE ........................................................................................... 72
TROUBLESHOOTING TIPS ..................................................................................................... 73
PROCEDURES...................................................................................................................... 73
OETIKER CLAMP................................................................................................................... 73
FUEL FILTER ........................................................................................................................ 74
FUEL TANK .......................................................................................................................... 75
FUEL PUMP.......................................................................................................................... 76
FUEL LEVEL SENSOR............................................................................................................ 79
FUEL PRESSURE REGULATOR .............................................................................................. 79
EVAP PURGE VALVE ............................................................................................................. 80
EVAP CANISTER ................................................................................................................... 82
07 E L E C T R I C A L S Y S T E M ........................................................................................................... 8 3
P O W E R D I S T R I B U T I O N A N D G R O U N D S . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 8 4
GENERAL .............................................................................................................................. 84
POWER DISTRIBUTION DIAGRAM........................................................................................... 84
OVERVIEW........................................................................................................................... 84
FUSES................................................................................................................................. 84
RELAY ACTIVATION .............................................................................................................. 85
GROUNDS ........................................................................................................................... 85
W I R I N G H A R N E S S A N D C O N N E C T O R S . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 8 6
GENERAL .............................................................................................................................. 86
CONNECTOR ABBREVIATION DESCRIPTION ........................................................................... 87
WIRING HARNESS SPLICE LOCATION ..................................................................................... 89
PROCEDURES...................................................................................................................... 92
SPLICE REPAIR PROCEDURES .............................................................................................. 92
BATTERY CABLE TERMINAL .................................................................................................. 94
I G N I T I O N S Y S T E M . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 9 5
GENERAL .............................................................................................................................. 95
IGNITION SYSTEM TESTING................................................................................................... 96
DIAGNOSTIC GUIDELINES ..................................................................................................... 96
PROCEDURES...................................................................................................................... 97
EMERGENCY ENGINE STOP SWITCH...................................................................................... 97
D.E.S.S. POST ...................................................................................................................... 98
START BUTTON .................................................................................................................... 98
STOP SWITCH ...................................................................................................................... 98
C H A R G I N G S Y S T E M . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 9 9
GENERAL .............................................................................................................................. 99
INSPECTION ......................................................................................................................... 99
V
TABLE OF CONTENTS
CHARGING SYSTEM OUTPUT ................................................................................................ 99

TROUBLESHOOTING......................................................................................................... 100
PROCEDURES.................................................................................................................... 100
VOLTAGE REGULATOR WIRE IDENTIFICATION ...................................................................... 100
LOAD TESTING THE BATTERY.............................................................................................. 100
LOAD TESTING THE CHARGING SYSTEM .............................................................................. 101
VOLTAGE REGULATOR (RD) ................................................................................................ 101
BATTERY ........................................................................................................................... 103
S T A R T I N G S Y S T E M .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 0 6
GENERAL ............................................................................................................................ 106
SYSTEM DESCRIPTION ....................................................................................................... 106
DIAGNOSTIC GUIDELINES ................................................................................................... 106
PROCEDURES.................................................................................................................... 106
STARTER SOLENOID........................................................................................................... 106
D I G I T A L L Y E N C O D E D S E C U R I T Y S Y S T E M ( D . E . S . S . ) . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 1 0
DIAGNOSTIC GUIDELINES ................................................................................................... 110
PROCEDURES.................................................................................................................... 110
IGNITION KEY..................................................................................................................... 110
RF D.E.S.S. POST OPERATION ............................................................................................. 111
L I G H T S . . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 1 2
GENERAL ............................................................................................................................ 112
SYSTEM DESCRIPTION (LIGHTING SYSTEM) ......................................................................... 112
DIAGNOSTIC TIPS............................................................................................................... 117
PROCEDURES.................................................................................................................... 118
HEADLIGHTS...................................................................................................................... 118
LICENSE PLATE LIGHT ........................................................................................................ 123
FRONT TURN SIGNAL AND HAZARD WARNING LIGHTS........................................................... 123
TURN SIGNAL LIGHT SWITCH............................................................................................... 124
HAZARD WARNING LIGHTS SWITCH ..................................................................................... 124
TAILLIGHT/BRAKE LIGHT/FLASHERS .................................................................................... 125
FRONT POSITION LIGHTS, TURN SIGNAL LIGHTS AND HAZARD WARNING LIGHTS.................... 127
BACK UP LIGHT .................................................................................................................. 127
G A U G E 4 . 5 " C O M P A C T . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 3 1
GENERAL ............................................................................................................................ 131
INDICATOR LAMPS DESCRIPTION ........................................................................................ 131
DIAGNOSTIC TIPS............................................................................................................... 132
MULTIFUNCTION GAUGE TROUBLESHOOTING...................................................................... 132
PROCEDURES.................................................................................................................... 132
MULTIFUNCTION GAUGE..................................................................................................... 132
0 8 D R I V E S Y S T E M ..................................................................................................................... 1 3 5
P R O P E L L E R S H A F T A N D R E A R W H E E L .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 3 6
GENERAL ............................................................................................................................ 138
PROCEDURES.................................................................................................................... 138
REAR WHEEL ..................................................................................................................... 138
REAR TIRE ......................................................................................................................... 140
FINAL DRIVE UNIT............................................................................................................... 140
PROPELLER SHAFT ............................................................................................................ 143
PROPELLER SHAFT U-JOINT................................................................................................ 143
VI
TABLE OF CONTENTS
09 C H A S S I S ................................................................................................................................. 1 4 5
V E H I C L E S T A B I L I T Y S Y S T E M ( V S S ) . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 4 6
GENERAL ............................................................................................................................ 146
SYSTEM DESCRIPTION (FEATURES) .................................................................................... 146
SYSTEM DESCRIPTION (COMPONENTS) ............................................................................... 147
TROUBLESHOOTING TIPS ................................................................................................... 151
PROCEDURES.................................................................................................................... 151
YAW RATE SENSOR (YRS) ................................................................................................... 151
PILLION RIDER (PASSENGER) SWITCH (PRS) ........................................................................ 153
BRAKE FLUID LEVEL SENSOR (BFS) ..................................................................................... 153
WHEEL SPEED SENSOR (WSS) ............................................................................................ 154
VEHICLE CONTROL MODULE (VCM)...................................................................................... 155
S T E E R I N G A N D F R O N T W H E E L S . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 5 9
GENERAL ............................................................................................................................ 161
TIRE PRESSURE ................................................................................................................ 161
WHEEL ALIGNMENT .......................................................................................................... 161
THEORY OF AN ALIGNMENT ................................................................................................ 161
PREREQUISITES ................................................................................................................ 162
ALIGNMENT PROCEDURE ................................................................................................... 162
REAR WHEEL ALIGNMENT................................................................................................... 165
RESETTING THE SAS ........................................................................................................ 165
PROCEDURES.................................................................................................................... 165
FRONT WHEELS ................................................................................................................. 165
FRONT TIRES ..................................................................................................................... 167
MIRRORS........................................................................................................................... 169
AIR DEFLECTOR ................................................................................................................. 169
HANDLEBAR GRIP .............................................................................................................. 170
LEFT HAND MULTIFUNCTION SWITCH .................................................................................. 170
RIGHT HAND MULTIFUNCTION SWITCH ................................................................................ 171
HANDLEBAR ...................................................................................................................... 171
THROTTLE HANDLE ............................................................................................................ 173
STEERING COLUMN............................................................................................................ 174
TIE-ROD ............................................................................................................................ 174
INTERMEDIATE ROD ........................................................................................................... 175
KNUCKLE........................................................................................................................... 175
UPPER BALL JOINT ............................................................................................................. 176
WHEEL AXLE...................................................................................................................... 177
WHEEL BEARING ................................................................................................................ 178
STEERING ANGLE SENSOR (SAS) ........................................................................................ 179
A D J U S T I N G T H E S U S P E N S I O N . . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 8 0
SUSPENSION ADJUSTMENT GUIDELINES..................................................................... 180
SUSPENSION FACTORY SETTINGS................................................................................ 180
SPRING PRELOAD ADJUSTMENT.................................................................................... 181
SHOCK DAMPING ADJUSTMENT ..................................................................................... 181
F R O N T S U S P E N S I O N .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 8 2
GENERAL ............................................................................................................................ 183
PROCEDURES.................................................................................................................... 183
SHOCK ABSORBER............................................................................................................. 183
UPPER SUSPENSION ARM................................................................................................... 183
UPPER BALL JOINT ............................................................................................................. 184
LOWER SUSPENSION ARM .................................................................................................. 184
LOWER BALL JOINT ............................................................................................................ 186
PIVOT BUSHINGS ............................................................................................................... 187
VII
TABLE OF CONTENTS
STABILIZER BAR................................................................................................................. 187

LINK ROD........................................................................................................................... 188
R E A R S U S P E N S I O N .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 8 9
GENERAL ............................................................................................................................ 191
PROCEDURES.................................................................................................................... 191
ACS SOLENOID VALVE ........................................................................................................ 191
SHOCK ABSORBER............................................................................................................. 192
SWING ARM ....................................................................................................................... 194
B R A K E S . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 9 7
GENERAL ............................................................................................................................ 201
SYSTEM DESCRIPTION ....................................................................................................... 201
FAULT CODES .................................................................................................................... 201
SYSTEM COMPONENTS DESCRIPTION ................................................................................. 201
INSPECTION ....................................................................................................................... 201
BRAKE SYSTEM PRESSURE VALIDATION.............................................................................. 201
TROUBLESHOOTING TIPS ................................................................................................... 202
PROCEDURES.................................................................................................................... 202
BRAKE FLUID ..................................................................................................................... 202
CALIPER ............................................................................................................................ 203
BRAKE PADS...................................................................................................................... 204
BRAKE DISC....................................................................................................................... 205
BRAKE PEDAL .................................................................................................................... 206
MASTER CYLINDER ............................................................................................................ 207
BRAKE LIGHT SWITCH (BLS) ................................................................................................ 208
WHEEL SPEED SENSOR (WSS) ............................................................................................ 210
VEHICLE CONTROL MODULE (VCM)...................................................................................... 210
B O D Y . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 2 1 1
RYKER SERIES................................................................................................................... 212
GENERAL ............................................................................................................................ 220
VEHICLE CARE ................................................................................................................... 220
PROCEDURES.................................................................................................................... 220
DECALS............................................................................................................................. 220
SERVICE COVERS .............................................................................................................. 221
FRONT FASCIA ................................................................................................................... 223
ROCKER PANELS ............................................................................................................... 223
UPPER BODY MODULE........................................................................................................ 224
DRIVER SEAT ..................................................................................................................... 232
GLOVE BOX COVER ............................................................................................................ 233
FOOTRESTS ...................................................................................................................... 234
REAR FENDER ................................................................................................................... 234
F R A M E . . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 2 3 6
GENERAL ............................................................................................................................ 237
PROCEDURES.................................................................................................................... 237
FRAME .............................................................................................................................. 237
1 0 T E C H N I C A L S P E C I F I C A T I O N S .......................................................................................... 2 3 9
R Y K E R .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 2 4 0
1 1 W I R I N G D I A G R A M I N F O R M A T I O N .................................................................................... 2 4 7
W I R I N G D I A G R A M I N F O R M A T I O N . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 2 4 8
GENERAL ............................................................................................................................ 248
WIRING DIAGRAM LOCATION............................................................................................... 248
WIRING DIAGRAM WITH COLORED LINES ............................................................................. 248
VIII
TABLE OF CONTENTS
WIRING DIAGRAM CODES ................................................................................................... 249

DIAGNOSTIC TIPS............................................................................................................... 249
IX
SERVICE TOOLS INDEX
65mm socket D.E.S.S. Post Remover Pressure gauge

(P/N 529036457) (P/N 529035943) (P/N 529036395)
Page:138, 166–167 Page:111
Alignment adaptor B RYKER Diagnostic cable

Front wheels (P/N 710000851)
(P/N 529036482) Page:71
Page:59 Rear wheel bearing pusher

(P/N 529036246)
Page:162
ECM adapter tool
Alignment adaptor C RYKER (P/N 529036166) Page:186
rear wheels
(P/N 529036483) Retaining beam
(P/N 529036477)
Page:38, 49, 77, 81, 97
Page:162 Page:226, 230
Fuel hose adapter
Alignment screw (P/N 529036509) Spring compressor
(P/N 529036490) (P/N 529036184)
Page:183, 193
Page:71
Page:174
Spring installer/remover
Fuel pump nut tool (P/N 529035983)
Alignment tool
(P/N 529036475) (P/N 529035899)
Page:39
Page:77–78 Steering column spacer 8,34

Page:162 (P/N 529036476)
MPI-3 interface card Page:174
Backlash measurement tool (P/N 529036353)
(P/N 529036387)
Stem puller
(P/N 529036459)
Page:59
Page:173
Page:142 Oetiker pliers
(P/N 295000070) Test cap
Ball joint remover support (P/N 529035991)
(P/N 529036121)
Page:49, 73
Page:186 Page:47
1
SERVICE TOOLS INDEX
Vacuum/pressure pump
(P/N 529021800)
Page:47, 72, 80
2
SERVICE TOOLS — OTHER SUPPLIER INDEX
Optional extension cableDo not

exceed 7.5 m (25 ft)
(Not sold by BRP)
Page:59
3
SERVICE PRODUCTS INDEX
BRP heavy duty cleaner

Page:157
Dielectric grease
Page:104
Extended life pre-mixed coolant

Page:23
Fuel stabilizer
Page:23
Loctite 243 (blue)

Page:205
Loctite 767 (anti-seize lubricant)

Page:39
Oil storage
Page:23
XPS Roadster wash

Page:24, 220
XPS synthetic grease

Page:139, 207
XPS synthetic suspension

grease
Page:194
5
01
SAFETY NOTICE
1
Safety Notice
Safety Notice
01 Safety Notice
Safety Notice CAUTION

Indicates a hazardous situation which, if not
This manual has been prepared as a guide to cor- avoided, could result in minor or moderate
rectly service and repair the Can-Am On-Road injury.
vehicles.
This edition was primarily published to be used by NOTICE
mechanical technicians who are already familiar
with all service procedures relating to BRP prod- Indicates an instruction which, if not followed,
ucts. Mechanical technicians should attend train- could result in severe damage to vehicle
ing courses given by BRPTI. components or other property.
Please note that the instructions in this manual will N O T E : Indicates supplementary information re-
apply only if proper hand tools and special service quired to fully complete an instruction.
tools are used.
The contents of this manual depicts parts and/or Although the mere reading of such information
procedures applicable to a particular product at does not eliminate the hazard, your understanding
the time of writing. Service and warranty bulletins of the information provided will promote its correct
may be published to update the content of this use.
manual. Dealer modifications that were carried out Always observe common shop safety practice.
after manufacturing of the product, whether or not
authorized by BRP, are not included. Unless otherwise noted, the engine must be
stopped and the tether cord must be removed pri-
In addition, the sole purpose of the illustrations or to perform any services.
throughout the manual, is to assist identification of
the general configuration of the parts. They are Torque wrench tightening specifications must be
not to be interpreted as technical drawings or ex- strictly adhered to. Use the torque values and
act replicas of the parts. service products as in the exploded views or in the
procedures when noted.
The use of BRP parts is most strongly recom-
mended when considering replacement of any Locking devices when removed must be replaced
component. Dealer and/or distributor assistance (e. g.: locking tabs, elastic stop nuts, self-locking
should be sought in case of doubt. fasteners, cotter pins, etc.).
The engines and the corresponding components Hoses, cables and locking ties removed during a
identified in this document should not be utilized procedure must be reinstalled as per factory
on product (s) other than those mentioned in this standards.
document. When ordering parts always refer to the specific
It is understood that certain modifications may ren- model Parts Catalogs.
der use of the vehicle illegal under existing federal, We strongly recommend that any services be car-
provincial and state regulations. ried out and/or verified by a highly skilled profes-
This manual emphasizes particular information sional mechanic.
which, is denoted by the following wording and It is understood that this manual may be translated
symbols: into another language. In the event of any discrep-
ancy, the English version shall prevail.
WARNING
Indicates a potential hazard that, if not BRP disclaims liability for all damages and/or inju-
avoided, could result in serious injury or ries resulting from the improper use of the con-
death. tents of this publication.
2
Safety Notice
Safety Notice
Important Safety Precautions manuals. Only you can decide whether or not you
We do not provide warnings about many basic should perform a given task. 01
shop safety practices (e.g.: Use Grinding Wheel –
wear safety glasses). If you have not received
shop safety training or do not feel confident about
your knowledge of safe servicing practices, we
recommend that you do not attempt to perform the
procedures described in BRP shop manuals.
You should have a clear understanding of all basic
shop safety practices. You should be wearing the
appropriate clothing, using appropriate safety
equipment and taking all necessary safety precau-
tions. Please be especially careful of the following:
– Read and understand all instructions before
you begin a procedure or repair.
– Ensure you have the proper tools, any neces-
sary replacement parts and the skills to per-
form the tasks safely and completely.
– Protect your eyes by using approved and prop-
erly fitted safety glasses.
– Use other protective wear when necessary, for
example safety shoes and gloves.
– Unless the service procedure requires that the
engine remain running, make sure the engine
is off b e f o r e beginning service.
– Be sure there is adequate ventilation whenever
you run the engine, to avoid the risk of Carbon
Monoxide poisoning.
– To avoid injury from moving parts, make sure
your hands, fingers and clothing are out of the
way when the engine is running.
– Gasoline vapors and hydrogen gases from bat-
teries are explosive. Keep all cigarettes, sparks
and flames away from the battery, fuel-related
components and other enclosed
compartments.
– Never use gasoline to clean parts, always use
an approved nonflammable solvent.
– Never drain or store gasoline in an open
container.
WARNING
The foregoing list represents general safety
practices. For details on workplace health
and safety requirements in your area, consult
your local workplace health and safety
agency or association.
We have provided you with some of the most im-

portant general service safety precautions, above.
We cannot, however, warn you of every conceiv-
able hazard that can arise in performing the serv-
ice and repair procedures depicted in BRP
3
Notes
Notes Notes
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
4
02
INTRODUCTION
5
Introduction
General Information
02 Introduction
General Information
The information and component/system descrip-
tions contained in this manual are correct at time
of writing. BRP however, maintains a policy of
continuous improvement of its products without
imposing upon itself any obligation to install them
on products previously manufactured.
Due to late changes, there may be some differen-
ces between the manufactured product and the
description and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.
6
Introduction
Vehicle Information
Vehicle Information Engine Identification Number (EIN)
Vehicle Identification Number (V.I.N.)

Canadian and USA Models
Bombardier Recreational Products Inc. DATE: XXXXX

02
GVWR/PNBV: XXX kg ( XXXX lb)
GAWR/PNBE: FR/AV: XXX kg ( XXXX lb)-RR/AR: XXX kg ( XXXX lb)
THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL
MOTOR VEHICLE SAFETY STANDARDS (FMVSS) IN EFFECT
ON THE DATE OF MANUFACTURE SHOWN ABOVE.
V.I.N. / N.I.V. :XXXXXXXXXXXXXXXXX
U.S. TYPE : MOTORYCLE - CAN TYPE: TRI - CAN ICES-2/NMB-2 7393
CURB WEIGHT / POIDS À VIDE : XXX kg ( XXXX lb)-MOD : XXXX
ASSEMBLED IN MEXICO / ASSEMBLÉ AU MEXIQUE
1 2
VEHICL E SERIAL NUM BER LABEL
1. VIN (Vehicle Identification Number)
2. Model number
600 ACE ENGINE
All Other Models 1. EIN (Engine Identification Number) location
Bombardier Recreational Products Inc

TYPE: L5e-A 2
XXXXXXXXXXXXXXXXX
1 V.I.N. :XXXXXXXXXXXXXXXXX
7394
XXXX dB(A) - XXXXX min-1

max XXXX kg - DATE: XXXXX - MOD: XXXX
ASSEMBLED IN MEXICO / ASSEMBLÉ AU MEXIQUE
TYPICAL - VEHICLE SERIAL NUMBER L ABEL

1. VIN (Vehicle Identification Number)
2. Model number
900 ACE ENGINE

1. EIN (Engine Identification Number) location
EPA Compliance Label (North

American Models)
This label is located inside the glove box.
TYPICAL - UNDER THE SEAT, AFFIX ON THE LEFT LOWER

REAR TUBE
7
Introduction
Vehicle Information
VEHICLE EMISSION CONTROL INFORMATION VEHICLE EMISSION CONTROL INFORMATION

BOMBARDIER RECREATIONAL PRODUCTS INC. BOMBARDIER RECREATIONAL PRODUCTS INC.
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS THIS VEHICLE CONFORMS TO U.S. EPA AND CALIFORNIA REGULATIONS
APPLICABLE TO MODEL YEAR NEW MOTORCYCLES AND IS CERTIFIED APPLICABLE TO MODEL YEAR NEW MOTORCYCLES AND IS CERTIFIED
TO AN HC+NOx EMISSION STANDARD OF GRAM/KILOMETER. TO AN HC+NOx EMISSION STANDARD OF GRAM/KILOMETER.
CERTIFIED FOR SALE IN ALL U.S. STATES EXCEPT CALIFORNIA.
RENSEIGNEMENT SUR LE DISPOSITIF ANTIPOLLUTION
BOMBARDIER PRODUITS RÉCRÉATIFS INC.
RENSEIGNEMENT SUR LE DISPOSITIF ANTIPOLLUTION CE VÉHICULE EST CONFORME AUX RÈGLEMENTS DE L'EPA DES É.U. ET DE LA
BOMBARDIER PRODUITS RÉCRÉATIFS INC. CALIFORNIE APPLICABLES AUX MOTOCYCLETTES NEUVES DE L'ANNÉE
CE VÉHICULE EST CONFORME AUX RÈGLEMENTS DE L'EPA DES É.U. MODÈLE ET EST CERTIFIÉ À LA NORME D'ÉMISSIONS HC+NOx de
APPLICABLES AUX MOTOCYCLETTES NEUVES DE L'ANNÉE GRAMME/KILOMÈTRE.
MODÈLE ET EST CERTIFIÉ À LA NORME D'ÉMISSIONS HC+NOx de
GRAMME/KILOMÈTRE. CERTIFIÉ POUR LA VENTE DANS TOUS LES ÉTATS DES Engine Displacement Cylindrée
É.U. SAUF LA CALIFORNIE.
Engine Family Famille de moteur
Permeation Family Famille de perméation
Evaporation Family Famille d’évaporation
Exhaust Emission Système de contrôle
Engine Displacement Cylindrée Control System des émissions
Engine Family Famille de moteur Idle Speed Ralenti moteur
Permeation Family Famille de perméation Fuel Essence 704907055
Exhaust Emission Système de contrôle

Control System des émissions VACUUM HOSE ROUTING
Idle Speed Ralenti moteur ENGINE FAMILY: EVAPORATION FAMILY:
Fuel Essence 704907709 INTAKE PLENUM
FUEL TANK
EVAP PURGE CONTROL
SOLENOID VALVE
MOTORCYCLE NOISE EMISSION CONTROL INFORMATION
THIS MOTORCYCLE, , MEETS U.S EPA NOISE EVAP CANISTER
EMISSION REQUIREMENTS OF dBA AT RPM BY THE FEDERAL TEST TO OPEN AIR
PROCEDURE. MODIFICATIONS WHICH CAUSE THIS MOTORCYCLE TO EXCEED
FEDERAL NOISE STANDARDS ARE PROHIBITED BY FEDERAL LAW. MOTORCYCLE NOISE EMISSION CONTROL INFORMATION
SEE OPERATOR’S GUIDE. THIS MOTORCYCLE, , MEETS U.S EPA NOISE
EMISSION REQUIREMENTS OF dBA AT RPM BY THE FEDERAL TEST
PROCEDURE. MODIFICATIONS WHICH CAUSE THIS MOTORCYCLE TO EXCEED
FEDERAL NOISE STANDARDS ARE PROHIBITED BY FEDERAL LAW.
SEE OPERATOR’S GUIDE.
TYPICAL - EXCEPT CALIFORNIA MODEL S
TYPICAL - CALIFORNIA MODELS
Compliance Labels (Australian Models)

This label is affixed on the right lower rear tube.
8
Introduction
Vehicle Information
APPROVAL No: xxxxx CATEGORY LEM2

BRP AUSTRALIA PTY LTD
BRP CAN AM XXXXXX
VIN
xx/xx XXXXXXXXXXXXXXXXX
THIS VEHICLE WAS MANUFACTURED TO COMPLY
02
WITH THE MOTOR VEHICULE STANDARD ACT 1989
TYPICAL - AUSTRALIA ADR LABEL
9
Introduction
Lifting and Supporting the Vehicle
Lifting and Supporting

the Vehicle
WARNING
Never lift both ends of the vehicle at the same
time.
Front of Vehicle
Place the vehicle on a level surface and apply
parking brake.
Place an hydraulic jack in the middle of the front of
the vehicle. Lift the rear of vehicle.
Install jack stands under the vehicle.
Lift the front of vehicle.

Install jack stands under the vehicle. Lower vehicle and ensure it is supported safely
onto both jack stands.
Lower vehicle and ensure it is supported safely

onto both jack stands.
Rear of Vehicle
Place the vehicle on a level surface and apply
parking brake.
Place an hydraulic jack in the middle of the rear of
the vehicle.
10
Introduction
Manual Information
Manual Information In order to avoid a poor assembly, tighten screws,

bolts, or nuts in accordance with the following
Manual Procedures procedure:
Many of the procedures in this manual are interre- 1. Manually screw all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
lated. Before undertaking any task, you should
read and thoroughly understand the entire section 3. Tighten fastener to the recommended torque 02
or subsection in which the procedure is contained. value.
WARNING NOTICE
Unless otherwise specified, the engine Be sure to use the recommended tightening
should be turned OFF and cold for all mainte- torque for the specified fastener used.
nance and repair procedures.
N O T E : When possible, always apply torque on
A number of procedures throughout the book re- the nut.
quire the use of special tools. Before starting any
procedure, be sure that you have on hand all re- N O T E : Always torque screws, bolts and/or nuts
quired tools, or their approved equivalents. using a crisscross pattern when multiple fasteners
are used to secure a part (eg. a cylinder head).
The use of RIGHT and LEFT indications in the text Some parts must be torqued according to a specif-
are always referenced to the driving position (sit- ic sequence and torque pattern as detailed in the
ting on the vehicle). installation procedure.
FAS FASTENER GRADE/TORQUE

TEN
TYPICAL ER 5.8 8.8 10.9 12.9
1. Left Grade Grade Grade Grade
2. Right SIZE
This manual uses technical terms which may be 1.5 – 2 2.5 – 3 3.5 - 4 4 - 5 Nm
different from the ones of the Parts Catalogs. M4 Nm (13 – Nm (22 – Nm (31 - (35 - 44
18 lbf-in) 27 lbf-in) 35 lbf-in) lbf-in)
When ordering parts always refer to the specific
model Parts Catalog. 3 - 3.5 4.5 - 5.5 7 - 8.5 8 - 10
M5 Nm (27 - Nm (40 - Nm (62 - Nm (71 -
Tightening Torques 31 lbf-in) 49 lbf-in) 75 lbf-in) 89 lbf-in)
Tighten fasteners to the torque specified in the ex- 8 - 12 10.5 – 15
ploded view (s) and/or in the written procedure. 6.5 - 8.5 16 Nm
Nm (71 - Nm (93 –
When a torque is not specified, refer to the follow- M6 Nm (58 - (142 lbf-
106 lbf- 133 lbf-
ing table. 75 lbf-in) in)
in) in)
WARNING 15 Nm
25 Nm 32 Nm 40 Nm
Torque wrench tightening specifications must M8 (133 lbf-
(18 lbf-ft) (24 lbf-ft) (30 lbf-ft)
be strictly adhered to. in)
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners, 29 Nm 48 Nm 61 Nm 73 Nm
M10
cotter pins, etc.) must be replaced. (21 lbf-ft) (35 lbf-ft) (45 lbf-ft) (54 lbf-ft)
11
Introduction
Manual Information
52 Nm 85 Nm 105 Nm 128 Nm
M12 (38 lbf-ft) (63 lbf-ft) (77 lbf-ft) (94 lbf-ft)
135 Nm 170 Nm 200 Nm

85 Nm
M14 (100 lbf- (125 lbf- (148 lbf-
(63 lbf-ft)
ft) ft) ft)
12
Introduction
Fastener Information
Threadlocker Application for Uncovered Holes

Fastener Information (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 re-
02
placed by customary fasteners or vice-versa.
Mismatched or incorrect fasteners could
cause damage to the vehicle or possible per-
sonal injury.
Self-Locking Fasteners Procedure
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.

2. Apply Loctite 7649 (Primer) on threads and al-
low to dry.
3. Choose proper strength Loctite threadlocker.
4. Fit bolt in the hole.
5. Apply a few drops of threadlocker at proposed
TYPICAL — SELF-LOCKING FASTENER
tightened nut engagement area.
6. Position nut and tighten as required.
The following describes common procedures used
when working with self-locking fasteners. Threadlocker Application for Blind Holes
Use a metal brush or a tap to properly clean a

threaded hole, then use a solvent. Allow the sol-
vent time to act, approximately 30 minutes, then
wipe off. Solvent utilization is to ensure proper ad-
hesion of the product used for locking the
fastener.
Loctite® Application Procedure

The following describes common procedures used
when working with Loctite products.
N O T E : Always use proper strength Loctite prod-
1. On fastener threads
uct as recommended in this Shop Manual. 2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.

2. Apply Loctite 7649 (Primer) on threads (bolt
and nut) and allow to dry for 30 seconds.
3. Choose proper strength Loctite threadlocker.
4. Apply several drops along the threaded hole
and at the bottom of the hole.
5. Apply several drops on bolt threads.
6. Tighten as required.
13
Introduction
Threadlocker Application for Stud Installation 5. Avoid touching metal with tip of flask.
in Blind Holes
N O T E : For preventive maintenance on existing
equipment, retighten nuts and apply proper
strength Loctite on bolt/nut contact surfaces.
Threadlocker Application for an Adjustment
Screw
1. On stud threads
2. On threads and in the hole
3. On retaining nut threads
1. Clean threads (stud and hole) with solvent.

2. Apply Loctite 7649 (Primer) on threads and al-
low to dry.
3. Put 2 or 3 drops of proper strength Loctite
threadlocker on female threads and in hole.
1. Apply here
N O T E : To avoid a hydro lock situation, do not 2. Plunger
apply too much Loctite. 1. Adjust screw to proper setting.
2. Apply a few drops of proper strength Loctite
4. Apply several drops of proper strength Loctite
threadlocker on screw/body contact surfaces.
on stud threads.
3. Avoid touching metal with tip of flask.
5. Install stud.
6. Install cover, part, etc. N O T E : If it is difficult to readjust, heat screw with
7. Apply a few drops of proper strength Loctite on a soldering iron (232 °C (450 °F)).
uncovered stud threads.
8. Install and tighten retaining nut(s) as required. Application for Stripped Thread Repair
Threadlocker Application for Pre-Assembled
Parts
1. Release agent
2. Stripped threads
3. Form-A-Thread
4. Tapes
2 5. Cleaned bolt
A00A3OA 6. Plate
7. New threads
1. Apply here
8. Threadlocker
2. Do not apply
1. Clean bolts and nuts with solvent. Standard Thread Repair

2. Assemble components. Follow instructions on Loctite FORM-A-THREAD
3. Tighten nuts. 81668 package.
4. Apply a few drops of proper strength Loctite on
bolt/nut contact surfaces. If a plate is used to align bolt:
14
Introduction
1. Apply release agent on mating surfaces. 4. Apply Loctite 518 on both sides of gasket, us-
2. Put waxed paper or similar film on the ing a clean applicator.
surfaces. 5. Place gasket on mating surfaces and assem-
3. Twist bolt when inserting it to improve thread ble parts immediately.
conformation.
N O T E : NOT intended for engine stud repairs.
N O T E : If the cover is bolted to blind holes, apply
proper strength Loctite in the hole and on threads.
02
Tighten fastener.
Repair of Small Holes/Fine Threads
If holes are sunken, apply proper strength Loc-
Option 1: Enlarge damaged hole, then follow tite on bolt threads.
Standard Thread Repair procedure. 6. Tighten as usual.
Option 2: Apply FORM-A-THREAD on the screw Threadlocker Application for Mounting on a
and insert in damaged hole. Shaft
Permanent Stud Installation (Light Duty) Mounting with a Press
1. Use a stud of the desired thread length.
2. DO NOT apply release agent on stud.
3. Follow Standard Thread Repair procedure.
4. Allow 30 minutes for Loctite FORM-A-
THREAD to cure.
5. Complete part assembly.
Gasket Compound Application
1. Bearing
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.
N O T E : Retaining compound is always forced out
when applied on shaft.
4. DO NOT use antiseize Loctite or any similar

1. Proper strength Loctite product.
2. Loctite Primer N and Gasket Eliminator 518 5. No curing period is required.
on both sides of gasket
3. Loctite Primer N only Mounting in Tandem
1. Remove old gasket and other contaminants 1. Apply retaining compound on internal contact
using Loctite chisel (gasket remover). Use a surface (bore) of parts to be installed.
mechanical means only if necessary. 2. Continue parts assembly as per previous
illustration.
N O T E : Avoid grinding.
2. Clean both mating surfaces with solvent.
3. Spray Loctite Primer N on both mating surfa-
ces and on both sides of gasket and allow to
dry 1 or 2 minutes.
15
Introduction
Threadlocker Application for Case-In

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

diameter.
2. Spray housing and gasket with Loctite 7649
(Primer).
3. Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
N O T E : 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.

5. Wipe off excess product.
6. Allow 30 minutes for product to cure.
N O T E : Normally used on worn-out housings to

prevent leaking or sliding.
It is generally not necessary to remove gasket

compound applied on outer gasket diameter.
16
03
MAINTENANCE
17
Maintenance
Periodic Maintenance Schedule
03 Maintenance
Maintenance
Maintenance is very important for keeping your vehicle in safe operating condition.
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.
Perform periodic checks and follow the maintenance schedule. T h e m a i n t e n a n c e s c h e d u l e d o e s n o t
exempt the pre-ride inspection.
Verifying fault codes, as first maintenance step, is a good practice and is highly recommended.
WARNING
Failure to properly maintain the vehicle according to the maintenance schedule and procedures
can make it unsafe to operate.
EPA Regulation - Canadian and USA Vehicles

A r e p a i r s h o p o r p e r s o n o f t h e o w n e r ' s c h o o s i n g m a y m a i n t a i n , r e p l a c e , o r r e p a i r emission control
devices and systems. These instructions do not require components or service by BRP or authorized
Can-Am On-Road dealers.
Although an authorized Can-Am On-Road dealer has an in-depth technical knowledge and tools to serv-
ice your vehicle, the emission-related warranty is not conditioned on the use of an authorized Can-Am
On-Road dealer or any other establishment with which BRP has a commercial relationship.
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.
Severe Dusty Conditions
Ryker 900 Rally Edition
Engine air filter and CVT air filter maintenance should be adjusted according to riding conditions.
The filters 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.
Riding in a group in these conditions would increase even more the filters maintenance.
18
Maintenance
Pre-Ride Inspection
Before starting the vehicle, inspect the following:
Item Procedure
Ensure that total load on the vehicle (including operator, cargo and added
Weight accessories) does not exceed recommended load as indicate in the technical
specifications section.
Glove box and all

Pull to check that it is properly latched.
03
service covers
Park position lever Make sure park position lever is applied and locked.
Handlebar, footpegs
Ensure vehicle is configured for the driver. Adjust as required.
and brake pedal
Press and make sure you feel firm resistance. Pedal must fully return when
Brake pedal released. Validate that the driver is able to apply the full stroke of the brake
pedal.
Twist several times. Be sure it operates freely and returns to idle position
Throttle handle
when released.
Leaks Look under the vehicle for any leaks.
RED Locking clip of

Check if all red locking clips are properly installed. If not, THE VEHICLE
the center lock wheel
MUST NOT BE USED.
NUT
Wheel Look for damages.
Tires Look for damages. Verify tread wear. Check tire pressure.
Mirrors Clean and adjust
Start the vehicle and inspect the following:
Item Procedure
Multifunction gauge Check the indicators, the messages and the fuel level
Check operation of headlights, taillights, brake lights, turn signals and, if

Lights
equipped, the hazard warning lights.
Horn Check operation.
Steering Verify that steering operates freely.
Engine stop switch Check that the engine stop switch is working properly.
Press brake pedal and release park position lever. Ensure brake indicator
Park position lever
lamp is off in the multifunction gauge.
Brake Drive a short distance forward slowly then apply brake to test.
Maintenance Schedule
Make sure to perform proper maintenance at recommended intervals as indicated in the tables.
19
Maintenance
The maintenance chart indicates the items needing to be addressed based on 2 criteria, whichever hap-
pens first:
– Calendar time
– Odometer reading.
Your driving habits will determine which criteria you should adhere too. For example:
– Someone who uses their vehicle daily or for frequent long weekend rides would follow the o d o m e t e r
r e a d i n g to determine the frequency of his maintenance.
– Someone using their vehicle seldomly over the year or only on a few occasions (vacation, short rides
every few weekends) would follow the c a l e n d a r t i m e to determine the frequency of his maintenance.
I M P O R T A N T : The following table shows the appropriate maintenance application for the first 2 years.
For subsequent years, repeat the same pattern alternatively.
Maintenance Overview
Calendar Years Odometer Regular Duty
1 10 000 km (6,000 mi) A
2 20 000 km (12,000 mi) A and B
20
Maintenance
Regular Maintenance A B
A = Adjust
C = Clean
Every year Every 2 years
I = Inspect
or or
L = Lubricate
10 000 km (6,000 mi) 20 000 km (12,000 mi)
R = Replace
T = Torque
Air Delivery
R
03
Dusty or wet conditions:
Engine air filter
R
Every 10 000 km (6,000 mi), regardless of calendar time
C
Engine air filter housing Dusty or wet conditions:

C
Every 10 000 km (6,000 mi), regardless of calendar time
Engine
Engine oil and oil filter R
Engine seals and gaskets I
R
Spark plugs Every 20 000 km (12,000 mi), regardless of calendar
time
Cooling
Engine cooling components (coolant concentration, coolant level,
I, A
hose condition, clamps, leaks)
Radiator C
R
Coolant
Every 5 years or 50 000 km (30,000 mi)
Exhaust
Exhaust clamp rings I, T
Exhaust components (gaskets, pipes, muffler condition, leaks) I
Fuel Delivery
Fuel components and function (Fuel hoses, clamps, fuel
I
evaporation lines and canister, leaks)
R
Fuel filter
Brake
Brake components and function I
R
Brake fluid
Every 2 years, , regardless the odometer
Drive
Drive components and function I, L
Tires I, A
Rear final drive oil R
Gearbox oil R
21
Maintenance
Regular Maintenance A B
A = Adjust
C = Clean
Every year Every 2 years
I = Inspect
or or
L = Lubricate
10 000 km (6,000 mi) 20 000 km (12,000 mi)
R = Replace
T = Torque
Continuously Variable Transmission (CVT)
CVT air filter R
I, C, L
Every 20 000 km (12,000 mi), regardless calendar time
CVT components and function
or when the message TRANSMISSION
MAINTENANCE REQUIRED appears
R
Every 20 000 km (12,000 mi), regardless calendar time
CVT drive belt
or when the message TRANSMISSION
MAINTENANCE REQUIRED appears
Electrical
Battery connections and condition I
Modules and applicable software updates I
Operation of control switches and lighting I
Steering
Steering components and function I
Handlebar clamp I, A
Controls
Park position lever operation I, A
Throttle operation I
Body and Frame
Body panels and hardware I, T
Pivots, latches, hinges and key barrels L
Suspension
I
Suspension components and function
22
Maintenance
Storage Procedure
Storage Procedure
SERVICE PRODUCTS
Description Part Number Page
EXTENDED LIFE PRE-MIXED COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
........................
........................
23
23 03
OIL STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 23
XPS ROADSTER WASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 24
General mode (throttle wide open and depress start

If the vehicle is not ridden for at least 4 months, button).
such as during the winter, proper storage is neces-
sary to keep the vehicle in good condition. Oil storage
Procedures
Fuel System
Protecting the Fuel System
1. With the new fuel additives, it is critical to use
the fuel stabilizer to prevent fuel deterioration
and fuel system gumming. Follow the manu-
facturer's instructions for proper use.
Fuel stabilizer
2. Pour fuel stabilizer in fuel tank before filling up.
NOTICE
Engine should be run after fuel stabilizer is 3. Reinstall clamp securing air intake manifold
added to ensure fuel system components adapter to throttle body.
protection against varnish deposits.
N O T E : Do not run engine during storage period.
3. Do not drain fuel system.
Cooling System
Engine
Inspecting the Coolant
Replacing the Engine Oil and Filter 1. Check coolant level.
Change engine oil and filter. Refer to Lubrication 2. Test coolant density using an antifreeze
System subsection. hydrometer.
Lubricating the Engine Internal Parts Extended life pre-mixed coolant
Engine internal parts should be lubricated to pro-
tect them from rust formation during the storage
period.
Proceed as follows:
1. Loosen clamp securing air intake manifold
adapter to throttle body.
2. Spray oil storage into throttle body (5 seconds
in each openings) while cranking in drowned
23
Maintenance
Storage Procedure
NOTE: Follow manufacturer's instructions for Using warm water works well to remove bugs
proper use. in the windshield and front panels.
For M a t t e f i n i s h e s , hand-wash with a soft
NOTICE
wash mitt and a mild cleaning product safe for
Do not use tap water, straight antifreeze or matte paint. To remove foreign substances
straight water in the system. Tap water con- such as insects, use a soft applicator and a
tains minerals and impurities which build up mild solvent. Saturate and soak area before
in the system. Straight water will cause the cleaning. Rub lightly.
system to freeze while straight antifreeze will 3. While washing the vehicle, check for grease or
cause system temperature problems. oil. You can use the following XPS product or a
mild automotive degreaser. Thoroughly follow
3. Change coolant if necessary. Refer to Cooling the manufacturer's instructions.
System.
XPS Roadster wash
Electrical System
Charging the Battery 4. Dry the vehicle with a chamois or a soft towel.
Slow charge the battery once a month at the rec- Waxing the Vehicle
ommended charging rate of 2 A. It is not neces-
sary to remove the battery. Surface Product/Precaution
Wheels and Tires Glossy Apply only non-abrasive wax,
finishes safe for clear coat paints
Tire Pressure
Inflate all tires to their recommended pressure. Matte Do not apply wax
finishes
Brake System
Inspecting the Brake Fluid Level WARNING
Check brake fluid level. Refill if necessary. Do not apply a vinyl or plastic protector on
the seat as the surface will become slippery
Lubricating the Brake System and the operator or the passenger may slip
Lubricate brake pedal pivot. off the vehicle.
Vehicle Protecting the Vehicle
Cleaning the Vehicle 1. Touch up all metal spots where paint has been
To clean the vehicle, d o n o t u s e h i g h - p r e s s u r e scratched off.
w a s h e r s (like the ones found in car washes) as 2. Install a plastic bag over muffler outlet to pre-
they may damage certain parts of the vehicle. vent moisture from entering it.
3. Cover the vehicle with a permeable material.
NOTICE Avoid using plastic or similar non-breathing,
For Matte finishes, do not use wax, detail coated materials that restrict air flow and allow
spray, or other products used on regular heat and moisture to accumulate.
paint. Do not wash with abrasive materials. 4. Store vehicle in a dry unheated area, away
Do not use mechanical cleaners or polishers, from sunlight, with a small amount of daily tem-
and do not rub the surfaces vigorously. perature variation.
To clean the vehicle:

1. Rinse the vehicle thoroughly with water to re-
move loose dirt.
2. Using a soft, clean cloth, wash the vehicle with
water mixed with a mild detergent, such as
soap specially formulated for motorcycles or
automobiles.
24
Maintenance
Preseason Preparation
Preseason Preparation – Check the level of engine coolant. Refer to

Cooling System - Vehicle Components
Prior to use the vehicle, proper preparation is re- subsection.
quired after the storage period. – Check the brake fluid level. Refer to Brakes
subsection.
Any worn, broken or damaged parts found during – Replace engine oil and filter. Refer to Lubrica-
the storage procedure should have been replaced. tion System subsection.
If not, proceed with the replacement.
Procedures 03
Vehicle Prepared as per Storage Procedure
Remove vehicle protective cover, muffler protec-
tive bag and clean the vehicle.
Charge battery as required. Refer to Charging
System.
Check the following items:
– T i r e s : Look for damage, incorrect inflation and
excessive tread wear.
– W h e e l s a n d c e n t e r l o c k w h e e l n u t s : Look for
damage. Be sure the RED locking clip pins are
in place.
– L e a k s : Look under the vehicle for any leaks.
– B r a k e p e d a l : Press and make sure you feel
firm resistance. Pedal must fully return when
released.
– T h r o t t l e h a n d l e : Twist a few times. Be sure it
operates freely and returns to idle position
when released.
– S h i f t L e v e r : Move shift lever in Forward and
Reverse position.
Wake up the vehicle by pressing briefly the Start
button:
1. Check the gauge, indicator lamps, and mes-
sages on the multifunction gauge cluster.
2. Ensure all lights work properly.
3. Ensure horn is working properly.
4. Verify if the steering operates freely.
5. Check that the engine stop switch is working
properly.
6. Start engine, release the park lever parking
brake and ensure the indicator is off on the
multifunction gauge cluster.
7. Drive forward slowly a few feet then apply
brake to test.
Vehicle not Prepared as per Storage
Procedure
Proceed with the same steps as specified in Ve-
hicles Prepared as per Storage Procedure above.
Carry out these additional steps:
25
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
26
04
ENGINE
27
Engine
Engine Removal and Installation
04 Engine
Engine Removal and

Installation
600 ACE
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
See tightening sequence
25 ± 3 N•m
(18 ± 2 lbf•ft)
NEW
7 ± 1 N•m
(62 ± 9 lbf•in)
NEW 24.5 ± 3.5 N•m

24.5 ± 3.5 N•m (18 ± 3 lbf•ft)
(18 ± 3 lbf•ft) See tightening
sequence NEW
NEW
7 ± 1 N•m
(62 ± 9 lbf•in) NEW
7 ± 1 N•m
(62 ± 9 lbf•in)
25 ± 3 N•m
(18 ± 2 lbf•ft) NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
See tightening
sequence
NEW
25 ± 3 N•m 7 ± 1 N•m
(18 ± 2 lbf•ft) (62 ± 9 lbf•in)
NEW = Component must be replaced when removed.
28
Engine
900 ACE
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
25 ± 3 N•m
(18 ± 2 lbf•ft)
NEW
7 ± 1 N•m
(62 ± 9 lbf•in)
NEW
24.5 ± 3.5 N•m
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
04
(18 ± 3 lbf•ft) See tightening
sequence NEW
NEW
7 ± 1 N•m
7 ± 1 N•m
(62 ± 9 lbf•in)
25 ± 3 N•m
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
NEW
25 ± 3 N•m 7 ± 1 N•m
(18 ± 2 lbf•ft) (62 ± 9 lbf•in)
29
Engine
General
CAUTION
To avoid potential burns, let engine and ex-
haust system cool down.
During assembly/installation, use the tightening

torque values and service products as in the ex-
ploded view.
Clean threads before applying a threadlocker. Re-
fer to Self-Locking Fasteners and Loctite Applica-
tion at the beginning of this manual for complete
procedure.
8. Remove coolant tank with water pump hose.
WARNING
Torque wrench tightening specifications must
be strictly adhered to.
Locking devices when removed must be re-
placed (e.g.: locking tabs, elastic stop nuts,
cotter pins, etc.).
NOTICE
Hoses, cables or locking ties removed during
the procedure must be reinstalled as per fac-
tory standard.
Procedures 9. Disconnect thermostat hose at housing and

ENGINE set aside.
Removing the Engine
1. Place vehicle on a workstation that will have
access to an engine-lifting hoist.
2. Remove battery.
3. Remove the upper body module.
4. Remove the propeller shaft.
5. Remove air intake silencer, engine air inlet and
their support on the engine.
N O T E : Place a clean shop rag in throttle body to
prevent dirt and contaminants entering.
6. Drain engine coolant.

7. Remove thermostat and water pump Oeitiker 10. Remove muffler.
clamps. 11. Remove the engine mounting screws.
30
Engine
3. Tighten fasteners as per sequence in

illustration.
12. Slightly lift the engine by the eyelet.

04
N O T E : Refer to Shim Installation Procedure be-

fore final tightening.
4. Tighten screws to specification.
Tightening Torque
24.5 ± 3.5 Nm
Engine mount screw
(18 ± 3 lbf-ft)
5. Fill cooling system.

6. Check oil level.
7. Install battery.
N O T E : Cut any locking ties from hoses or wiring 8. Start engine and let it reach its operating
harness that prevent engine removal. temperature.
9. Stop engine and check coolant and oil levels.
13. Disconnect connector A from ECM. Refill as necessary.
10. Test drive vehicle to confirm proper operation.
Shim Installation Procedure
Before tightening the rear RH engine mount,
measure distance between engine mount and
frame.
Install shim to properly support engine.
14. Remove engine.

Installing the Engine
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
1. Prior to installing engine, inspect condition of
engine mounts, replace if necessary.
2. Install all mounting screws.
31
Engine
5. Remove front engine mount.

Rear Rubber Mounts
1. Pivot upper body module, refer to Body
subsection.
2. Loosen engine mount screws.
NOTICE
If more than one shim is required, inspect
frame and engine support.
ENGINE MOUNTS
Removing the Engine Mounts 3. Remove skid plate.
Front Rubber Mount
1. Remove upper body module, refer to Body
subsection.
2. Loosen engine mount screws.
4. Using a floor jack and a piece of wood, support

engine while removing engine mounts.
5. Remove rear engine mount from engine.
Installing the Engine Mounts
3. Remove skid plate.
Front Rubber Mounts
The installation is the reverse of the removal
procedure.
Rear Rubber Mounts
procedure.
Reinstall correct shim on RH side.
4. Using a floor jack and a piece of wood, support

engine while removing engine mounts.
32
Engine
Air Intake System
Air Intake System

1.7 ± 0.2 N•m
(15 ± 2 lbf•in)
1.7 ± 0.2 N•m

(15 ± 2 lbf•in)
04
NEW
1 ± 0.2 N•m
(9 ± 2 lbf•in)
NEW
7.5 ± 1 N•m
(66 ± 9 lbf•in)
1.7 ± 0.2 N•m

(15 ± 2 lbf•in)
NEW
7.5 ± 1 N•m
(66 ± 9 lbf•in)
1 ± 0.2 N•m
(9 ± 2 lbf•in)
33
Engine
Air Intake System
General Cleaning the Air Filter

WARNING Inspect air filter for cleanliness and damage.
To avoid potential burns, never touch ex- NOTICE
haust system components immediately after It is not recommended to blow compressed
the engine has been run as these compo- air on the paper filter. This could damage the
nents are very hot. Let engine and exhaust paper fibers and reduce its filtration ability
system cool down before performing any when used in dusty environments.
servicing.
NOTICE
WARNING
Do not wash the paper filter with any cleaning
Torque wrench tightening specifications must solution.
be strictly adhered to. Locking devices must
be replaced when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners, NOTICE
cotter pins, etc.). Inspect air intake silencer and remove any
dust or debris, taking care not to blow or
Hoses, cables or locking ties removed during a move anything inside the clean side of the
procedure must be reinstalled as per factory engine air inlet (past air filter).
standards.
NOTICE
Procedures
Remove any dust or debris that may have
AIR FILTER moved or shifted inside the clean side of the
Removing the Air Filter air intake silencer (past air filter). Clean by
pulling on the dust and not pushing it inside.
1. The air filter is located under the left service
cover.
2. Remove the left service cover. Replace air filter as necessary according to rec-
3. Remove the air filter from the cover. ommended maintenance schedule and particular
use (especially in dusty environments).
Installing the Air Filter
Make sure the ring on which the air filter sits is flat
and well positioned before seating the air filter.
AIR INTAKE SILENCER
Removing the Air Intake Silencer
1. Pivot the upper body module.
2. Loosen the clamps securing the air intake si-
lencer to the air intake adaptor.
NOTICE
Remove air filter slowly to keep dust and de-
bris from falling into the clean area of the air
intake silencer (passed air filter).
34
Engine
Air Intake System
Tightening Torques
7.5 ± 1 Nm
Retaining screws
(66 ± 9 lbf-in)
Engine air inlet 1.7 ± 0.2 Nm
adapter clamp (15 ± 2 lbf-in)
3. Remove retaining screws securing the air in-

04
take silencer to the engine.
4. Remove air intake silencer.

Installing the Air Intake Silencer
NOTICE
Make sure air intake silencer and engine air
inlet are clean and that no debris or dust are
in the silencer before installation.
Install N E W retaining screws.
35
Engine
Exhaust System
Exhaust System
SERVICE TOOLS
ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036166) . . . . . . . . . . . . . . . . . . . . . 38, 49

OETIKER PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 295000070) . . . . . . . . . . . . . . . . . . . . . . . . 49
SPRING INSTALLER/REMOVER . . . . . . . . . . . . . . . . . . . . (P/N 529035983) . . . . . . . . . . . . . . . . . . . . . . . . 39
TEST CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529035991) . . . . . . . . . . . . . . . . . . . . . . . . 47
VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . (P/N 529021800) . . . . . . . . . . . . . . . . . . . . . . . . 47
SERVICE PRODUCTS
LOCTITE 767 (ANTI-SEIZE LUBRICANT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

NEW
48 ± 6 N•m
10 ± 2 N•m (35 ± 4 lbf•ft)
(89 ± 18 lbf•in)
NEW
NEW
NEW
10 ± 2 N•m
(89 ± 18 lbf•in)
7 ± 1 N•m
(62 ± 9 lbf•in)
Loctite 243
NEW
600 ACE

NEW
900 ACE
Loctite 243
10 ± 2 N•m 7 ± 1 N•m
(89 ± 18 lbf•in) (62 ± 9 lbf•in)
NEW
NEW
10 ± 2 N•m
(89 ± 18 lbf•in)
36
Engine
Exhaust System
General – Do not use any compound on sensor threads

unless labeled as compatible with oxygen
WARNING sensor.
To avoid potential burns, never touch ex- – Do not use impact wrench or conventional
haust system components immediately after socket type wrench to install sensor.
the engine has been run as these compo- – Do not allow sensor or wire to touch exhaust
nents are very hot. Let engine and exhaust system or any other hot component.
system cool down before performing any – Do not route sensor wires to create tension in
servicing. the wires. This could cause faults or sensor
malfunction.
WARNING Oxygen Sensor Troubleshooting
Torque wrench tightening specifications must Always use BUDS2 to check for fault codes. Carry
be strictly adhered to. Locking devices must out service actions. 04
be replaced when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners, In BUDS2, also check oxygen sensor voltage and
cotter pins, etc.). refer to following table.
Oxygen Sensor Voltage in BUDS2

Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory Voltage Reading Condition
standards.
Normal oxygen sensor
Inspection Varies 0.1 to 0.8 Volts operation in closed
Always inspect exhaust system parts for the fol- loop
lowing defects or damages: Oxygen sensor circuit
– Cracks Constant 0.45 Volts open
– Tearing
– Bending Indicates fuel mixture
– Dents too lean,
– Corrosion possible oxygen
– Leaks Constant low voltage sensor fault,
– And any other damage or defect which could possible fuel system
affect system performance. fault,
possible air leak
Replace as required.
Indicates fuel mixture
Procedures too rich,
H E A T E D O X Y G E N S E NS O R ( H O 2S ) possible fuel system
Constant high voltage
fault,
Oxygen Sensor Location possible fuel canister
This vehicle is equipped with 1 heated oxygen problem
sensor (HO2S): The sensor is located on the ex-
haust manifold. Testing the Oxygen Sensor Using BUDS2
Oxygen Sensor General Precautions 1. Connect the vehicle to the BRP diagnostic soft-
Take the following precautions to avoid sensor ware (BUDS2).
malfunction: 2. In BUDS2, select:
– Do not use any product on sensor probe. – M e a s u r e m e n t s page
– Do not expose sensor to water, oil, windshield – E C M button.
cleaner, anticorrosion oil, grease, terminal 3. Start engine.
cleaner, etc. 4. Observe the O 2 s e n s o r V and O x y g e n S e n -
– Do not drop or use an oxygen sensor that has s o r S t a t u s indications in BUDS2
been dropped.
37
Engine
Exhaust System
If a fault code related to an oxygen sensor is Oxygen Sensor Connector

active, the oxygen sensor indicator will n o t turn (Harness Side)
on. The fault code(s) need(s) to be solved first. Measurement
When a properly functioning oxygen sensor cir- PIN
cuit is first initiated, the oxygen sensor heats C Battery ground Battery voltage
up and the ECM is operating in a closed loop
control mode. The status of the oxygen sensor If Input voltage is good, refer to Testing the Re-
circuit will change from “Init” to “Active” as it sistance of the Oxygen Sensor Heater and
progresses through a series of steps. These Testing for Oxygen Sensor Circuit Continuity.
steps may be viewed on the E C M M e a s u r e -
m e n t s page of BUDS2 in the O x y g e n S e n s o r If input voltage is not good, test the continuity
S t a t u s window. of the power circuit from the Fuel Pump/02 sen-
sor fuse. Refer to the applicable wiring diagram
N O T E : The steps listed in the following sensor for details.
status table may not all be displayed, and may
vary from one time to the next. The steps dis- If input voltage wire continuity is at fault, repair
played will depend on the engine operating status or replace wiring or connector.
and oxygen sensor operating status. Testing the Resistance of the Oxygen Sensor
Heater
List of oxygen sensor status indications:
Test the resistance value of the oxygen sensor be-
– Init tween the sensor pins as follows.
– Heating Active
– Control Active Oxygen Resistance
– Error Sensor Pin @ 20 °C (68 °F)
When the oxygen sensor reaches the “Active”
Approximately
state, it becomes operational and its indicator C D
7 - 11 Ω
will turn on in BUDS2.
N O T E : At room temperature (approximately 21° If reading is n o t within specification, replace the

C (70° F)), the engine needs to run for approxi- oxygen sensor.
mately 15 seconds before the oxygen sensor be- Testing for Oxygen Sensor Circuit Continuity
comes C O N T R O L A C T I V E and its indicator light
turns on in BUDS2. N O T E : This test validates the heater element cir-
cuit and the sensor circuits.
If a sensor status does not change or does not
reach the C O N T R O L A C T I V E state, or the 1. Remove main power relay.
oxygen sensor indicator light does not come 2. Disconnect the B connector from the ECM.
on, try a new oxygen sensor. 3. Install the connector on the ECM adapter tool.
N O T E : Before replacing a sensor, check wiring, ECM adapter tool
terminals and sensor condition. (P/N 529036166)
Testing for Oxygen Sensor Input Voltage
N O T E : This test validates the heater element
circuit. 4. Using a multimeter set to "Ω", test for continuity
between the oxygen sensor harness connector
1. Ensure main power relay is properly installed. and the ECM adaptor as per following tables.
2. Disconnect the oxygen sensor connector.
3. Turn ignition switch ON.
4. Using a multimeter set to VDC, read the input
voltage provided to the sensor heater.
38
Engine
Exhaust System
Oxygen Sensor Circuit Continuity Test

ECM Resistance
Oxygen
Connector @ 20 °C (68 °F)
Sensor Pin
“B”
A J1
B D2 Close to 0 Ω
D L2 TYPICAL
1. Apply antiseize lubricant first two threads
2. Must be free of any product
If a resistance value is NOT as specified, repair
or replace the wiring and connectors. NOTICE
Do not apply any antiseize lubricant to the
04
Replacing the Oxygen Sensor
1. Remove main power relay. sensor probe as it could affect its operation.
CAUTION 7. Screw sensor as per specification.

Exhaust system and oxygen sensor may be
hot. To avoid possible injury, allow exhaust Tightening Torque
system components time to cool before 50 ± 10 Nm
proceeding. Oxygen sensor
(37 ± 7 lbf-ft)
2. Disconnect oxygen sensor connector. 8. Install all other removed parts.

3. Cut locking tie securing oxygen sensor
harness. MUFFLER
4. Unscrew oxygen sensor from exhaust
Removing the Muffler
manifold.
NOTICE 2. Remove exhaust springs.
Handle oxygen sensor with clean hands.
Oxygen sensor probe must remain free of oil, Spring installer/
grease, antiseize lubricant and any other for- remover
eign matter that could affect its operation. (P/N 529035983)
5. If a new oxygen sensor is installed, its threads

are already coated with an antiseize product.
Sensor is ready for installation.
6. If the same oxygen sensor is installed, apply
an anti-seize lubricant on its f i r s t t w o t h r e a d s .
Loctite 767 (anti-seize lubricant)
NOTICE
Always use a product that is oxygen sensor
safe.
3. Remove the muffler mounting screw.
39
Engine
Exhaust System
1. Exhaust pipe
4. Remove muffler. 2. Exhaust pipe gasket
Installing the Muffler 3. Install a new gasket on the exhaust pipe.

The installation is the reverse of the removal pro- 4. Install the muffler as per procedure in this
cedure. However, pay attention to the following. subsection.
1. Install a new retaining screw. N O T E : Be sure to apply specified torques and
2. Install the plate as illustrated. verify for proper clearances as specified.
Replacing the Exhaust Pipe Gasket
1. Remove the muffler assembly.
2. Remove the old gasket from the exhaust pipe.
1. Exhaust pipe
2. Exhaust pipe gasket
3. Refer to the exploded view for tightening
torque. 3. Install a new gasket on the exhaust pipe.
4. Install the muffler.
CATALYTIC CONVERTER
Catalytic converter is an integral part of the N O T E : Be sure to apply specified torques and
muffler. verify for proper clearances as specified.
EXHAUST PIPE GASKET EXHAUST MANIFOLD

Replacing the Exhaust Pipe Gasket Removing the Exhaust Manifold
1. Remove the muffler assembly. 1. Raise the upper body module.
2. Remove the old gasket from the exhaust pipe. 2. Remove the air intake silencer.
40
Engine
Exhaust System
3. Unplug and remove the oxygen sensor. 6. Remove exhaust manifold retaining screws. 04
600 ACE
4. Remove screws and washers retaining the ex-
haust manifold deflector.
900 ACE
5. From underneath of the vehicle, remove 7. Remove the rear deflector.

springs securing the exhaust pipe to the ex-
haust manifold.
41
Engine
Exhaust System
900 ACE
Inspecting the Exhaust Manifold
Check if the manifold is cracked or damaged. Re-
place if necessary.
Installing the Exhaust Manifold
1. Install the exhaust manifold with a N E W
gasket.
2. Install exhaust manifold screws and tighten as
per specification and tightening sequence.
Tightening Torque
10 ± 2 Nm
Step 1
Exhaust (89 ± 18 lbf-in)
manifold
screws 23 ± 2 Nm
Step 2
(17 ± 1 lbf-ft)
600 ACE
42
Engine
Cooling System - Vehicle

Components
SERVICE TOOLS

SPRING INSTALLER/REMOVER . . . . . . . . . . . . . . . . . . . . (P/N 529035983) . . . . . . . . . . . . . . . . . . . . . . . . 39
TEST CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529035991) . . . . . . . . . . . . . . . . . . . . . . . . 47
VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . (P/N 529021800) . . . . . . . . . . . . . . . . . . . . . . . . 47
04
COOLING SYSTEM
1. Coolant tank 3. Coolant flows to radiator
2. Coolant returns from radiator 4. Radiator
43
Engine
NEW
NEW
NEW
NEW
NEW
5 ± 1 N•m
(44 ± 9 lbf•in)
NEW
7 ± 1 N•m
(62 ± 9 lbf•in)
NEW
8.5 ± 1.5 N•m

(75 ± 13 lbf•in)
NEW

COOLING SYSTEM COMPONENTS
44
Engine
General
System Description
CAUTION
Always disconnect battery before servicing
the cooling system. Cooling fans may start
without warning even when engine and start
key are turned OFF.
NOTICE
Never start engine without coolant. Engine
parts like the rotary seal of the water pump
shaft can be damaged. 04
The cooling system keeps the temperature
1. Bleed hose nipple
constant. 2. Water pump module
A separate coolant tank ensures that enough en- Coolant temperature sensor is located on the cyl-
gine coolant is in the circuit during any operating inder head.
condition.
When engine has reached operating temperature
the thermostat opens completely and closes the
bypass channel completely. Then coolant takes
the way through the radiators.
The cooling system keeps the temperature
constant.
A separate coolant tank ensures that enough en-
gine coolant is in the circuit during any operating
condition.
The coolant flow comes from the water pump
module and goes into the cylinder head. After-
wards coolant is directed to the oil radiator for
cooling the engine oil, and to the cylinder block. In
the cylinder head the water channels flow around 1. Coolant temperature sensor (CTS)
2. Intake manifold
the exhaust and then the intake valves. From
there the coolant goes back to the water pump NOTICE
module. At cold, engine coolant flows through a
bypass channel to the thermostat directly back to Never modify cooling system arrangement.
the water pump impeller and back into the engine. Otherwise, serious engine damage could
When engine has reached operating temperature occur.
the thermostat opens completely and closes the
bypass channel completely. Then coolant takes Maintenance
the way through the radiator. Engine Coolant
The cylinder head and water pump are self bleed- WARNING
ing via a hose nipple on the water pump module. To avoid potential burns, do not remove the
coolant tank cap or any fastener from the
cooling system if the engine is hot.
45
Engine
Recommended Engine Coolant

NOTICE
Always use ethylene-glycol antifreeze con-
taining corrosion inhibitors specifically for in- 2
ternal combustion aluminum engines.
To prevent antifreeze deterioration, always use

the same brand and grade. Never mix different
1
brands or grades unless cooling system is com-
pletely flushed and refilled.
XPS Recommended Coolant

Extended life pre-mixed coolant 1. MIN mark
2. MAX mark
If the Recommended XPS Product is not 4. If required, add coolant until it is visible in the
Available reservoir slightly above the MIN level mark.
Use a low silicate, extended life ethylene-glycol Use a funnel to avoid spillage. D o n o t o v e r f i l l .
premixed coolant (50%-50%) specifically formulated 5. Reinstall the service cover.
for internal combustion aluminum engines.
N O T E : A coolant system that frequently requires
coolant indicates leaks or engine problems. See
Verifying the Engine Coolant Level
an authorized Can-Am On-Road dealer.
WARNING
Replacing the Engine Coolant
When opening the reservoir, the coolant can Have the engine coolant replaced by an author-
be very hot and spray out if the engine is hot.
ized Can-Am On-Road dealer, a repair shop, or a
In order to avoid getting burned, check the
person of your own choosing.
coolant level when the engine is cold.
Draining the System
With the engine cold, check the coolant level as WARNING
follows:
Never drain or refill cooling system when en-
1. Park the vehicle on a firm, level surface. gine is hot.
2. Remove the front service cover. Refer to Serv-
ice cover section. 1. Remove the battery.
3. Check the coolant level on the right hand side. 2. Remove the front service cover and front
Coolant must be visible slightly above the MIN fascia.
level mark. 3. Install a drain pan underneath the radiator.
4. Cut Oetiker clamp connecting the radiator inlet
N O T E : If engine is hot, coolant must be visible hose to the engine.
without exceeding the MAX level mark.
46
Engine
04
THIS HOSE BECOMES HOT WHEN THERMOSTAT OPENS
5. Remove the coolant tank cap.
6. Dispose coolant as per local regulations. 4. Stop engine.
7. Position N E W Oetiker clamp onto the radiator 5. When engine has completely cooled down, re-
inlet hose and secure the hose to the engine. check coolant level and top up if necessary.
6. Install pressure cap.
Refilling the System 7. Install all previously removed parts.
Vehicle should be level and engine cold for
refilling. Inspection
1. Pour antifreeze into coolant tank until the level Cooling System Leak Test
reaches the MIN mark. WARNING
To avoid potential burns, do not remove the
coolant tank cap or any fastener from the
cooling system if the engine is hot.
1. Open the storage compartment cover and re-

move the front service cover.
2. Pressurize system through coolant tank.
Test cap
(P/N 529035991)
(P/N 529021800)
1. MAX mark
2. MIN mark
2. Do not install pressure cap at this time. Cooling System Leak Test
3. Start engine and let vehicle run until engine is
hot (fan starts). 100 kPa (15 lbf/in²)
3. Check all system components for coolant

leaks. Spray a soap and water solution and
look for air bubbles.
Troubleshooting
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and it
should not be assumed to list all possible
problems.
47
Engine
Always check for fault codes. If a fault code is de- Testing the CTS Using BUDS2
tected, service the fault code first. Refer to Diag- 1. Connect the vehicle to the BRP diagnostic soft-
nostic and Fault Codes subsection. ware (BUDS2).
Troubleshooting 2. Select the following:
1. Engine Overheating – M e a s u r e m e n t s page
– E C M button.
Low coolant level. 3. Look for the engine temperature indication.
– Refill and check for leaks. Repair or replace. 4. The engine temperature gauge in BUDS2
should provide an indication of the actual en-
Air in cooling system gine coolant temperature. Otherwise, perform
– Refill and bleed cooling system. Testing the CTS Resistance.
– Check for leaks. Testing the CTS

1. Disconnect the CTS connector.
Water temperature sensor defective 2. Test the resistance of the sensor as per follow-
– Check or replace. Refer to Electronic Fuel In- ing tables.
jection (EFI).
CTS Resistance
Radiator or hoses damaged
CTS pin Specification
– Check or replace damaged components.
Refer to CTS
Internal passage blocked in cooling system 1 2 Temperature Sensor
– Inspect and clean. table
Procedures CTS Temperature Sensor Table

COOLANT TEMPERATURE SENSOR (CTS)
Temperature Ω (Low/High)
The CTS is located on the intake manifold.
–10 °C
Overheat Warning (14 °F) 8 640 / 10 149
The CTS will cause the engine overheat warning
to come on when the coolant temperature is above 0 °C
110 °C (230 °F). (32 °F) 5 465 / 6 324
CTS Location 20 °C
(68 °F) 2 351 / 2 648
The CTS is located between the water pump and
the oil cooler.
80 °C
(176 °F) 313 / 332
120 °C
(248 °F) 110 / 116
To test sensor at various temperatures, remove

sensor and use a heat gun, ice and a
thermometer.
3. If resistance is out of specification, replace the

CTS.
4. If resistance test is good, reconnect the CTS
connector.
5. Disconnect the A connector from the ECM.
6. Install the connector on the ECM adapter tool.
48
Engine
ECM adapter tool Cap Opening Pressure

(P/N 529036166)
110 ± 7 kPa
Opening range
(16 ± 1 lbf/in²)
7. Recheck resistance from the ECM connector CLAMPS

as per following table. Replacing the Oetiker Clamp
CTS Resistance Test 1. Use only a pliers specially design for Oetiker
clamps.
ECM adapter pin Specification
Oetiker pliers
Refer to CTS
A1 J2 Temperature Sensor
(P/N 295000070)
04
table
8. If resistance value is correct, refer to Replacing

the CTS.
9. If resistance value is incorrect, repair the con-
nectors or replace the wiring harness between
ECM connector and the CTS.
Replacing the CTS
1. Drain coolant.
2. Cut locking ties of wiring harnesses and move
wiring aside for access.
1. Cutting clamp
Take note of wiring and locking tie position before
removal.
3. Disconnect the CTS connector.
4. Remove the CTS from engine.
5. Install the new CTS and torque as specified.
Tightening Torque
22 ± 2 Nm
CTS (16 ± 1 lbf-ft)
1. Securing clamp
6. Reinstall remaining removed parts.
Ensure to reinstall wiring harness as noted prior to

removal.
7. Refill and bleed the cooling system.

PRESSURE CAP
Testing the Pressure Cap
Using a pressure cap tester, check cap opening
pressure. If opening pressure is out of range, in-
stall a new pressure cap.
1. Securing clamp in limited access
49
Engine
2. Always check general condition of hoses and Testing the Radiator Cooling Fan Using
clamp tightness. BUDS2
1. Connect vehicle to the BRP diagnostic soft-
RADIATOR
ware (BUDS2).
Removing the Radiator 2. In BUDS2, select:
1. Remove front service cover and front fascia. – F u n c t i o n s tab
2. Place a drain pan under the radiator. – E C M tab.
3. Unplug both radiator hoses to drain the cooling
3. Click on the appropriate radiator cooling fan to
system. Discard the Oetiker clamp.
activate it.
4. Remove screws securing the radiator and the
cooling fan. Discard nuts. If cooling fan works:
– Check coolant temperature sensor (CTS).
If the cooling fan does not work:
– Check the cooling fan fuse.
If fuse is good:
– Check the cooling fan relay.
Testing the Radiator Cooling Fan Relay
1. Remove the cooling fan relay.
2. Install a fused jumper wire end between pins
30 and 87.
3. If the fan works correctly by jumping the relay,
replace the relay.
4. If the fan does not work:
Installing the Radiator – Check the wiring harness and connectors
The installation is the reverse of the removal pro- between fuse box and cooling fan.
cedure. However, pay attention to the following. – Check the relay control circuit wires.
5. If the fan does not work after all tests, replace
Tightening Torque the fan.
Radiator/cooling fan 7 ± 1 Nm Removing the Radiator Cooling Fan

retaining screws (62 ± 9 lbf-in) 1. Remove front fascia.
2. Remove radiator.
Refill and bleed the cooling system. 3. Disconnect the radiator fan connector.
RADIATOR COOLING FAN

Operating Condition of the Radiator Cooling
Fans
Radiator Cooling Fan
Engine Cooling Fan Cooling Fan
Temperature Relay Operation
> 101 °C (214 4. Remove the screws securing the fan
°F) Close Starts
assembly.
< 97 °C (207
Open Stops
°F)
50
Engine
5. Remove the radiator cooling fan.

Installing the Radiator Cooling Fan
The installation is the reverse of the removal pro- 04
Tightening Torque
Radiator/cooling fan 7 ± 1 Nm
retaining screws (62 ± 9 lbf-in)
Refill and bleed the cooling system.
51
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
52
05
ELECTRONIC MANAGEMENT SYSTEMS
53
Electronic Management Systems
Engine Management System
05 Electronic Management Systems
Engine Management
System
General
The vehicle senses its surroundings utilizing multi-
ple on-board electronic control modules. These
sophisticated systems monitor and control a broad
range of functions.
The vehicle features the following systems:
– Engine Management System (EMS)
– Vehicle Stability System (VSS)
54
Engine Management System (EMS)

600 ACE
05
1. COIL_1 (Ignition Coil Cylinder 1)

3. CPS (Crankshaft Position Sensor)
4. CTS (Coolant Temperature Sensor)
5. ECM (Engine Control Module)
6. ETC (Electronic Throttle Control)
7. FWD (Forward Switch)
8. INJ_1 (Injector 1)
10. MAPTS (Manifold Absolute Pressure and Temperature Sensor)
11. OPS (Oil Pressure Switch)
12. PARK (Park Switch)
13. REV (Reverse Switch)
55
900 ACE

4. CPS (Crankshaft Position Sensor)
5. CTS (Coolant Temperature Sensor)
6. ECM (Engine Control Module)
10. MAPTS (Manifold Absolute Pressure and Temperature Sensor)
11. OPS (Oil Pressure Switch)
12. PARK (Park Switch)
13. REV (Reverse Switch)
56
A highly advanced engine management system Vehicle Stability System (VSS)

(EMS) has been used to ensure a high power out- The VSS helps to maintain vehicle control in nor-
put with cleaner combustion. mal riding conditions as well as in emergency
There are 5 main systems that are controlled by avoidance maneuvers.
the engine management system (EMS): To maintain vehicle stability, the VSS interacts
1. Electronic Fuel Injection (EFI) with several other subsystems as well as with the
2. Cooling system engine management system. Refer to the Vehicle
3. Evaporative emission control system (EVAP) Stability System (VSS) for more details.
4. Ignition system
5. Starting system
Engine Control Module (ECM)
The ECM is the central point of the engine man-
agement system. It reads the inputs, makes com-
putations, uses pre-determined parameters and
sends the proper signals to the outputs for proper
engine management.
05
The ECM is located on the RH side of the engine.
The ECM features a permanent memory that will

keep the fault codes, customer information and
other engine information, even when the battery is
removed from the vehicle.
Drowned Mode
This special mode can be activated to prevent fuel
injection and ignition while cranking. Proceed as
follows to activate it.
Twist and HOLD throttle at WOT position.
Press the start button and hold to crank engine.
The mode is now on.
Once it's activated, it stays as long as the start but-
ton is pressed.
57
Controller Area Network (CAN)
N O T E : D.E.S.S. is not linked to CAN, it commu-

Controller Area Network nicates via radio wave signal with the key
(CAN) antenna.
Communication Between Modules Through
General the CAN Bus
System Description The following table shows what modules commu-
The CAN (Controller Area Network) protocol is an nicate with each other.
ISO standard for serial data communication. CAN
lines consisting of a pair of twisted wires (WHITE/ Communicate with
Module/Sensor
BEIGE and WHITE/BLACK), link several elec- Module/Sensor
tronic modules (ECUs) and sensors in the vehicle.
ECM (engine control All except SAS and
This allows the various modules and components
module) YRS
of the system to be in constant communication
with each other. Refer to Communication Between Multifunction cluster
Modules Through the CAN Bus. gauge All
If a component or system malfunction is detected,
VCM (vehicle control
a module and/or sensor may generate a fault All
module)
code, which it transmits through the CAN bus as a
coded signal. The fault signal may be used for var- SAS (steering angle Multifunction cluster
ious functions such as triggering the display of an sensor) gauge, VCM
error message in the multifunction gauge cluster,
turning on a fault indicator light, and limiting or in- VCM, Multifunction
YRS (yaw rate sensor)
hibiting vehicle or engine operation, or viewed us- cluster gauge
ing the BRP diagnostic software (BUDS2) for
troubleshooting.
Using BUDS2, technicians may also communicate
through the diagnostic connector (DB) with elec-
tronic modules (ECM, Cluster, VCM) for reasons
such as:
– Extracting data
– Programming a module
– Changing settings
– Viewing fault codes
– and for various other functions.
CAN-HI
WH/BG
B-C1 CL-13 VCM-26 SAS-4 YRS-3 DLC-1
ECM CLUSTER VCM SAS YRS DLC
B-C2 CL-14 VCM-14 SAS-1 YRS-2 DLC-2
WH/BK
CAN-LO
1. CLUSTER: Multifunction Gauge
2. DLC: Diagnostic Link Connector
3. ECM: Engine Control Module
4. SAS: Steering Angle Sensor
5. VCM: Vehicle Control Module
6. WH/BG: White/Beige
7. WH/BK: White/Black
8. YRS: Yaw Rate Sensor
58
Communication Tools
Communication Tools
SERVICE TOOLS
DIAGNOSTIC CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 710000851) . . . . . . . . . . . . . . . . . . . . . . . . 59

MPI-3 INTERFACE CARD . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036353) . . . . . . . . . . . . . . . . . . . . . . . . 59
SERVICE TOOLS — OTHER SUPPLIER

OPTIONAL EXTENSION CABLEDO NOT EXCEED 7.5 M (25 FT) . . . (NOT . . . . . . . . . . . . . . . . . . . . . . . . 59

SOLD BY BRP)
Required Communication Tools Diagnostic Connector Location

05
1. Refer to the B.U.D.S. d i r e c t o r y on Knowledge The diagnostic connector is located under the
Center for all BUDS-related information, front service cover, stored in its protective cap.
including:
– Download link
– User manual (programming keys, reading
fault codes, navigation through menus, writ-
ing data to modules etc.)
– Installation instructions.
2. Download and install the software on a PC.
3. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2) using the following tools:
MPI-3 interface card

(P/N 529036353)
Diagnostic cable
(P/N 710000851) Troubleshooting
Diagnostic Tips
Optional extension cable I M P O R T A N T : Make sure all connections are
Do not exceed 7.5 m (25 ft) made and vehicle is powered up b e f o r e s t a r t i n g
(Not sold by BRP) t h e B R P d i a g n o s t i c s o f t w a r e ( BUDS2)) to allow
proper communication between the vehicle and
BUDS2.
The MPI-2 interface card (P/N 529036018) can
also be used instead of the MPI-3 interface card. Multi-Purpose Interface Card Connection
Troubleshooting
Multi-Purpose Interface Card (MPI-2 or MPI-3) MPI Status Lights
The Multi-Purpose Interface (MPI) in conjunction The MPI card includes 2 status lights that indicate
with the diagnostic cable is used with BUDS2 to the connection condition: USB and CAN. B o t h
communicate with the Engine Control Module l i g h t s m u s t b e G R E E N to function properly. Oth-
(ECM) and other modules. erwise, refer to the following charts.
The MPI card uses power from the PC computer’s
USB port.
59
Communication Tools
Communication Problem (CAN)

Status What To Do
– BUDS2 does not communicate

with
CAN the vehicle.
Light is – Check connections from computer
MPI-2 CARD to vehicle.
OFF
– Check if BUDS2. is started.
– Check if vehicle is powered: Is
cluster turned ON?
USB This occurs when BUDS2 loses
communication with vehicle.
CAN
CAN Light is – Check connections from computer
RED to vehicle.
– Check if vehicle is powered: Is
cluster turned ON?
CAN
MPI-3 CARD
Light is – Connections are GOOD.
Prerequisite for USB Communication GREE BUDS2 communicates normally
N with the vehicle.
– Computer turned on.
– MPI card connected to computer.
Communication Problem (Usb)

Status What To Do
Check USB connection between
USB Light MPI card and computer.
is OFF Check USB operation on computer
(hardware or USB drivers)
Connections are GOOD.
USB Light
Communication can take place on
is GREEN
USB side
Prerequisite for CAN Communication

– MPI card connected to diagnostic connector
on vehicle.
– Computer turned ON
– The D.E.S.S. key installed on the engine D.E.
S.S. post (if applicable).
– ECM is powered.
– BUDS2 started and logged on.
60
Diagnostic and Fault Codes (Premium Gauge)
Diagnostic and Fault

Codes (Premium Gauge)
Most of the time, a message will scroll across the
General d i g i t a l d i s p l a y to provide additional information
Monitoring System related to the fault that triggered the lamp.
The Engine Management System (EMS) and Ve-
hicle Stability System (VSS) (including their sub The fault message will continue to scroll across
systems) feature a monitoring system that self-di- the digital display as long as the fault is active.
agnose their electronic components. This mode
becomes active when the ignition key is turned Lights Description
ON. GREEN - Left or right turn signal is
turned on,
N O T E : Some components require the engine to
be running for them to be monitored for normal op- Hazard Warning Flasher (if
eration (fuel injectors for example). equipped) - All front and rear turn
signals will flash 05
The monitoring system continuously validates that
the electronic components (control modules, sen-
ORANGE - Vehicle malfunction
sors and actuators) work in their operating range
and are not faulty or defective. When one of these
BLUE - The high beam are
conditions is encountered, the related electronic
selected
module(s):
– Sets an active fault code. RED - The engine temperature is
– Adapts the proper protection strategy accord- too high.
ing to the failure.
– Sends out signals to the multifunction gauge to RED - Parking brake is engaged or
inform the rider of a particular condition. malfunction of the brake system
A fault code is an indication that a glitch or mal-
function is detected by the monitoring system of RED - The battery voltage too low
the vehicle. or problem with the electrical
If a minor fault occurs, the engine and vehicle will system
continue to operate without noticeable loss of
performance. ORANGE - Malfunction of the ABS
system
If a more significant fault occurs, engine RPM may
be limited. The engine/vehicle will continue to op-
RED - Low engine oil pressure
erate with reduced performance.
If a major fault is detected by the EMS or VSS, en-
gine RPM will be limited as well as vehicle speed. ORANGE - Low fuel level
These strategies are used to protect
engine/electrical system from damage and to ORANGE
maintain safe operation of the vehicle. T u r n o n : Malfunction of the vehicle
emissions control system
Indicator Lamps or Icons for Problematic B l i n k : Engine problems, the limp
Conditions home mode is activated. Have the
When a problem is detected, an indicator lamp will vehicle serviced immediately.
turn on or blink i n t h e m u l t i f u n c t i o n g a u g e .
Limp Home Mode
When a major component of the EMS and/or VSS
(including their sub-systems) is not operating
properly, fault code (s) will be triggered and limp
home mode will be set.
61
Engine RPM will be limited and vehicle speed may Active Fault Codes
be limited depending on the failure. An active fault code is an indication of a fault that
This mode allows the rider to safely return home. is c u r r e n t l y t r i g g e r e d .
This would not be possible without this advanced The active fault may or may not compromise nor-
system. mal operation of the related system(s). Service ac-
LIMP HOME will be displayed in the multifunction tion should be taken to correct the problem that
gauge. caused the fault code.
Fault Codes Once the fault condition(s) of the active fault is no

longer present, its state will change to “occurred”.
Fault Code Categories
Occurred Fault Codes
1. A fault code consists of an alphanumeric des-
ignator followed by a hexadecimal number of An occurred fault code indicates a fault that was
3 digits. The alphanumeric designator defines active, but n o l o n g e r is.
the category of the fault code while the hexa- The occurred fault does not presently affect sys-
decimal number refers to a unique fault. tem or component operation but is retained as a
history of the faults that were detected.
Fault Code Categories
The fault may have been generated due to a sys-
Alphanumeric Module/ Example tem or component that was momentarily operating
Designator System of Fault outside normal parameters. Repeated occurred
Code faults of this type should be considered when trou-
bleshooting a problem, and may require that main-
Power train,
From P0 to P3 P062F tenance action be taken.
TCM and DPS
An occurred fault may also be generated when
Vehicle stability
From C0 to C3 C0031 disconnecting and reconnecting a component, re-
system (VSS)
placing a burnt fuse, when the software update of
Communication an electronic module has been carried out, or may
From U0 to U3 between module U0073 be due to a momentary high or low voltage.
and sensors Inactive Fault Codes
Body An inactive fault code represents a fault code that
(including is neither active, nor occurred. It is simply part of a
From B0 to B3 luggage B1000 list of all possible faults which may be monitored
compartments) by the various ECUs and the multifunction gauge,
which may become active or occurred if the moni-
Related Module and Faults toring system detects an applicable fault.
Fault Code Category These codes can be viewed only in the BRP diag-
Module
nostic software BUDS2.
Cluster P, B, C and U How to Read Fault Codes Using the
Mainly P and some U Multifunction Gauge
ECM
VCM Mainly C and some U N O T E : A fault code must have the "Active" state
to be displayed in the multifunction gauge. Other
fault code states must be read using the BRP di-
Fault Code States agnostic software (BUDS2).
The various electronic control units (ECUs) used
in the vehicle can generate a variety of fault codes If a fault is detected, an indicator light and a fault
depending on the level of monitoring they are ca- message may come on in the gauge.
pable of. Fault codes have 3 possible states:
Proceed as follows to view the fault codes:
– Active
– Occurred 1. Turn vehicle ON by pressing start button with-
– Inactive. out activating brake pedal.
62
2. Push lower multifunction gauge button until General Guidelines to Solve Fault Codes
S e t t i n g s menu appears.
3. Hold lower button to enter the S e t t i n g s menu. Condition Action
4. Press the lower button until C o d e s menu ap-
pears. This menu will only appear if active Use BUDS2 to:
faults are present on the vehicle. Read fault codes.
Display "Active" faults to see
How to Read Fault Codes Using BUDS2 components currently not
operating normally.
N O T E : All fault code types can be read with the Display "Occurred" faults to
BRP diagnostic software (BUDS2). troubleshoot intermittent
problems.
1. Connect the vehicle to the BRP diagnostic soft- Monitor system(s), sensor(s),
ware (BUDS2). Troubleshoot switches and actual conditions.
2. In BUDS2, go to the F a u l t s page. ing vehicle Activate component(s) for
3. Select V e h i c l e button or the appropriate ECU. troubleshooting.
Set components (resets etc).
How to Find Fault Code Descriptions
Connect the vehicle to the BRP Diagnostic Soft-
Know the last minute of 05
operating conditions by using
ware BUDS2.
the "History" page.
Navigate to the F a u l t s page. Know the operating conditions,
if available, when a fault code
Browse lists of active/occurred and inactive fault occurred by using the "More
codes. details" button in the fault page.
Fault code Diagnostic
Check sensor connections or
Diagnostic Tips mixed up connections.
To see the last two minutes of operating condi-
tions, click on the S u m m a r y page in BUDS2 and B e f o r e vehicle maintenance.
select S t a t i s t i c s . Read the electronic modules
with BUDS2
N O T E : The page displays data whatever there is Save and print the BUDS2 file
fault code(s) or not. New fault(s) (keep faults option only).
appear after a
vehicle A f t e r vehicle maintenance.
maintenance Read the electronic modules
or repair with BUDS2.
Compare the fault code(s)
before and after the
maintenance using the printed
copy and the current reading.
Investigate only the newly fault
codes.
Clear all occurred faults.
Sensor Read the fault description in
"Active" fault BUDS2.
63
General Guidelines to Solve Fault Codes General Guidelines to Solve Fault Codes
Condition Action Condition Action
Check related fuse(s) and When several modules and
relay. sensors report that a module is
Check related power and missing.
Low system ground wires. The missing module may report
voltage on Check for common power CAN bus off.
one module. supply to several sensors/ Check related CAN wires
Power modules (refer to power CAN buss (continuity, short to ground,
problem on distribution and grounds). OFF short between CAN low and
sensor(s) N O T E : Some sensors are high).
supplied by the battery while Check module pins and wiring
others are supplied by a terminals.
module. Then, the other modules should
stop reporting that module is
Low system missing.
voltage on Check battery condition and
several connections. May have been generated due
modules Check related fuse(s) and to a system or component that
(several relay. was momentarily operating
communica Check voltage regulator/ outside normal parameters.
tion faults will rectifier.
also appear) May be generated when
disconnecting and reconnecting
A battery charger has likely a component, replacing a burnt
been used to substitute the fuse, or may be due to a
High system
vehicle battery. momentary high or low voltage.
voltage on
Clear all occurred faults and
several Before being "Occurred", a fault
check again.
modules has always been "Active" for a
Check voltage regulator/
rectifier. Occurred certain time, indicating that an
fault(s) unexpected condition or
Check the module that is problem has been present
When all
reported as missing. during the driving cycle.
modules
Check related fuse(s) and A frequent momentarily fault or
report that a
relay. an intermittent fault may never
module is
Check related power and be seen as "Active" in BUDS2
missing
ground wires. while there is still a pending
When several problem.
Search for a common problem This type of malfunctions can
modules are such as a faulty sensor.
in fault 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".
L o w v a l u e : Suggests handling
problems (connections,
terminal contact/
Fault count shape etc.).
(0 - 255) H i g h v a l u e : Suggests a
frequent and unsolved problem.
The problem should be
investigated.
64
General Guidelines to Solve Fault Codes If both sensors in the TAS are at fault, a TAS
FAULT message will appear in the gauge, the
Condition Action check engine light will come ON and the engine
will run at idle. The accelerator pedal will not have
Fault Look for abnormal, excessive any affect on engine RPM.
conditions values.
When the basic troubleshooting
has been done and the fault
code(s) persists, often the
problem is related to the wiring
harness, connections or
Hard to find electromechanical components.
problems Short to ground, to battery or
between wires.
Wire splices, chafing, terminal
problems (pulled out, bent, out
of shape, corroded etc.). 05
Bad contacts in switch or relay.
ECUs share information and their systems may in-

teract with each other. Certain faults may cause
more than one ECU to set a fault code or indica-
tion (pilot lamp or message) as the failure of some
components may affect the operation of several
systems.
Specific Faults
TPS Fault
A TPS fault may be considered to be a major fault
as the TPS provides the most important feedback
(2 signals) to the ECM on throttle position.
A TPS fault affects engine control as the throttle
plate is moved by the ETA (electric throttle actua-
tor) which, is controlled by the ECM (see Intelli-
gent Throttle Control (ITC) subsection).
A TPS fault is generally followed by LIMP HOME
mode and the engine is brought back to idle, or
may be completely shut down.
Low Battery Voltage Fault
If the battery voltage is low when the engine is run-
ning at idle RPM, the ECM will command an in-
crease in RPM to a set value, thereby increasing
the charging system output in order to prevent the
battery from being discharged, and to allow nor-
mal system operation.
TAS Fault
If one TAS (throttle accelerator sensor) signal is
missing, LIMP HOME MODE will be activated and
the check engine light will come ON.
The throttle will still be functional, but not at the
same time as brake pedal is applied.
65
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
66
06
FUEL SYSTEM
67
Fuel System
Fuel Tank and Fuel Pump
06 Fuel System

SERVICE TOOLS

FUEL HOSE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036509) . . . . . . . . . . . . . . . . . . . . . . . . 71
FUEL PUMP NUT TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529035899) . . . . . . . . . . . . . . . . . . . . . 77–78
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036395) . . . . . . . . . . . . . . . . . . . . . . . . 71
VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . . (P/N 529021800) . . . . . . . . . . . . . . . . . . . . . 72, 80
29 ± 1 N•m
(21 ± 1 lbf•ft)
NEW
NEW
NEW
NEW
NEW
68
Fuel System
General procedure must be reinstalled as per factory

standards.
WARNING
Torque wrench tightening specifications must WARNING
be strictly adhered to. Locking devices must Replace any damaged, leaking or deterio-
be replaced when removed (e.g.: locking rated fuel line. Use of damaged fuel lines, or
tabs, elastic stop nuts, cotter pins, etc.). fuel lines not approved by BRP, could com-
promise fuel system integrity.
WARNING
Always disconnect battery prior to working on NOTICE
the fuel system. All resistance tests must be performed at nor-
mal room temperature, around 20 °C (68 °F).
WARNING
Fuel is flammable and explosive under cer- System Description
tain conditions. Always work in a well venti- The fuel and evaporative (evap) system main
lated area. components are:
WARNING
Do not allow fuel to spill on hot engine and 06
exhaust parts and/or on electrical
connectors.
WARNING
Always proceed with care and use appropri-
ate safety equipment when working on pres-
surized fuel system. Wear safety glasses.
When replacing a fuel line, be sure to use BRP ap- FUEL SYSTEM M AIN COMPONENTS
proved fuel hoses as available from the BRP parts 1. EVAP purge valve
department. This will ensure continued proper and 2. Electric fuel pump module
3. Fuel tank
safe operation. 4. EVAP canister
5. Vent valve
Fuel lines remain under pressure at all times. Pro-
ceed with care when removing/installing high pres-
Evap Purge Valve
sure test equipment.
Disconnect fuel pump electrical connector to dis-
able fuel pump and crank engine to release fuel
pressure prior to disconnecting any fuel hose.
Cover the fuel hose connections with an absorb-
ent shop rag and carefully disconnect them to min-
imize spilling.
Wipe off any fuel spillage.
EVAP PURGE VALVE
The ECM controls the evap purge valve.

The evap purge valve is a duty cycle solenoid.
The evap purge valve is used in conjunction with
the evap canister. A hose connects the solenoid
69
Fuel System
operated valve to a vacuum port on the intake Evaporative Emission System (EVAP)
manifold. As the vehicle is sitting and not running, fuel evap-
Electric Fuel Pump Module orates within the fuel tank.
Once the engine is running and reaches predeter-
mined conditions, the ECM controls the purge sol-
enoid valve according to engine RPM and load.
Thus, vacuum from the engine draws (or purges)
the hydrocarbon emissions from the canister and
burns them during the combustion process. The
ECM cycles the solenoid ON and OFF as
necessary.
In order for engine vacuum to draw in the hydro-
carbon emissions from the canister, a flow must
be created. As the hydrocarbon emissions are
drawn out of the canister, they are replaced with
fresh air by means of the canister pre-filter. Thus
ensuring proper fuel system venting.
In order for engine vacuum to draw in the hydro-
carbon emissions from the canister, a flow must
be created. As the hydrocarbon emissions are
drawn out of the canister, they are replaced with
fresh air. Thus ensuring proper fuel system
venting.
The vent valve ensures that, if the vehicle is ever
upside-down, only minimal quantities of liquid fuel
can escape through the vent line.
Inspection
FUEL PUMP MODULE Depressurizing Fuel System
1. Fuel pump module It is recommended to depressurize the fuel system
2. Fuel level sensor
3. Fuel level float before disconnecting fuel hoses.
4. Fuel filter
1. Disconnect fuel pump connector.
The fuel pump module is inserted in the fuel tank. 2. Start and idle engine.
3. Allow the engine to stall.
It provides fuel delivery for the EFI system and in-
cludes an electric fuel pump and a float-type level Testing the Fuel System for Leaks
sensor that varies in resistance according to the 1. Fill up fuel tank (recommended).
fuel level. 2. Disconnect the purge hose from the EVAP
The ECM controls the fuel pump module. canister.
When running, the fuel pump module supplies

pressurized fuel.
Fuel Pressure Regulator
The fuel pressure regulator is integrated into the
fuel pump module mounted inside the fuel tank. It
controls the fuel pressure in the system.
The nominal fuel pressure is set at 400 kPa (58
lbf/in²).
70
Fuel System
– Internal component and external fuel system

leak checks (high-pressure system)
– Static fuel pressure test (engine not running).
1. Ensure there is enough fuel in fuel tank (mini-
mum 3 l (.8 gal (liq.,US))).
2. Pivot upper body module.
3. Depressurize the fuel system by disconnecting
the fuel pump connector and starting the en-
gine. Let engine shut down by itself.
4. Reconnect the fuel pump connector.
5. Connect the fuel gauge to the fuel hose
adapter.
3. Install a smoke machine onto the purge hose.
4. Pinch EVAP vent and drain hoses. Pressure gauge
(P/N 529036395)
Fuel hose adapter

(P/N 529036509)
06
6. Install a 50 mm (2 in) piece of hose on one end

of the fuel hose adapter. Secure with a gear
clamp.
7. Unplug the fuel pump hose from the fuel pump.
5. Pressurize the fuel system as per the following
specifications.
For smoke machine operation, refer to the
manufacturer's instructions.
Fuel System Leak Test
Time Without
Pressure Pressure Drop
32 kPa (5 lbf/in²) 30 seconds
If pressure drops, locate leak (s) and repair or

replace leaking component(s). 8. Install this hose on the other end of the fuel
6. Remove the smoke machine and reconnect hose adapter. Secure with a gear clamp.
the purge hose to the EVAP canister. 9. Install fuel hose adapter to the fuel pump. Se-
cure with a gear clamp.
Testing the Fuel System Pressure
10. Remove RF D.E.S.S. key and set engine stop
The fuel system pressure tests provide an indica- switch to OFF.
tion of the available pressure in the fuel system. 11. Press engine start button.
They validate the pressure regulator, the fuel 12. Observe fuel pressure on test gauge while
pump and injectors. pump is running.
13. Repeat the test 3 - 4 times to ensure a consis-
N O T E : Ensure vehicle battery is fully charged tent pressure reading.
before performing tests.
Static Test
This test allows the following fuel system checks:
71
Fuel System
Fuel System Pressure Test (Static) – Check fuel injectors for leaks. If not leaking, re-
place fuel pump.
Minimum Maximum Testing Injector Balance
392 kPa 408 kPa
(57 lbf/in²) (59 lbf/in²) This test verifies that the injectors all inject the
same amount of fuel when given the same com-
mand. Refer to Electronic Fuel Injection (EFI).
If pressure is not within specifications within 5
seconds following ECM wake-up, check for: Testing Injectors for Leaks
– External leaks This test verifies that the injectors do not leak fuel
– Proper fuel pump power and ground. when closed. Refer to Electronic Fuel Injection
(EFI).
N O T E : A symptom of a system that does not
maintain pressure after key off is longer start time Vent Valve / Rollover Valve
when hot. Testing the Vent Valve Operation
Dynamic Test 1. Disconnect vent hose from fuel tank vent
This test validates the following components in the valve.
fuel system: 2. Connect the vacuum pump and a short piece
of hose to the fuel tank vent valve.
– Fuel pump (under partial load)
– Fuel supply and return hoses Vacuum/pressure
– Pressure regulator. pump
– Fuel filter (if badly clogged) (P/N 529021800)
1. Follow the instructions in the Static Test proce-
dure to disconnect the fuel pump pressure 3. Set vacuum/pressure pump to P R E S S U R E
hose and install the pressure gauge. and activate pump. The gauge on the pump
2. Start engine. s h o u l d n o t c h a n g e i n r e a d i n g ; air should flow
3. Safely operate vehicle to load engine. through the vent valve and fuel tank freely.
4. Observe fuel pressure while operating.
N O T E : If engine is not loaded and throttle is

snapped, fuel pressure may momentarily drop be-
low specification. This is normal.
Fuel System Pressure Test (Static)

Minimum Maximum
392 kPa 408 kPa
(57 lbf/in²) (59 lbf/in²)
5. Stop engine and turn ignition key to OFF.

Test Conclusion 4. Set vacuum/pressure pump to V A C U U M and
The fuel pressure should be within specification in activate pump. The g a u g e s h o u l d n o t c h a n g e
static or dynamic tests. i n r e a d i n g ; air should flow through the vent
valve and fuel tank freely.
A rapid pressure drop after the engine is stopped
indicates leakage either from a fuel hose, fuel rail,
or from the fuel pump check valve.
– Check fuel hoses, fuel rail and fittings for leaks.
If not leaking, replace fuel pump.
A slow pressure drop after the engine is stopped
indicates leakage either from a fuel injector or from
the fuel pressure regulator.
72
Fuel System
Damaged component power wires or grounds.

– Measure voltage drop across suspected por-
tion of power or ground wires.
– Clean contact surfaces, replace power or
ground wires if damaged.
2. Engine Backfiring or Misfiring
Inadequate fuel system pressure.

– Test fuel pressure. Refer to procedure in this
subsection.
Testing for Rollover Protection EVAP purge valve hoses incorrectly installed.
1. Remove the fuel tank. – Verify hose condition and routing. Refer to ex-
2. Turn the tank upside down. ploded views in this subsection.
3. Set vacuum/pressure pump to V A C U U M and
activate pump. The vacuum g a u g e r e a d i n g Leaking, kinked or obstructed fuel hoses.
s h o u l d i n c r e a s e ; air should n o t f l o w t h r o u g h – Verify fuel hose condition and routing. Refer to
the valve. exploded views in this subsection. 06
The fuel tank vent valve is defective if air flows – Disconnect all EVAP system hoses.
freely through the valve when upside down and
the vacuum indication does not increase on the – Blow air (not compressed air) through hoses
pump gauge. and canister pre filter to ensure they are not
leaking or clogged.
If the valve is defective, replace the fuel tank.
Damaged component power wires or grounds.
TROUBLESHOOTING
– Measure voltage drop across suspected por-
Troubleshooting Tips tion of power or ground wires.
Troubleshooting – Clean contact surfaces, replace power or
1. Engine Surging or Not Holding a Steady Speed ground wires if damaged.
Fuel system pressure out of specification. PROCEDURES
– Test fuel pressure. Refer to procedure in this OETIKER CLAMP
subsection.
Replacing the Oetiker Clamp
EVAP purge valve stuck opened. 1. Use only a pliers specially design for Oetiker
– Test EVAP purge valve. Refer to procedure in clamps.
this subsection.
Oetiker pliers
Air intake system leak. (P/N 295000070)
– Check for vacuum leaks. Refer to Air Intake
System subsection
Leaking, kinked or obstructed fuel hoses.
– Verify fuel hose condition and routing. Refer to
exploded views in this subsection.
– Disconnect all EVAP system hoses.
– Blow air (not compressed air) through hoses
and canister pre filter to ensure they are not
leaking or clogged.
73
Fuel System
1. Cutting clamp
2. Remove rubber pad.
1. Securing clamp
3. Remove push nut securing strainer to fuel

pump. Be careful not to break the assembly lo-
cator pin.
1. Securing clamp in limited access
2. Always check general condition of hoses and

clamp tightness.
FUEL FILTER
Fuel Filter Access
Remove the fuel pump.
Replacing the Fuel Pump Filter
1. Unlock tabs on strainer plastic ring.
4. Pull strainer off fuel pump.
74
Fuel System
2. Disconnect fuel pump connector.

3. Start engine and let idle until it runs out of fuel.
5. Before installing new strainer on fuel pump, re-
place O-ring and lubricate assembly areas
circled, with O-ring lubricant or clean oil.
N O T E : Ensure no debris are present in pump in-
let and new filter. 06
4. Disconnect fuel line.
6. Insert the new strainer on fuel pump making

sure to press it in fully and tightly against the
fuel pump surface.
7. Using a small nut driver or socket, press in a
N E W push nut to secure strainer.
8. Reinstall remaining removed parts.
FUEL TANK
Draining the Fuel Tank 5. Remove canister solenoid and set aside.
Siphon fuel from tank into an approved fuel stor-
age container.
Removing the Fuel Tank
1. Remove the fuel tank cover
75
Fuel System
6. Remove the following fasteners under the seat

area. 1. Fuel tank locating tab
2. Upper frame groove
FUEL PUMP
Fuel Pump Location
The fuel pump module is mounted inside the fuel
tank.
Fuel Pump Quick Test
Press the engine start button without installing the
RF D.E.S.S. key.
The fuel pump should run for a few seconds to
build up pressure in the fuel system, and then shut
off. If you do not hear the fuel pump function,
7. Pivot upper body module. check fuse. If fuse is good, carry out a Testing the
8. Split upper frame halves to remove fuel tank. Fuel Pump Power Circuit.
Inspecting the Fuel Tank Testing the Fuel Pump Power Circuit
Inspect fuel tank for any damage or cracks that 1. Disconnect fuel pump ( F P ) electrical
may result in fuel leaks. Replace fuel tank as connector.
required. 2. Press the engine start button without installing
the RF D.E.S.S. key.
Installing the Fuel Tank
The installation is the reverse of the removal pro- N O T E : Fuel pump is powered for 3 seconds
cedure. However, pay attention to the following: after ECM is powered on if engine is not started.
1. Reinstall fuel tank. Ensure the locating tabs

are properly located in upper frame grooves.
CONNECTOR PIN-OUT
76
Fuel System
Fuel Pump Power Circuit Test 5. If test succeeded, wiring is good. Continue with
Testing the Fuel Pump Control Circuit
Pump Continuity.
Harness Vehicle Result Testing the Fuel Pump Control Circuit
Connector Continuity
Close to 1. Remove main relay to remove power from the
Chassis
Pin 3 battery ECM,
ground
voltage 2. Disconnect the B connector from the ECM.
3. Install the connector on the ECM adapter tool.
3. If battery voltage I S N O T read, carry out a
Testing the Fuel Pump power Circuit ECM adapter tool
Continuity. (P/N 529036166)
4. If battery voltage I S read, carry out a Testing
the Fuel Pump Control Circuit Continuity.
5. If voltage is low to battery ground, test for a
short or partial short circuit to ground with the 4. Set multimeter to Ω and test circuit continuity
pump circuit isolated from parallel circuits, refer as per following table.
to the Wiring Diagram.
Fuel Pump Circuit Continuity (Control Wire)
N O T E : A fault in the ECM or in a parallel circuit
may prevent fuel pump operation. Use BUDS2 to Pump 06
ECM
check for fault codes. Harness Resistance
Connector
Connector
Testing the Fuel Pump Power Circuit
Continuity M1 Pin 4 Close to 0 Ω
1. Remove the fuel pump fuse.
5. If test failed, repair or replace the faulty wiring.
2. Disconnect fuel pump ( F P ) electrical
6. If test succeeded, wiring is good. Try a new
connector.
ECM.
3. Set multimeter to Ω and test circuit continuity
7. Reinstall main relay.
as per following table.
Removing the Fuel Pump
Fuel Pump Power Circuit Continuity Test 1. Remove fuel tank cover.
Pump 2. Remove fuel pump locking ring.
Fuse Box Harness Resistance
Fuel pump nut tool
Connector
(P/N 529035899)
B5 Pin 3 Close to 0 Ω
FUSE BOX
3. Carefully pull out fuel pump paying attention to
4. If test failed, repair or replace the faulty wiring.
float arm. Discard sealing ring.
77
Fuel System
1. Fuel pump module

2. Sealing ring
Installing the Fuel Pump

4. Pay attention to pump orientation as in follow-
ing illustration.
NOTICE
Manipulate fuel pump with care.
1. Wipe off any fuel residue in the sealing area.

2. Install a N E W sealing ring.
N O T E : Make sure arrow on fuel pump points to-

ward the line on fuel tank.
5. Insert fuel pump locking ring over the fuel pres-

sure hose and electrical wiring connector.
1. Fuel pump module 6. While firmly holding pump down against tank,
2. Sealing ring engage fuel pump locking ring on fuel tank
3. Ensure the fuel pump motor is fully toward the flange.
front of the vehicle to ensure proper fuel float 7. Turn locking ring until it is fully engaged.
movement.
N O T E : Make sure the pump body has not ro-
tated during nut torquing procedure.
8. Tighten locking ring to specification.
Fuel pump nut tool

(P/N 529035899)
78
Fuel System
CLUSTER CONNECTOR PIN-OUT
TYPICAL - TORQUE WRENCH PERPENDICUL AR TO TOOL

HANDLE
Tightening Torque
29 ± 1 Nm
Fuel pump locking ring
(21 ± 1 lbf-ft) 06
9. Check fuel level sensor operation by connect-
ing the electrical connector and flipping the
tank upside down. FUEL PUMP PIN-OUT
10. Refill fuel tank and perform a Fuel Tank Leak
Test and a Fuel Pressure Test. Testing Fuel Level Sensor Wiring Continuity
FUEL LEVEL SENSOR 1. Disconnect the fuel pump module electrical
connector.
Testing the Fuel Level Sensor Resistance 2. Measure for continuity of the wiring from t he
fuel pump connector ( F P ) and the multifunc-
Fuel Level tion gauge cluster connector ( C L ) as per fol-
Cluster Fuel Pump
Sensor lowing table. Refer to the appropriate wiring
Connector
Resistance diagram for details.
Between pins 3 and 8 1 and 2
Continuity Test of Fuel Level Sensor Wiring
Resistance EMPTY: 90 ± 5Ω
reading Fuel pump
FULL: 6± 1Ω Cluster pin Resistance
pin
Carry out the
Testing the 1 3 Close to 0 Ω
If reading not as Fuel Level Replace the
fuel pump 2 8 Close to 0 Ω
specified Sensor
Wiring module.
If resistance readings are as specified, refer to
Continuity Bench Testing the Fuel Level Sensor.
If reading as Replace the multifunction Repair or replace wiring and connectors as
specified gauge. required.
FUEL PRESSURE REGULATOR
The fuel pressure regulator is mounted inside the
fuel pump.
The fuel pump pressure hose is connected to the
fuel rail. It provides the full fuel pump pressure to
the injector fuel rail.
79
Fuel System
The pressure regulator regulates the pressure 2. Disconnect purge valve vacuum hose from the
from the pump by bleeding away excess pressure intake manifold.
and returning it to the fuel pump.
Testing the Fuel Pressure Regulator
Refer to Testing the Fuel System Pressure.
N O T E : The fuel pressure regulator is an internal

component of the fuel pump module.
Replacing the Fuel Pressure Regulator
Replace the fuel pump module.
EVAP PURGE VALVE
EVAP Purge Valve Location
PURGE VALVE VACUUM HOSE
3. Install the vacuum/pressure pump on the vac-

uum hose.
(P/N 529021800)
4. Set vacuum/pressure pump to v a c u u m

function.
5. Activate vacuum/pressure pump until vacuum
reaches the specification. Air should not come
Testing the EVAP Purge Valve Using BUDS2 through the purge valve. Otherwise, replace
1. Remove RF D.E.S.S. key. the purge valve.
2. Press engine start button.
3. Using BUDS2, activate the purge valve. EVAP Purge Valve Vacuum
The operation of the solenoid can be felt within 20 kPa (3 lbf/in²) for 10 seconds
the purge valve.
If operation of the solenoid is felt when acti- 6. Remove RF D.E.S.S. key.
vated, carry out the Testing the Evap Purge 7. Press engine start button.
Valve Operation. 8. Using BUDS2, activate the purge valve as il-
lustrated in Testing the EVAP Purge Valve Us-
If solenoid does not function, carry out the ing BUDS2.
Testing the EVAP Purge Valve Solenoid.
Air should now flow through the purge valve
Testing the Evap Purge Valve Solenoid when you apply vacuum with the vacuum/pres-
1. Disconnect the purge valve connector. sure pump. If it does not, replace purge valve.
2. Connect small jumper wires to the purge valve 9. Remove the vacuum/pressure pump and re-
solenoid. connect the vacuum hose on the intake
3. Momentarily connect the jumper wires to a re- manifold.
mote 12 Vdc battery. Testing EVAP Purge Valve Input Voltage
If the solenoid does not function, replace it. 1. Remove fuel tank cover.
2. Disconnect the purge valve connector.
If the solenoid functions, carry out the Testing 3. Remove RF D.E.S.S. key.
the Evap Purge Valve Input Voltage. 4. Press engine start button.
Testing EVAP Purge Valve Operation 5. Set multimeter to Vdc and test circuit voltage
1. Pivot upper body module. as per following table.
80
Fuel System
EVAP Purge Valve Input Voltage 5. If continuity is good, carry out the Testing the
EVAP Purge Valve control Circuit.
Purge Valve Testing EVAP Purge Valve Control Circuit
Vehicle Result
Solenoid Continuity
Close to 1. Disconnect the A connector from the ECM.
Chassis
Pin B battery 2. Install the connector to the ECM adapter tool.
ground
voltage
ECM adapter tool
in this subsection. (P/N 529036166)
6. If input voltage is as specified, carry out the
Testing EVAP Purge Valve Control Circuit
Continuity.
7. If input voltage is not as specified, check the 3. Set multimeter to Ω and test for continuity of
fuel pump fuse. the purge valve control circuit (ground) as per
following table.
N O T E : If the fuel pump fuse is burned, the igni-
tion coils and injectors will not function either. EVAP Purge Valve Control Circuit
8. If fuse is good, carry out a Testing EVAP Purge EVAP Purge

Valve ECM adapter
Valve Input Circuit Continuity
Harness tool
Resistance 06
Testing EVAP Purge Valve Input Circuit Connector
Continuity
1. Remove the fuel pump fuse. A M3 Close to 0 Ω
2. Disconnect the purge valve connector.
3. Set multimeter to Ω and test for continuity of 4. If ground circuit is faulty, repair or replace wir-
the purge valve input circuit as per following ing and connector.
table. Removing the EVAP Purge Valve
EVAP Purge Valve Input Circuit Continuity 1. Disconnect purge valve electrical connector.
2. Remove Oetiker clamps securing hoses to
EVAP Purge purge valve.
Valve 3. Pull hoses off valve.
Fuse box Resistance
Harness
Installing the EVAP Purge Valve
Connector
Close to 0 Ω cedure. However, pay attention to the following.
B B5 (continuity)
1. Secure hoses to the purge valve using NEW
Oetiker clamps.
2. Reconnect purge valve connector.
FUSE BOX
4. If continuity is not good, repair or replace wiring

and connectors between fuse box and valve
connector.
81
Fuel System
EVAP CANISTER – Loose connections

– Secure Oetiker clamps.
EVAP Canister Location
Installing the EVAP Canister
procedure.
Use the exploded view to ensure proper vent hose
routing.
Removing the EVAP Canister

1. Remove the left side fairing and the fuel tank
cover.
2. Slide spring clamps securing hoses to EVAP
canister.
3. Remove support mounting screws and remove

canister.
Inspecting the EVAP Canister

Check canister and vent hoses for:
– Proper rooting an kinks
– Leaks
– Cracks
82
07
ELECTRICAL SYSTEM
83
Electrical System
POWER DISTRIBUTION AND GROUNDS
07 Electrical System
POWER DISTRIBUTION
AND GROUNDS
GENERAL
Power Distribution Diagram
Refer to appropriate wiring diagram.
In a colored wiring diagram, the power distribution
is shown in RED.
Overview
The battery is the primary source of power for the
electrical system, it is recharged by the magneto.
Some components are permanently connected to
the battery (unswitched) while some require a re-
lay or switch to be closed (switched). Fuse Box Items Description
At high RPM if the magneto power is greater than F8 F7 F5 F4 F3 F2 F1
the loads, the rectifier/regulator will regulate power RY3
as necessary.
The system uses an external voltage regulator/
rectifier.
RY2 RY1
FUSES
Fuse Locations
The fuse box is located in front of the vehicle, be-
side the battery. J5 J4 J2 J1
To access to the fuse box, remove the front serv-
ice cover. Refer to Service Covers section. Description Rating
F1 Horn / Hazard 7.5 A
F2 Headlamps 15 A
F3 USB / ACC 5A
F4 Cooling fan 15 A
F5 Fuel pump / Engine 20 A
F6 EMPTY -
F7 Electronic module 10 A
F8 Start button / Cluster 15 A
J1 VCM pump 40 A
J2 VCM valves 25 A
J3 EMPTY -
84
Electrical System
POWER DISTRIBUTION AND GROUNDS
Description Rating
J4 Main 30 A
J5 Battery 50 A
RY1 Main relay
RY2 Cooling fan relay
RY3 Headlamps relay
Relay Activation
ENGINE GROUND
Relay Activation Condition
Tightening Torque
Main power
relay Engine 10 ± 2 Nm
When key ON
(Left fuse box ground terminal (89 ± 18 lbf-in)
- LFB)
Load When engine speed reaches

shedding approx. 600 RPM
(Right fuse AND
box - RFB) Battery voltage is higher than
11.5 Vdc. 07
Grounds
Ground Locations
CHASSIS GROUND - ENGINE REMOVED FOR CLARITY
Tightening Torque
Chassis 7 ± 1 Nm
ground terminal (62 ± 9 lbf-in)
85
Electrical System
WIRING HARNESS AND CONNECTORS
WIRING HARNESS AND different number of pin cavities, are used on the
vehicle.
CONNECTORS
GENERAL
The illustrations in this subsection are typical. Sev-
eral variants of the connector types, such as
MSR TAS LHL FLF VSS1 CL USB - USB +
ENG_GND
MSL
DLC1
ACC HN -
GND FB
HN +
PGV CF
HO2S1
BAT -
FP FRF
RHL SAS
RFID
STS VSS2
RLFL
PRS
REG
VSS3
GND
VCM
ECM
PL + YRS
BFS
HIC
BLS
PL -
RRFL
CANADA AND USA MODELS
86
Electrical System
MSR TAS FLF VSS1 CL LHL USB + ENG_GND

RHL
DLC1
LBHL FB
HN -
MSL
HN +
ACC BAT +
USB - STS
GND RBHL
BAT -
PGV
FP CF FRF
RFID GND
REG VSS2
BFS
PRS HO2S1
RLFL_EXT (+) RLFL
YRS
SAS
RLFL_EXT (-) VSS3 RRFL_EXT (-)
RRFL BLS HIC ECM VCM
PL +
PL -
RRFL_EXT (+)
RRFL
07
RRFL
OUTSIDE CANADA AND USA MODELS

Connector Abbreviation Description
Vehicle Connector Code Description
Engine Connector Code Description BFS Brake fluid level switch
COIL Ignition coil BL Backup light
CPS Crankshaft position sensor BLS Brake light switch
CTS Coolant temperature sensor CF Cooling fan
ECMA Electronic control module – CH_GND Chassis ground
connector A
CL Multifunction gauge
ETC Electronic throttle control
CRZ Cruise control
INJ Fuel injector
DLC Diagnostic link connector
MAPTS Manifold air pressure and
temperature sensor ECMB Engine control module – connector
B
OPS Oil pressure switch
ENG_ Engine ground
Vehicle Connector Code Description GND
FB Fuse box
ACC Accessories connector
FLF Front left flasher
BAT Battery
FRF Front right flasher
87
Electrical System
Vehicle Connector Code Description Vehicle Connector Code Description

FP Fuel Pump RHL Right headlamp
HIC Harness inter connection RLFL Rear left light module
HO2S Oxygen sensor RLFL_EX Rear left flasher
HN Horn RRFL Rear right light module
LBHL Left low beam RRFL_EX Rear right flasher
LHL Left headlamp
SAS Steering angle sensor
LOCK Glove box lock
STS Starter solenoid
MSL Multifunction switch left
TAS Throttle sensor
MSR Multifunction switch right
USB USB connector
OBDII Diagnostic connectoc VCM Vehicle control module
PGV Purge valve VSS Vehicle speed sensor
PL Licence light YRS Yaw rate sensor
PRS Pillon rider switch
RBHL Right low beam
RFID RF identification key (D.E.S.S.)
88
Electrical System
Wiring Harness Splice Location
JT WH/BK JT BK1
JT WH/BG
07
JT BK3
89
Electrical System
JT GY/BN
JT GY
JT RD/YE
JT BK4
JT RD
JT RD/BU
JT RD/OG1 JT VT/BU JT BK2
90
Electrical System
JT GY/GN
JT GY/YE
JT WH
07
JT RD/OG2
JT BK6
91
Electrical System
PROCEDURES
This section gives the procedures in order to
quickly repair electrical harness splices.
1. Make sure to perform the usual electrical tests
before investigating the harness splices.
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 Splice Repair Procedures. NOTICE
3. To repair a splice, we recommend the use of a Be careful with the blade to avoid cutting
tin solder meeting the followings requirements wires insulation.
or an equivalent.
5. Slightly heat the shrink tube using a heat gun.
Tin Solder Requirements
SN 60
PB 40
DIA 0.062
FLUX RA 2%
Splice Repair Procedures

Case 1: Wire Detached from Splice
NOTICE 6. Remove the shrink tube with long nose pliers.
Repairs described in this section should
never be performed on harness sections that
can be exposed to water.
1. Locate splice. Refer to splices location

diagrams.
2. Remove wires from protector tube.
3. Locate the shrink tube protecting the defective
splice.
1. Detached wire
2. Splice
7. Locate detached wire from splice.

8. Twist detached wire around splice.
1. Shrink tube
4. Using a blade, cut the shrink tube.
1. Twisted wire
92
Electrical System
9. Perform a tin solder on twisted wire.

10. Apply electrical tape to cover splice. Make sure
tape overlaps on wire insulation, approximately
13 mm (1/2 in) each side.
11. Reinstall wires into protector tube.
Case 2: Wire Broken from Splice
NOTICE
Repairs described in this section should
never be performed on harness sections that
can be exposed to water. 6. Remove the shrink tube with long nose pliers.
7. Locate broken wire from splice.
1. Locate splice. Refer to splices location
diagrams.
2. Remove wires from protector tube.
3. Locate the shrink tube protecting the defective
splice.
1. Broken wire
2. Splice
07
8. Strip wire insulation at the end of broken wire.
1. Shrink tube
9. Strip wire insulation below the splice.
4. Using a blade, cut the shrink tube.
NOTICE 1. Broken wire stripped

Be careful with the blade to avoid cutting 2. Splice wire stripped
wires insulation. 10. Twist wire around stripped wire.
5. Slightly heat the shrink tube using a heat gun.
1. Twisted wire
93
Electrical System
11. Perform a tin solder on twisted wire.

12. Apply electrical tape to cover splice. Make sure
tape overlaps on wire insulation, approximately
13 mm (1/2 in) each side.
13. Reinstall wires into protector tube.
N O T E : Always perform a solder on a bigger wire
(lower gage).
Battery Cable Terminal
Crimping the Terminal
1. Carefully strip the wire approximately to 13 mm
(1/2 in) in length, using a wire stripping tool or
sharp blade/knife.
CRIMPING OF WIRE
A. 13 mm (1/2 in) PROPERLY CRIMPED WIRE
4. To verify, if the wire is properly crimped, apply

N O T E : Make sure not to cut wire strands while some pulling force on wire and the terminal at
stripping the wire. the same time from both directions.
2. Install the appropriate terminal on the wire ac- NOTICE

cording to the requirement. Refer to appropri- Never solder the wire to the terminal. Solder-
ate Parts Catalog. ing can change the property of the wire and it
can become brittle and break.
5. Install the protective heat shrink rubber tube on

the terminal. Heat the heat shrink rubber tube
using the heat gun so that it grasps the wire
and the terminal.
NOTICE
INSTALLATION OF TERMINAL Make sure that the protective heat shrink rub-
ber tube has been properly installed and no
part of wire is exposed.
N O T E : Different wires require different crimp pli-
ers settings, so make sure to follow the instruction
supplied with the tool.
3. After positioning the crimp pliers, crimp the ter-
minal already installed on wire.
94
Electrical System
IGNITION SYSTEM
IGNITION SYSTEM
SERVICE TOOLS
D.E.S.S. POST REMOVER . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529035943) . . . . . . . . . . . . . . . . . . . . . . . 111

ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036166) . . . . . . . . . . . . . . . . . . . . . . . . 97
GENERAL
WARNING
Locking devices when removed, must be re-
self-locking fasteners, cotter pins, etc.).
Cables and locking ties removed during a proce-

dure must be reinstalled as per factory standards.
NOTICE
600 ACE ENGINES
Never force a multimeter probe into an elec-
trical terminal. 07
System Description
The ignition system is a digital inductive type (IDI)
system.
Ignition system parameters such as ignition timing,
spark duration, and firing order, as well as many
other engine related functions are controlled by
the Engine Management System (EMS) in order
to meet engine operational requirements. The
EMS can detect many abnormalities including a
short circuit in the primary winding of the ignition
900 ACE ENGINES
coils as well as its associated circuits.
The direct ignition coils receive power from the When a ground signal is provided by the ECM to
Fuel Pump/Ignition Coils/Injectors fuse. an ignition coil primary winding, a high voltage is
induced in the coil secondary winding that is used
The 600 ACE engines have two (2) ignition coils to produce a spark at the spark plug electrode.
while the 900 ACE have three (3).
Cylinder 1 is located on the PTO side of the en-
gine. Each cylinder is identified by a number on
cylinder block housing.
600 ACE
95
Electrical System
IGNITION SYSTEM
TROUBLESHOOTING
It is good practice to check for fault codes using
the BRP diagnostic software (BUDS2) as a first
troubleshooting step.
Refer to Power Distribution and Grounds for infor-
mation on fuses and relays.
Always refer to the appropriate wiring diagram
when troubleshooting an electrical circuit.
NOTICE
Never force a multimeter probe into an elec-
CYLI NDER BLOCK - EXHAUST SIDE trical terminal.
900 ACE
N O T E : Install a battery charger on battery termi-
nals for any tests that involve a prolonged "key
ON" period. If battery voltage gets too low, some
accessories are shut off by the ECM and test re-
sults can be altered.
Ignition System Testing
The ECM controls the ignition system.
If a fault is detected by the ECM, the check engine
light will turn on.
The ECM can detect a problem on the primary
winding or circuit of the ignition coils.
CYLI NDER BLOCK - EXHAUST SIDE The secondary winding of the ignition coils is not
monitored by the ECM.
Ignition Timing
Other sensors in relation with the ignition system
Ignition timing is not adjustable. are also monitored by the ECM.
The ECM is programmed with ignition maps that it Testing Ignition System
uses along with data received from a variety of
sensors to establish optimum ignition timing under Check for fault codes using the BRP diagnostic
all engine operating conditions. software (BUDS2) as a first troubleshooting step.
It receives signals from a variety of sensors that it Ensure the ignition coil fuse and related relay are
compares with the ignition mappings and uses it powered and in good condition.
to control the ignition spark timing, duration and fir- If a fuse is burnt, test for a short circuit or faulty
ing order. component on that fuse circuit before replacing
The firing of each spark plug is independent of the the fuse.
other(s). Check ignition spark. Refer to Ignition Coils and
Engine RPM Limiter Spark Plugs in the appropriate Engine Service
Manual.
The ECM will limit the maximum engine speed by
cutting off ignition spark and fuel at a predeter- Diagnostic Guidelines
mined engine RPM. The following is provided to help in diagnosing the
probable cause of a problem. It is a guideline and
600 ACE 7300 RPM should not be assumed to list all possible causes.
900 ACE 8500 RPM
96
Electrical System
IGNITION SYSTEM
Troubleshooting Damaged trigger wheel or loose CPS

1. Engine Stop at Idle
–
Ensure it is not the Automatic Engine Shut Down. Defective ignition circuit
– Refer to Operator Guide for more detail. – Check fuses, ignition coils, wiring and
Check fuel level. connectors.
– Fill-up if necessary. Poor engine grounds
Check fuel filter. – Check grounds condition.
– Refer to Fuel Tank and Fuel Pump. 5. Engine Continually Backfires

Check fuses, ignition coils, wiring and connectors.
Fouled, defective spark plugs
– Repair or replace as required.
– Check spark plug condition. Replace if
necessary.
2. Engine Will Not Start (Engine Turns Over)
Damaged trigger wheel or defective or loose CPS
Fouled or defective spark plug
– Check.
necessary. 6. Engine Lacks Acceleration or Power
Defective CPS
Weak spark
– Test CPS.
– Check spark plugs, coils, wiring and 07
Defective trigger wheel connections.
– Check. PROCEDURES
Defective ignition circuit EMERGENCY ENGINE STOP SWITCH
– Check fuses, ignition coils, wiring and Emergency Engine Stop Switch Operation
connectors. The emergency engine stop switch provides a
ground signal to the ECM when RUN is selected.
3. Engine Hard To Start
The ground signal is applied to the ECM as per fol-
Faulty, fouled or worn out spark plug lowing table.
– Check spark plug condition. Replace if Right multifunction

necessary. ECM
switch
Drowned engine Pin 1 A1
– Check engine temperature value using
Testing the Emergency Engine Stop Switch
BUDS2. Continuity
– If the temperature read is lower than the ambi-
ent temperature, CTS sensor may be defective 1. Remove all necessary panels to reach the
or have a bad connection. Therefore, the ECM ECM.
would erroneously set the engine in cold start 2. Disconnect the connector B from the ECM.
mode and it could flood the spark plugs. 3. Install the connector on the ECM adapter tool.
ECM adapter tool

4. Engine Misfires, Runs Irregularly
(P/N 529036166)
Fouled, defective, worn spark plugs
necessary. 4. Check switch continuity as per following table.
97
Electrical System
IGNITION SYSTEM
Emergency Engine Stop Switch Continuity Test 5. If it does not turn on, check the start button and
(at ECM) wiring.
Start Button Resistance Test
Switch
ECM pin Battery Result 1. Disconnect the multi switch connector.
position
2. Using a multimeter, measure resistance as per
Infinite the following table.
STOP (OL)
A1 Ground Start Button
Position Resistance
Close to 0 Connector Pin
RUN
Ω
Switch Infinite (OL)
5. If readings are as specified, the emergency en- released
gine stop switch and its circuit to the ECM are Switch 3 4
good. de
6. If readings are not as specified, disconnect the 0.6 Ω max.
pressed
RH multifunction switch connector (MSR). and held
7. Check switch continuity as per following table.
3. Replace start button if defective.
Emergency Engine Stop Switch Continuity Test
(at MSR connector) STOP SWITCH
Switch Stop Switch Test with BUDS2

Connector pins Result 1. Connect the vehicle to the BRP diagnostic soft-
position
ware (BUDS2).
Infinite 2. In BUDS2, go to:
STOP (OL)
2 1 – M e a s u r e m e n t s page
Close to 0 – E C M button
RUN
Ω – C u s t o m tab.
3. Press the vehicle's stop switch and look at the
8. If readings are as specified, check wiring and S t o p S w i t c h value.
connectors between the emergency engine 4. It should turn on, indicating the stop signal
stop switch connector and the ECM. reaches the ECM.
9. If readings are not as specified in table, check 5. If it does not turn on, check the stop switch and
wiring and connections going to switch. If wiring.
good, replace the switch.
Stop Switch Resistance Test
D.E.S.S. POST
1. Disconnect the multi switch connector.
Refer to Radio Frequency Digitally Encoded Se- 2. Using a multimeter, measure resistance as per
curity System (RF D.E.S.S.). the following table.
START BUTTON
Stop Switch
Position Resistance
Start Button Test with BUDS2 Connector Pin
1. Connect the vehicle to the BRP diagnostic soft- Switch
ware (BUDS2). 0.6 Ω max.
released
2. In BUDS2, go to:
Switch 1 2
– M e a s u r e m e n t s page de
– E C M button Infinite (OL)
pressed
– C u s t o m tab. and held
3. Press the vehicle's start button and look at the
S t a r t S w i t c h value. 3. Replace stop switch if defective.
4. It should turn on, indicating the start signal
reaches the ECM.
98
Electrical System
CHARGING SYSTEM
CHARGING SYSTEM
SERVICE PRODUCTS
DIELECTRIC GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
GENERAL
WARNING
Locking devices when removed, must be re-
self-locking fasteners, cotter pins, etc.).

procedure must be reinstalled as per factory
standards.
System Description
The purpose of the charging system is to keep the
battery at a full state of charge and to provide the TYPICAL 07
electrical system with the required electrical power
for normal vehicle operation. Voltage Regulator/Rectifier
Battery The rectifier receives AC current from the magne-
The battery supplies DC power to the electric to and transforms it into direct current (DC).
starter for cranking the engine. During engine The voltage regulator, included in the same unit,
starting, it also supplies DC power to all electrical limits voltage to prevent any damage to electrical
and electronic systems, including alternator field components.
current. At low engine RPM operation and high
current load conditions, it supplements the alterna-
tor output (if required), and helps to maintain a
steady system voltage.
Magneto
The magneto is the primary source of electrical
energy. It transforms magnetic field into electric
current (AC).
The magneto has a 3–phase, series stator.
TYPICAL – VOL TAGE REGUL ATOR/RECTIFIER
INSPECTION
Charging System Output
First ensure that battery is in good condition prior
to performing the following tests.
Testing the Output Voltage
ware (BUDS2) and activate the roller bench
mode.
99
Electrical System
CHARGING SYSTEM
In BUDS2, go to: Always refer to the appropriate wiring diagram

– M e a s u r e m e n t s page when troubleshooting an electrical circuit.
– E C M button
– B a t t e r y v o l t a g e (V) NOTICE
2. Lift rear of vehicle by passing a suitable lifting Never force a multimeter probe into an elec-
strap under the seat as shown. trical terminal.
Troubleshooting
1. Battery Regularly Discharged or Weak
Loose or corroded battery cables connections.

– Tighten or repair battery cables connections.
Worn or defective battery.
– Charge and test battery.
Defective magneto stator.
– Test stator.
Defective regulator/rectifier.
PASS LIFTING STRAP UNDER SEAT
– Test system voltage.
WARNING
Damaged magneto rotor or Woodruff key.
Do not sit on vehicle while engine is running.
– Replace magneto rotor or Woodruff key.
3. Start engine.
4. Increase engine RPM as specified in the fol- PROCEDURES
lowing table. Voltage Regulator Wire Identification
Output Voltage Test Using BUDS2 Function Pin

Engine Speed Voltage (DC) 12 Vdc output RD1-1
4000 RPM 14.3 ± .3 Vdc 12 Vdc ground RD1-3
If voltage is above specification, replace volt- 12 Vac input RD2-1

age regulator/rectifier. 12 Vac input RD2-2
If voltage is below specification, check stator
12 Vac input RD2-3
output and wiring harness prior to concluding
that voltage regulator/rectifier is defective. Re-
fer to Magneto and Starter subsection. Load Testing the Battery
1. Connect a battery load tester to battery.
TROUBLESHOOTING 2. Ensure proper test conditions.
It is good practice to check for fault codes using
Test Conditions
troubleshooting step. Initial battery voltage Above 12.5 Vdc
Refer to Power Distribution and Grounds for infor- Engine OFF
mation on fuses and relays.
3 times the amp-hour
Load (AH) rating
Time 15 seconds
100
Electrical System
CHARGING SYSTEM
If battery voltage drops below specification during

test, replace battery. Proceed to Load Testing the
Charging System.
Specification
Battery Above 9.6 Vdc
Load Testing the Charging System

+
RD
RD1 -
+
TYPICAL - DC CURRENT TEST WITH INDUCTIVE AMMETER
1. Output connector of voltage regulator
2. Ammeter clamped over RED wire
8. Ensure proper test conditions.

- Test Conditions
RD2
Battery voltage at idle Above 12.6 Vdc
1. Connect a battery load tester to the battery.
2. Start vehicle and read voltage on tester. Engine Increase to 4000 RPM
Specification As required to
Load decrease battery
voltage to 12 Vdc
07
Voltage 12.5 - 15 Vdc
Time 15 seconds
3. If voltage is a b o v e specification, replace regu-
lator and continue the procedure. 9. Read amperage on ammeter.
4. If voltage is l o w e r than specification, stop
engine. Specification
ware (BUDS2) and activate the roller bench Amperage 30 ± 5 Amps
mode.
6. Lift rear of vehicle by passing a suitable lifting
strap under the seat as shown.
N O T E : With a fully charged battery and no elec-
trical loads, specification is less than 10A.
10. If amperage or voltage is not within specifica-

tion, verify magneto and wires.
11. Replace voltage regulator if magneto test is
within specifications.
12. Replace magneto if magneto test is not within
specifications.
VOLTAGE REGULATOR (RD)
Voltage Regulator Continuity Test
Due to internal circuitry, there is no static test
available.
PASS LIFTING STRAP UNDER SEAT Accessing the Voltage Regulator

The voltage regulator is located on the LH side,
WARNING behind the wheel.
7. Connect an ammeter around RD1-1 wire.
101
Electrical System
CHARGING SYSTEM
Voltage Regulator Power Test

PASS L IFTING STRAP UNDER SEAT
1. Check voltage at RD1-1.
+ WARNING
RD Do not sit on vehicle while engine is running.
RD1 -
+

5. Start vehicle.
Test Conditions
-
RD2
Engine Increase to 4000 RPM
Test Conditions
As required to
RD1-1 Hot at all times Load decrease battery
voltage to 12 Vdc
BackProbe Probe Specification
Time 15 seconds
RD1-1 BAT2 (-) Battery voltage
7. Measure voltage drop.
ware (BUDS2) and activate the roller bench +
RD
mode. RD1 -
+
3. Lift rear of vehicle by passing a suitable lifting

strap under the seat as shown.
-
RD2
RD1-1 BAT1 (+) Under 0.4 Vdc
8. If voltage drop is above specification, locate

and repair damaged connector or wire.
Voltage Regulator Ground Test
1. Check ground at RD1-3.
102
Electrical System
CHARGING SYSTEM
+ Test Conditions
RD
RD1 -
As required to
+
Load decrease battery
voltage to 12 Vdc
Time 15 seconds
- 7. Measure voltage drop.

RD2
+
RD
RD1 -
+
Test Conditions
RD1-3 Permanent ground
RD1-3 BAT1 (+) Battery voltage -

RD2
ware (BUDS2) and activate the roller bench
mode.
3. Lift rear of vehicle by passing a suitable lifting RD1-3 BAT2 (-) Under 0.4 Vdc
strap under the seat as shown. 07
8. If voltage drop is above specification, locate
and repair damaged connector or wire.
BATTERY
Battery Information
These vehicles are equipped with a VRLA battery
(Valve Regulated Lead Acid).
It is a sealed, maintenance-free, non-spillable
type battery.
Refer to the battery manufacturer's instructions for
proper charging procedures.
PASS LIFTING STRAP UNDER SEAT Accessing the Battery
The battery is located under the front service
WARNING cover.

5. Start vehicle.
Test Conditions
Engine Increase to 4000 RPM
103
Electrical System
CHARGING SYSTEM
3. Recharge the battery once a month with an ap-

proved battery charger as per manufacturer's
recommendations.
4. Clean battery, battery support and connections
as required, refer to Cleaning the Battery.
5. For other recommendations during storage, re-
fer to battery manufacturers instructions.
WARNING
Ensure battery is stored in a safe place, out
of reach for children.
Removing the Battery Activating a New Battery

1. Disconnect BLACK (-) cable first, then the Refer to the instructions provided with the battery.
RED (+) cable. Charging the Battery
NOTICE WARNING
Always respect this order for removal; dis- Always charge in a well ventilated area.
connect BLACK (-) cable first. Never charge or boost a battery while it is in-
stalled on vehicle. Do not open the sealed
2. Remove battery. cap during charging. Do not place battery
near open flame.
Cleaning the Battery
1. With the battery removed from vehicle, clean
the battery rack, cables, battery casing and
NOTICE
posts using a solution of baking soda and If battery becomes hot, stop charging and al-
water. low it to cool before continuing.
2. Remove any corrosion from battery cable ter-
minals and battery posts using a firm wire N O T E : Sealed VRLA batteries have an internal
brush. Rinse with clear water and dry thor- safety valve. If battery pressure increases due to
oughly using a clean cloth. overcharging, the valve opens to release excess
3. Apply a light coat of dielectric grease on pressure, preventing battery damage.
terminals.
1. An automatic charger is a fast and convenient
Dielectric grease way for error-proof charging.
2. Always follow the battery manufacturer's
Inspecting the Battery charging instructions.
Visually inspect battery casing for cracks or any 3. When using a constant current charger, charge
other damage. If casing is damaged, replace bat- battery according to the chart below.
tery and thoroughly clean battery rack with a water Battery Voltage Below 12.8 V and Above 11.5
and baking soda solution. V
Inspect battery posts, connectors, battery rack, Standard Charging
battery holding strap and strap attachment points. (Recommended)
Storing the Battery
Time Charge
1. It is not necessary to remove the battery during
vehicle storage but it is recommended for long 4 - 9 hours 2A
term storage.
2. If the battery is left in the vehicle during storage Quick Charging
or used infrequently, disconnect the BLACK (-)
negative battery cable to eliminate battery cur- Time Charge
rent drain from the electrical equipment.
50 minutes 10 A
104
Electrical System
CHARGING SYSTEM
Installing the Battery

Installation is the reverse of removal procedure.
NOTICE
Always connect RED (+) cable first then
BLACK (-) cable.
07
105
Electrical System
STARTING SYSTEM
STARTING SYSTEM Defective or discharged battery

– Test battery.
GENERAL
System Description Defective START button or ignition circuit
The starting system is composed of an electric – Check START button or ignition circuit.
starter supplied in current by the battery through a
solenoid. 3. Engine Does Not Crank But Gauge Turns On
The starter solenoid receives a 12 volt input from Defective brake switch
the ignition switch and the ground signal is pro-
vided by the ECM when the following engine – Check brake switch.
cranking conditions are met.
Defective START button or circuit
– Emergency engine stop switch to RUN
– D.E.S.S. recognizes the key – Test the START button.
– Start button activated Defective starter solenoid or circuit
– Brake pedal applied
– Safety card acknowledge done – Test starter solenoid.
TROUBLESHOOTING Defective engine stop switch

It is good practice to check for fault codes using – Test engine stop switch.
Defective starter motor
troubleshooting step.
– Check starter motor.
Clear any fault code after solving a problem.
Always refer to the appropriate wiring diagram PROCEDURES
when troubleshooting an electrical circuit. STARTER SOLENOID
Refer to Power Distribution and Grounds for fuses Accessing the Starter Solenoid Connector
and relays information. To access starter solenoid:
Check all connections, cables and wires. – Open front storage compartment.
– Remove storage bin and service cover.
Tighten any loose connections.
Replace any chafed or corroded wires or cables.
Diagnostic Guidelines
Troubleshooting
1. The Starting Fuse Burns While Attempting to
Crank Engine
Defective starter solenoid

– Test starter solenoid.
Wiring short to ground
– Check wiring.
2. Engine Does Not Crank and Gauge Does Not The starter solenoid is located under the front
Turn On service cover, behind the fuse box.
Burnt main fuse (J4) Testing the Starter Solenoid Input Voltage
– Check fuse and replace if necessary. 1. Disconnect connector.
Burnt starting fuse

– Check fuse and replace if necessary.
106
Electrical System
STARTING SYSTEM
2. Wake up the ECM by installing the D. E. S. S. 2. Apply 12Vdc to B terminal.

key on the D. E. S. S. post and pushing the 3. Ground the A terminal.
START button.
3. Measure voltage as per following table.
07
Starter Solenoid Input Voltage Test
Result
(Start Button
Test Probes Released and All
Starting
Conditions Met)
Battery
Pin B Battery voltage
ground
B IS THE LEFT TERMINAL
Testing the Starter Solenoid Operation 4. If starter runs, carry out the Testing the Starter
Solenoid Input Voltage.
5. If starter does not run, carry out the Testing the
+
-
Starter Solenoid Winding Resistance.

Testing the Starter Solenoid Ground Signal
1. Disconnect connector.
1. Disconnect connector
107
Electrical System
STARTING SYSTEM
Starter Solenoid Winding Resistance Test

Solenoid pin Result
Approximately
B A
5Ω
2. Wake up the ECM by installing the D. E. S. S. 3. If measurement is out of specification, replace

key on the D. E. S. S. post and pushing the solenoid.
START button.
3. Measure voltage as per following table. Testing the Starter Solenoid Voltage Drop
1. Wake up the ECM by installing the D. E. S. S.
Starter Solenoid Ground Signal Test key on the D. E. S. S. post and pushing the
START button.
Result 2. Measure voltage as per following table while
Test Probes (Start Button cranking engine in d r o w n e d m o d e (to prevent
Depressed) engine starting).
Battery N O T E : For drowned mode, refer to Engine Man-
Pin A Battery voltage
positive post agement System subsection.
Testing the Starter Solenoid Winding Starter Solenoid Voltage Drop Test
Resistance
1. Disconnect terminals from solenoid. Result (While
Test Probes Cranking)
2. With a multimeter, check primary winding re-
sistance as follows.
Post
coming Post going to
from 0.2 Vdc max.
starter
battery
108
Electrical System
STARTING SYSTEM
3. If voltage is out of specification, replace

solenoid.
07
109
Electrical System
DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)
DIGITALLY ENCODED
SECURITY SYSTEM (D.
E.S.S.)
SERVICE TOOLS
D.E.S.S. POST REMOVER . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529035943) . . . . . . . . . . . . . . . . . . . . . . . 111

ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036166) . . . . . . . . . . . . . . . . . . . . . . . . 97
TROUBLESHOOTING
Diagnostic Guidelines
The following is provided to help in diagnosing the
probable cause of a problem. It is a guideline and
should not be assumed to list all possible causes.
Troubleshooting
1. Key Not Read (Condition Can Be Duplicated
With a Magnet on the D.E.S.S. Post)
Damaged RFID chip

No voltage at pins C and/or D of the RFID
connector
– Try a new key
3. Briefly press the start button to wake up the
– Refer to appropriate wiring diagram and / or electrical system.
Ignition System and troubleshoot RF D.E.S.S. / 4. In BUDS2, go to:
engine cut-off switch
– K e y s page
2. Invalid Key – Press R E A D button
– Press A D D button.
Key not programmed to ECM
The new key should now be displayed in the
– Program key table.
PROCEDURES RF D.E.S.S. Key Recognition

Ignition Key To allow key recognition, carry out the following
steps:
Adding a Key
1. Install the RF D. E. S. S. key on the D. E. S. S.
1. Connect the vehicle to the BRP diagnostic soft- post.
ware (BUDS2). 2. Briefly press the start button to wake up the
2. Install a RF D.E.S.S. key on the D.E.S.S. post. electrical system.
Erasing a Key
1. Install the RF D.E.S.S. to be erased on the D.
E.S.S. post.
2. In BUDS2, go to:
– K e y s page
– Click on E r a s e K e y .
110
Electrical System
DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)
After approximately 10 seconds the following 4. Install and align the engine cut-off switch in this
message will appear: hole.
5. Secure the engine cut-off switch using the
The key is now erased. large plastic nut.
Erasing All Keys 6. Connect the RFID connector.
1. In BUDS2, go to: 7. Install all removed parts.
8. Test operation of the engine cut-off switch.
– K e y s page
– Click on E r a s e A l l K e y s .
2. When done, program at least one new key to
the vehicle. Refer to Adding a Key in this
subsection.
RF D.E.S.S. Post Operation
Testing the Continuity of the D.E.S.S. Post
1. Disconnect the RFID connector.
2. Using a multimeter, measure resistance as per
following table.
RFID Reading
PIN Key Ω
Installed Close to 0 Ω
A to B 07
Removed Infinite Ω
RFID Reading
Post ECM Ω
A F2 Close to 0 Ω
B E4 Close to 0 Ω
C B2 Close to 0 Ω
RFID Reading
Post Fuse Box Ω
D B7 Close to 0 Ω
3. If continuity is good, wiring and connectors are

functional. Replace the D.E.S.S. post.
Replacing the D.E.S.S. Post
1. Remove all panels necessary to reach the
RFID connector.
2. Unscrew the large plastic nut retaining the en-
gine cut-off switch in place.
D.E.S.S. Post Remover

(P/N 529035943)
3. Remove the engine cut-off switch.
111
Electrical System
LIGHTS
LIGHTS
GENERAL
NOTICE
It is recommended to always disconnect the
battery when replacing any electrical compo-
nent. Always disconnect battery as specified,
BLACK (-) cable first. Do not place tools on
battery.
WARNING
Do not place tools on battery.
CANADA AND USA
Clean threads before applying a threadlocker. Re- 1. Headlight — high and low beams
fer to Self-Locking Fasteners and Loctite Applica- 2. Turn signal lights/Position lights
procedures.
WARNING
be strictly adhered to. Locking devices when
removed, must be replaced (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners,
cotter pins, etc.).
System Description (Lighting System)

Front Lights JAPAN
STD and Sport Models 1. Headlight — low beam

2. Headlight — high beam
3. Turn signal lights/Position lights
AUSTRALIA
1. Headlight — low beam RUSSIA
2. Turn signal lights/Hazard warning lights 1. Headlight — low beam
3. Headlight — high beam 2. Headlight — high beam
4. Position lights 3. Turn signal lights/Position lights/Hazard warning lights
112
Electrical System
LIGHTS
CANADA AND USA
ALL OTHER COUNTRIES 1. Headlight — high and low beams

1. Headlight — low beam
3. Signature light
Rally Models
07
JAPAN
AUSTRALIA
2. Turn signal lights/Hazard warning lights
3. Position lights
5. Signature light
RUSSIA
3. Turn signal lights/Position lights/Hazard warning lights
4. Signature light
113
Electrical System
LIGHTS
ALL O THER COUNTRI ES

1. Headlight — low beam CANADA AND USA
1. Brake lights/Turn signal lights/Tail lights
2. License plate light
4. Signature light
Rear Lights
STD and Sport Models
JAPAN
1. Brake lights
2. Turn signal lights/Tail lights/Hazard warning lights
3. RED reflectors
5. Reverse light
AUSTRALIA
1. Brake lights
3. RED reflectors
5. Reverse light
RUSSIA
1. Brake lights
3. RED reflectors
114
Electrical System
LIGHTS
CANADA AND USA
ALL OTHER COUNTRIES 1. Brake lights/Turn signal lights/Tail lights

1. Brake lights
2. Turn signal lights/Tail lights
3. RED reflectors
Rally Models
07
JAPAN
1. Brake lights
3. RED reflectors
5. Reverse light
AUSTRALIA
1. Brake lights
3. RED reflectors
5. Reverse light
RUSSIA
1. Brake lights
3. RED reflectors
115
Electrical System
LIGHTS
Turn Signal Lights

When the turn signal switch on the left front multi-
function switch is activated, a signal is generated
by the module in the switch assembly. This signal
is sent to the multifunction gauge.
ALL O THER COUNTRI ES

1. Brake lights
3. RED reflectors
Headlights
The headlights automatically come ON when the L R
engine is started and reaches 800 RPM, and go
OFF automatically 20 seconds after engine shut
down.
The headlight beam selector switch is located in
the left multifunction switch.
1. L = Left turn signal

2. R = Right turn signal
The turn signals will turn off automatically in the

following conditions:
1. After the vehicle has made a turn, the multi-
function gauge is programmed to turn the sig-
nals off, after a certain amount of degrees of
steering has been made and then returned to
center. The multifunction gauge receives a
1. High beam position CAN signal from the SAS (Steering Angle Sen-
2. Low beam position sor) to determine when the turn has been
initiated.
North American Models
The high and low beams are incorporated into a N O T E : The turn signals turn off automatically
single unit (one each side). Each unit contains a after a normal turn, however after a shallow turn or
double filament bulb, one filament for LOW lane change they may have to be turned off
beams, and one filament for HIGH beams. manually.
All Except North American Models 2. If turn signals are left ON, they will automati-
cally turn off after 30 seconds while the vehicle
The low beams are located on the upper frame on is moving.
each side of the vehicle, while the high beams are
located in the console assembly. N O T E : If the vehicle did not move, they will stay
ON until selected OFF, or until the ignition key is
switched OFF.
116
Electrical System
LIGHTS
The turn signals can be turned off manually at any Power for the flashers/hazard lights comes from
time by pressing in the turn signal button on the the multifunction switch (cluster).
left multifunction lever.
Position Lights / License Plate Light
Hazard Warning Lights Operation Position Lights
Australian and Russian Models Only This vehicle is equipped with two position lights,
When the hazard switch is pushed, a voltage sig- one located on top of each front fender.
nal is sent from the hazard switch to the multifunc- The two position lights (or marker lights) come ON
tion gauge. when the ignition switch is ON. They receive
The hazard warning flasher button is located on power from the ignition switch and will remain on
the right side of the left side multifunction switch. as long as the ignition switch is left ON.
Position Lights
This vehicle is equipped with two position lights,
one located on top of each front fender.
The two position lights (or marker lights) come ON
when the electrical system is awakened. They re-
ceive power from the main relay and will remain
on as long as the electrical system is awake.
License Plate Light
A single light bulb is used in the license plate light.
It receives power from the ignition switch and will
remain ON as long as the ignition switch is left
07
ON.
The multifunction gauge is programmed to turn on
the lights when it receives this voltage signal. If License Plate Light
the multifunction gauge receives another voltage An LED is used in the license plate light.
signal from the hazard switch, it will turn off the
hazard lights. It receives power from the main relay and will re-
main ON as long as the electrical system is
The hazard warning flashers are powered directly awake.
by the battery and can be activated even when en-
gine is turned off. Reverse Light Operation
Australian Models
Taillights and Brake Lights
This vehicle is equipped with two taillight assem- When the gearbox is shifted into reverse, a signal
blies. LED tail/brake light and flashers. The tail is sent to the ECM. A CAN (Controller Area Net-
light is always lit when the ignition key is turned work) protocol signal is generated by the ECM.
ON and act as rear position (or parking) lights. This CAN signal indicating gearbox is in reverse is
sent to the multifunction gauge.
For more information, refer to Taillight/Brake Light/
Flasher in this subsection. The multifunction gauge interprets the CAN sig-
nals from the ECM and is programmed to provide
Power for the taillights (rear position lights) comes voltage to the back up light.
from the main relay. When the electrical system is
awakened (engine does not need to be started), All other models
the following lights turn on: All turn signals are activated when the gearbox is
– Taillights (rear position lights) shifted into reverse.
– Front position lights
– License plate light. TROUBLESHOOTING
Diagnostic Tips
Power for the brake lights comes from the BLS
(Brake Light Switch) located on the brake pedal I M P O R T A N T : When solving an electrical prob-
assembly at the master cylinder. lem, the first thing to do is to check the battery
condition as well as its cables and connections.
117
Electrical System
LIGHTS
Install a battery charger on battery terminals for

any tests that involves a prolonged "key ON" peri- 90°
od. If battery voltage gets too low, not only test re-
sults can be altered, but the vehicle electrical
system may not operate normally.
Pay attention to ground wires. They could become TYPICAL
loose or corroded which causes them to act as an
additional load in a circuit, dropping voltage and 3. Trace 2 lines parallel with the ground on the
reducing current to components. Some compo- test surface as per the follow table:
nents may be grounded through their outer casing Ryker 600ACE
and mounted hardware. This should also be
considered. 486 mm
Line A (19.134 in)
Electrical Connectors
Pay particular attention to ensure that pins are not 449 mm
out of their connectors, loose, or damaged. The Line B (17.677 in)
troubleshooting procedures may not cover prob-
lems resulting from one of these causes. Ryker 900ACE
NOTICE 481 mm
Ensure all terminals are properly crimped on Line A (18.937 in)
wires and connector housings are properly
fastened. When replacing any electric or 443 mm
electronic part(s), always check electrical Line B (17.441 in)
connections. Make sure that they are clean,
corrosion-free, tight and make good contact. Ryker Rally 900ACE /
The voltage and current might be too weak to Ryker Sport 900ACE
go through dirty or corroded connector pins
or terminals. 466 mm
Line A (18.346 in)
PROCEDURES
429 mm
HEADLIGHTS Line B (16.89 in)
Verifying the Headlights Aiming
The headlight aiming verification must be per- 4. Select H I G H beam.
formed without weight on the vehicle. 5. Beam aiming is correct when the focus point
(brightest spot) of the headlight reflection is be-
Canada and USA tween the marks.
1. Verify tires are correctly inflated. See the Tire
Label located inside the right side service A
cover.
2. Position the vehicle at 10 m (33 ft) from a test B
surface.
Make sure the vehicle is level and positioned
perpendicularly with the test surface. TYPICAL - HEADLIGHT REFLECTION ON TEST SURFACE
All Other Countries

1. Verify tires are correctly inflated. See the Tire
A Label located inside the right side service
90°
cover.
2. Position the vehicle at 10 m (33 ft) from a test
TYPICAL surface.
A. Distance from the test surface
Make sure the vehicle is level and positioned
perpendicularly with the test surface.
118
Electrical System
LIGHTS
497 mm
Line C (19.567 in)
A
446 mm
90° Line D (17.559 in)
TYPICAL
A. Distance from the test surface 4. Select H I G H beam.
5. Beam aiming is correct when the focus point
(brightest spot) of the headlight reflection is be-
90°
tween the lines A and B.
TYPICAL B
3. Trace 4 lines parallel with the ground on the

test surface as per the follow table:
TYPICAL - HEADL IGHT REFL ECTION ON TEST SURFACE
Ryker 600ACE
6. Select L O W beam.
486 mm 7. Beam aiming is correct when the focus point
Line A (19.134 in) (brightest spot) of the headlight reflection is be-
tween the lines C and D.
449 mm
Line B (17.677 in) C 07
517 mm
Line C (20.354 in) D
TYPICAL - HEADL IGHT REFL ECTION ON TEST SURFACE

466 mm
Line D (18.346 in)
Headlights Aiming Adjustment
Ryker 900ACE The headlight aiming adjustment must be per-
formed without weight on the vehicle.
481 mm
Line A Canada and USA
(18.937 in)
1. Remove the side fairing.
443 mm 1. Open the glove box and slide the fuel filler
Line B (17.441 in) door backward.
511 mm
Line C (20.118 in)
461 mm
Line D (18.15 in)
Ryker Rally 900ACE /

Ryker Sport 900ACE
466 mm TYPICAL
Line A (18.346 in)
2. Remove and keep the plastic rivets retain-
429 mm ing the side fairing.
Line B (16.89 in)
119
Electrical System
LIGHTS
TYPICAL
TYPICAL
3. Pull the front bottom corner to unlatch the 2. Remove and keep the plastic rivets retaining
retaining tab. the side fairing.
4. Remove the side fairing. TYPICAL

2. Open the right service cover. Refer to Service 3. Pull the front bottom corner to unlatch the re-
Covers section. taining tab.
3. Using the screwdriver provided with the ve-
hicle, adjust each headlight by turning gently
the headlight adjuster located on the headlight
housing.
WARNING
Adjust both headlights evenly.

2 5. Open the right service cover. Refer to Service
Covers section.
6. Using the screwdriver provided with the ve-
hicle, adjust each headlight by turning gently
the adjusters located on the headlight housing.
1. Headlight adjuster for the horizontal adjustment (left and right)
2. Headlight adjuster for the vertical adjustment (up and down) WARNING
4. When completed, reinstall all removed parts. Adjust both headlights evenly.
All Other Countries
High Beam
1. Open the glove box and slide the fuel filler door
backward.
120
Electrical System
LIGHTS
1 Switch Ohm (Ω)

Pin
Position
LO beam 0Ω
2 10
HI beam O.L.
12
HI beam 0Ω
4
LO beam O.L.
1. Adjuster for the horizontal adjustment (left and right)
2. Adjuster for the vertical adjustment (up and down)
Hi/Low Beam Headlight Bulbs (Inside North
7. When completed, reinstall all removed parts. America)
Low Beam
Using the screwdriver provided with the vehicle,
adjust each projector by turning gently the adjust-
ers located on the projector housing
WARNING
Adjust both headlights evenly.
1
2
07
2. Disconnect the headlight connector.
1. Adjuster for the horizontal adjustment (left and right)

2. Adjuster for the vertical adjustment (up and down)
Testing the Headlight Beam Selector Switch

1. Remove the left side fairing panel.
2. Disconnect the multifunction switch (MSL).
3. Remove the headlight bulb cover.
3. Using a multimeter, measure the resistance as

follows.
121
Electrical System
LIGHTS
Hi Beam Headlight Bulbs (Outside North

America)
4. Turn the bulb stopper counterclockwise to un-

lock it.

2. Disconnect the headlight connector.
5. Remove the defective bulb.

6. Install the new bulb. Align bulb tabs with hous-
ing recesses.
WARNING 3. Remove the headlight bulb cover.

Improper bulb installation, may cause its dis-
lodgement from the headlight housing.
In this situation, the bulb could enter into con-
tact with the headlight housing, lens or any
other parts located in this area, resulting in
parts melting and/or fire hazard.
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 and a clean cloth.
7. Secure the bulb in place by turning the bulb

stopper clockwise. 4. Turn the bulb stopper counterclockwise to un-
8. Properly reinstall all parts in the reverse order lock it.
of their removal.
122
Electrical System
LIGHTS
LICENSE PLATE LIGHT
5. Remove the defective bulb. Replacing the Licence Plate Light

6. Install the new bulb. Align bulb tabs with hous-
ing recesses.
WARNING
Improper bulb installation, may cause its dis-
lodgement from the headlight housing.
In this situation, the bulb could enter into con-
tact with the headlight housing, lens or any
other parts located in this area, resulting in 07
parts melting and/or fire hazard.
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 and a clean cloth.
7. Secure the bulb in place by turning the bulb

stopper clockwise.
8. Properly reinstall all parts in the reverse order
of their removal.
Low Beam Headlight Projectors (Outside
North America) Tightening Torque
The bulb in the low beam projectors cannot be re-
placed. In the unlikely event they do not work, License plate bulb 0.55 ± 0.15 Nm
have projectors replace. retaining screws (5 ± 1 lbf-in)
FRONT TURN SIGNAL AND HAZARD

WARNING LIGHTS
Testing the Front Turn Signal Lights
1. Perform following test at front turn signal light
connector.
2. Turn ignition ON and activate turn signal switch
on side to be tested.
123
Electrical System
LIGHTS
Front Turn Signal Test 2. Disconnect multifunction switch connector

(MSL).
Test Probes Results 3. Using a multimeter, measure the resistance as
follows.
Pin 2 Pin 3 Pulsing 8 to 12 Vdc
Switch Ohm (Ω)
Chassis Pin
Pin 3 Pulsing 8 to 12 Vdc Position
ground
Right 0
Positive PIN 8
battery Close to battery Left O.L.
Pin 2 voltage PIN 3
connec Left 0
tion PIN 7
Right O.L.
3. If results are as specified, replace turn signal
light assembly. HAZARD WARNING LIGHTS SWITCH
4. If there is no voltage at pin 3, refer to Testing
the Turn Signal Switch with BUDS2. Testing the Hazard Warning Lights Switch
5. If result at pin 2 is not as specified, repair If the hazard and brake lights do not function, in-
ground circuit. spect the fuse F7 and the fuse F8.
Replacing a Front Turn Signal Light (Australia) If the turn signals function but the hazard warning
1. Remove the low beam cover. lights do not, perform the following test.
2. Disconnect the light. 1. Remove the multifunction gauge.
3. Remove light. 2. Perform the following test at the multifunction
4. Install new turn signal light. gauge connector.
Replacing a Front Turn Signal Light/Position
Light (All Countries except Australia) Hazard Warning Lights Switch Test at
Gauge Connector
1. Remove the front fender and disconnect the
position light. Switch
2. Remove and discard the reflector. Test Probes Result
Condition
Close to
Pin 18 and
Activated battery
chassis ground
voltage
3. If test is within specification, replace the multi-

function gauge.
4. If test is not within specification, refer to Test-
ing the Hazard Warning Switch at the RH Multi-
function Switch Connector.
3. Remove the screw securing the position light

to the front fender.
4. Remove position light.
5. Install new position light.
6. Clean the front fender surface using isopropyl
alcohol, then install a new reflector.
TURN SIGNAL LIGHT SWITCH
Testing the Turn Signal Light Switch
1. Remove the left side fairing panel.
124
Electrical System
LIGHTS
TAILLIGHT/BRAKE LIGHT/FLASHERS Replacing Brake Light Assembly (North

America models)
1. Remove the licence plate light.
2. Remove this screw located under the licence
plate location.
3. Lift rear trim panel starting by the front.

CANADA AND USA
07
OUTSIDE OF CANADA AND USA
Testing the Taillights/Brake Lights

1. Check system fuse(s).
2. Measure voltage at the taillight connector using
the following table. 4. Remove the following fasteners.
Taillight/Brake Light Test

Test Probes Condition Results
Close to
Pin 4 to chassis Brakes
battery
ground applied
voltage
Close to
Pin 3 to chassis Ignition battery
ground switch ON voltage
3. Connect a test light to battery B+ terminal.

4. Probe pins 1 with the test light.
1. Light comes on. Grounds OK.
2. Light does not come on. Check ground
wires.
125
Electrical System
LIGHTS
Tightening Torques
5.5 ± 0.5 Nm (49 ± 4
M6 X 14 lbf-in)
2.5 ± 0.5 Nm (22 ± 4
M5 X 16 lbf-in)
0.55 ± 0.15 Nm (5 ± 1
K40 X 12 lbf-in)
Replacing Brake Light Assembly (Outside

North America)
1. Remove brake light assembly.
2. Disconnect taillight/turn signal light.
5. Remove light.
3. Remove the screw securing the taillight/turn

signal light support.
6. The assembly is the reverse of the removal

procedure. However, pay attention to the
following.
4. Remove the nut securing the LED light to the
support.
126
Electrical System
LIGHTS
FRONT POSITION LIGHTS, TURN SIGNAL

LIGHTS AND HAZARD WARNING LIGHTS
5. Remove light.
Testing the Position Lights

Check system fuse(s).
1. Measure voltage at the position light connector 07
6. The installation is the reverse of the removal using the following table.
following. Position Light Test
Tightening Torque Test probes Condition Result
5.5 ± 0.5 Nm Close to
M6 X 14 Pin 1 to chassis Ignition
(49 ± 4 lbf-in) battery
ground switch ON voltage
2.5 ± 0.5 Nm
M5 X 16 (22 ± 4 lbf-in) 2. Connect a test light to battery B+ terminal.
0.55 ± 0.15 Nm 3. Probe pin 2 with the test light.
K40 X 12 (5 ± 1 lbf-in) 1. Light comes on. Grounds OK.
wires.
Replacing a Position Light
Refer to Replacing a Front Turn Signal Light/Posi-
tion Light (All Countries except Australia) in this
subsection
BACK UP LIGHT
Australian Models
127
Electrical System
LIGHTS
7. Lift rear trim panel starting by the front.
Testing the Back Up Light

Before testing the system, connect the vehicle to
the BRP diagnostic software (BUDS2) and ensure
Ryker Conversion Australia is selected. 8. Cut wires and measure voltage using the fol-
lowing table.
1. Check system fuse(s).
2. Get access to the cluster connector.
3. Start the engine and put vehicle in reverse.
4. Back probe connector as follow:
Reverse Light Test at Gauge Connector

Test Probes Condition Result
Close to
Pin 9 to chassis Vehicle in battery
ground reverse voltage
5. Remove the licence plate light.

6. Remove the screw located under the license
plate location.
Reverse Light Test
Test Probes Condition Result
Close to
PK/BG wire to Vehicle in battery
chassis ground reverse voltage
9. Connect a test light to battery B+ terminal.

10. Probe BK wire.
128
Electrical System
LIGHTS
If tests fail, replace reverse light.

1. Light comes on. Grounds OK.
wires.
Replacing the Back Up Light
1. Remove the back up light using the following
illustrations.
07
2. Install new light by using heat shrink tubes.

129
Electrical System
LIGHTS
3. Insert wires into heat shrink , ensuring the

wires pass beyond the soldered part of the
heat shrink.
4. Use a heat gun and evenly heat all around the
heat shrink.
5. Ensure all soldering material has melted, and
both sealant sections also have shrunk onto
wires.
130
Electrical System
Gauge 4.5" Compact
Gauge 4.5" Compact NOTICE

It is recommended to always disconnect the
General battery when replacing any electrical compo-
Refer to the appropriate wiring diagram to trouble- nent. Always disconnect battery as specified,
shooting the system. BLACK (-) cable first.
Indicator Lamps Description

Important information about vehicle condition is displayed on the multifunction gauge. When starting the
engine, always look at the gauge for any indicator lamps or special messages.
Indicator Lamps (Malfunctions)

Indicator
Digital Warning Cause
Lamp(S)
– Use the right key for the vehicle.

Wrong or – Program a new key if the previous key
None BAD KEY defective key is defective.
– Check wiring and connectors.
Engine is – Stop and wait for engine to cool off.

HIGH ENGINE
overheating – Check for leaks.
TEMPERATURE
– Check and adjust the coolant level.
ON 07
LO BATT VOLT – Recharge battery.
Low or high – Check battery connections.
or battery voltage
HI BATT VOLT – Check the charging system.
ON
ABS – Check the brake system.
ABS FAULT malfunction. No
ON ABS operation
– Check the VSS system.

VSS FAULT VSS malfunction
ON
EBD – Check the brake system.
EBD FAULT
malfunction
Low brake fluid – Check for brake fluid leaks.
ON BRAKE FAILURE level or faulty – Check and adjust the brake fluid level.
sensor
– Move the park position lever in the

locked position.
Park position
FLASHING NONE lever not locked
+ at key off
BEEPING AT
KEY OFF
Engine – Stop the engine. The cluster must be
management completely shuts down.
CHECK ENGINE
component
ON malfunction
131
Electrical System
Gauge 4.5" Compact
Indicator Lamps (Malfunctions)

Indicator
Digital Warning Cause
Lamp(S)
Important – Connect the vehicle to the BRP
engine diagnostic software (BUDS2). Check
LIMP HOME MODE management faults codes and perform
component or recommended actions.
FLASHING
VSS malfunction
NONE Low oil pressure – Check for oil leaks.

– Check and adjust the engine.
ON
Variable messages - The message changes in accordance with the defective

component.
ON
Troubleshooting Multifunction Gauge Troubleshooting
Diagnostic Tips Troubleshooting
I M P O R T A N T : When solving an electrical prob- 1. Gauge Functions Inoperative or Working
lem, the first thing to do is to check the battery Intermittently
condition as well as its cables and connections.
Power supply or ground problem
Make sure the battery is fully charged or install a
power pack for any tests that involves a prolonged – Check power supply and ground circuits.
"key ON" period. If battery voltage gets too low,
not only test results can be altered, but the vehicle Procedures
electrical system may not operate normally. Multifunction Gauge
Pay attention to ground wires. They could become Testing the Multifunction Gauge
loose or corroded which causes them to act as an Before beginning any troubleshooting, test or re-
additional load in a circuit, dropping voltage and pair, always check for fault codes.
reducing current to components. Some compo-
nents may be grounded through their outer casing 1. Check for fault codes using BUDS2.
and mounted hardware. This should also be 2. Record all fault codes, then erase them.
considered. 3. Perform a complete shutdown of the electrical
system and reactivate it.
Electrical Connectors 4. Check fault codes. If a previous fault codes re-
Pay particular attention to ensure that pins are not appears, perform the required service actions.
out of their connectors, loose, or damaged. The Testing the Multifunction Gauge Using BRP
troubleshooting procedures may not cover prob- Diagnostic Software (BUDS2)
lems resulting from one of these causes.
NOTICE ware (BUDS2).
2. In BUDS2, select the following:
Ensure all terminals are properly crimped on
wires and connector housings are properly – F u n c t i o n s page
fastened. When replacing any electric or – Routines - Execute Cluster WOW test.
electronic part(s), always check electrical 3. All indications will come and stay ON so that
connections. Make sure that they are clean, you can verify each indication.
corrosion-free, tight and make good contact.
The voltage and current might be too weak to N O T E : The W O W T e s t only tests the gauge
go through dirty or corroded connector pins L E D s and L C D . It does not test the actual circuit
or terminals. functions related to each indication.
132
Electrical System
Gauge 4.5" Compact
Testing the Multifunction Gauge Power Input 3. If the ground tested to specification, continue
1. Remove the multifunction gauge. with Testing the Multifunction Gauge CAN Wire
2. Perform the test at multifunction gauge con- Circuit.
nector as per following illustration and tables. Testing the Multifunction Gauge CAN Circuit
1. Remove the front service cover for access to
the DLC (Diagnostic Link Connector)..
2. Test as per the following table.
Multifunction Gauge CAN Wire Test

CL
DLC Results
Connector
Pin 13
(CAN HI) Pin 1
MUL TI FUNCTION GAUG E CONNECTOR (PINOUT) Close to 0.4 Ω
Pin 14
(CAN LO) Pin 2
Multifunction Gauge Power Test
Cl Connector Battery Result 3. If the CAN wire verification test fails, check the
related circuit.
With the D.E.S.S. key installed 4. If the multifunction gauge functions, however
there is a suspected communication problem
Close to with another component, perform this test be-
Pin 11
Negative (-)
post
battery tween the multifunction gauge and that 07
voltage component.
5. If the multifunction gauge power, ground and
With the D.E.S.S. key installed and START CAN verification tests are all to specifications
button pressed and the multifunction gauge is inoperative, re-
Close to place the multifunction gauge.
Negative (-)
Pin 1 battery
post
voltage
3. If there is no power at pin 1, check the cluster

fuse and the related circuit.
4. If there is no power at pin 11, check the CL,
ECM fuse, the MAIN relay, and the related
circuit.
5. If the power test is within specification, contin-
ue with Testing the Multifunction Gauge
Ground Circuit.
Testing the Multifunction Gauge Ground
Circuit
1. Test as per the following table.
Multifunction Gauge Ground Test
CL Connector Battery Result

Negative (-)
Pin 2 post Close to 1 Ω
2. If the ground at pin 2 is not within specification,

check the related circuit.
133
Electrical System
Gauge 4.5" Compact
Removing the Multifunction Gauge Vehicle Mileage Transfer

1. In BUDS2, go to:
– S E T T I N G S page
– C L U S T E R button
– S E T T I N G S tab.
2. Select I n c r e a s e O d o m e t e r M i l e a g e .
3. Click on the upper right arrow in the green
circle.
4. Read carefully the on-screen instructions be-
fore clicking in the value box.
5. Enter the new mileage if it is different from the
indicated one.
6. Press SET button.
7. Press the WRITE TOTAL button.
8. Select OK to confirm the mileage.
9. Close the window.
Setting Language and Units of Measurement
1. In BUDS2, go to:
– S E T T I N G S page
– C L U S T E R button
– S E T T I N G S tab
– Configure Language and Units.
Installing the Multifunction Gauge

1. The installation is the reverse of the removal
following.
Tightening Torque
Multifunction 2.5 ± 0.5 Nm
gauge retaining (22 ± 4 lbf-in)
screws
2. Start the vehicle and test gauge functions.

3. If the multifunction gauge was replaced, con-
nect the vehicle to the BRP diagnostic software
(BUDS2) and apply any available updates.
4. When updates are completed, perform the
following:
– Transfer the vehicle mileage as described
in Vehicle Mileage Transfer.
– Change settings as per customer preferen-
ces (language and units) as described in
Setting Language and Units of
Measurement
134
DRIVE SYSTEM
08
135
DRIVE SYSTEM
Propeller Shaft and Rear Wheel
08 DRIVE SYSTEM
SERVICE TOOLS
65MM SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036457) . . . . . . . . . . . . . . . . . . . . . . . 138

BACKLASH MEASUREMENT TOOL . . . . . . . . . . . . . . . . . . (P/N 529036387) . . . . . . . . . . . . . . . . . . . . . . . 142
SERVICE PRODUCTS
XPS SYNTHETIC GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
136
DRIVE SYSTEM
300 ± 15 N•m
(221 ± 11 lbf•ft)
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
16 ± 3 N•m
(142 ± 27 lbf•in)
NEW
NEW 08
NEW
7.5 ± 1 N•m
(66 ± 9 lbf•in)
137
DRIVE SYSTEM
GENERAL
During assembly or installation, use the torque
values and service products as in the exploded
view(s).
procedure.
WARNING
Locking devices when removed (e.g.: locking 4. Loosen the center lock wheel nut.
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced. 65mm socket
(P/N 529036457)
NOTICE
During installation, make sure every part is
free from old grease and dirt. This allows for
a clean reassembly and will avoid premature
wear caused by dirt contamination.
NOTICE
Hoses, cables and locking ties removed dur-
ing a procedure must be reinstalled as per
factory standards. 1. RED locking clip
2. Center lock wheel nut
Road test vehicle at moderate speeds a few mi- 5. Lift and support the rear of the vehicle using
nutes to ensure normal operation following main- the following locations.
tenance or repair.
PROCEDURES
REAR WHEEL
Removing the Rear Wheel
1. Place the vehicle on a level surface.
2. Move the park position lever in the locked
position.
3. Remove the RED locking clip.
6. Unscrew caliper retaining bolts from the LH
side and move the caliper aside.
138
DRIVE SYSTEM
Tightening Torque
Center lock wheel 300 ± 15 Nm

nut (221 ± 11 lbf-ft)
WARNING
Failure to install the RED locking clip may
cause the loss of a wheel if the center lock
wheel nut becomes loose.
7. Remove the center lock wheel nut and the con-
ical washer. 4. Install the RED locking clip. The folded end
8. Remove the wheel from the vehicle. must point inside the drive axle. Ensure the
RED locking clip is seated correctly on nut.
NOTICE
Never loosen the nut to align the RED locking
clip hole. Tighten the nut to the nominal val-
ue, then tighten further to align the hole.
1
2. Conical washer
Installing the Rear Wheel

cedure. However, pay attention to the following. 08
NOTICE
The installation instruction and tightening tor-
que values must be strictly adhered to. Fail-
ure to do so can lead to rim damage.
1. Folded end pointing inside the drive axle
1. Each time the rear wheel is removed, apply

synthetic grease on brake disc splines.
XPS synthetic grease
NOTICE
All contact surfaces of the wheel, wheel hub,
brake disc and the thread in the wheel hub
must be free of abrasion, sand, dust or chips.
Do not use fluids of any kind to wash the sur-
faces, use only dry soft cloth.
2. Install the conical washer and the center lock

wheel nut.
3. Tighten the center lock wheel nut to
specification.
NOTICE
Never use impact tools to tighten wheel nuts.
139
DRIVE SYSTEM
Final Drive Unit

Removing the Final Drive Unit
1. Remove the following.
REAR TIRE
Tire Pressure
Use the recommended cold inflation pressure for 2. Disconnect speed sensor connector and cut
optimum tire performance and wear. Under-infla- locking ties.
tion or over-inflation may cause uneven tread
wear patterns.
Recommended tire inflation pressure is found on
the Tire Label located inside the right side service
cover.
When weather temperature changes occur, tire in-
flation pressures also change. A drop of 6 °C (10 °
F) can cause a corresponding drop of 7 kPa (1
PSI)in inflation pressure. Check tire pressures fre-
quently and adjust them to the proper pressure
Recommended Tire
Refer to Technical Specifications for recom- 1. Speed sensor connector
mended tire. 2. Locking ties
Inspecting the Rear Tire 3. Remove rear wheel.

4. Remove the following fasteners.
Refer to Front Tires in Steering and Front Wheels
subsection.
Replacing the Rear Tire
Refer to Replacing Front Tires in Steering and
Front Wheels subsection.
140
DRIVE SYSTEM
RYKER 90 0 RALLY EDITION
5. Pull final drive unit.

08
ALL OTHER MODELS
6. Remove the pinch bolt.
141
DRIVE SYSTEM
4. Position the dial indicator tip against the tab at

a 90° angle.
5. Gently, move the tool tab back and forth. Note
N O T E : To prevent oil spillage, the speed sensor the backlash result.
should be left installed on the rear final drive unit. 6. Rotate pinion gear 1/2 turn and recheck back-
lash. Note the result.
Inspecting the Rear Final Drive (Assembled) 7. Rotate pinion gear 1 turn and recheck
Manually turn rear final drive gear; it should turn backlash.
smoothly. Repair if necessary.
Backlash Specification
Check if oil seal is brittle, hard or damaged. Re-
place if necessary. 0.132 to 0.264 mm
(.005 to .01 in)
Measuring the Backlash
1. Install wheel on final drive unit and hand 8. If backlash is out of specification, replace final
tighten. drive unit.
2. Put wheel flat on workbench.
3. Place the backlash measurement tool at the Installing Final Drive Unit
end of pinion gear. The installation is the reverse of the removal pro-
Backlash measure-
ment tool 1. Install the upper rear final drive retaining
(P/N 529036387) screws first.
2. Hand tighten all screws prior to final tightening.
torque.
4. Refill the final drive with recommended oil.
Verifying the Final Drive Unit Oil Level
1. Remove rear wheel.
2. With the vehicle on a level surface, remove the
oil level plug.
1. Install backlash measurement tool here
142
DRIVE SYSTEM
Filling the Final Drive Unit Oil

1. Fill the final drive unit 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
plug to specification.
Tightening Torque
16 ± 2 Nm
Oil level plug
(142 ± 18 lbf-in)
Propeller Shaft
3. Check oil level. Removing the Propeller Shaft
4. The oil should be level with the bottom of the
Remove rear final drive unit.
oil level hole.
Inspecting the Propeller Shaft
NOTICE
1. Inspect if propeller shaft is not bent or twisted.
Operating the final drive unit with an improper 2. Check propeller shaft splines for wear or
oil level may severely damage it. damage.
3. Inspect if propeller shaft U-Joint.
5. Reinstall oil level plug. 4. Replace if necessary.
Tightening Torque Installing the Propeller Shaft

16 ± 2 Nm cedure. However, pay attention to the following.
Oil level plug
(142 ± 18 lbf-in)
1. Install a N E W stop ring. 08
Draining the Final Drive Unit Oil
Remove magnetic drain plug and sealing ring. Dis-
card sealing ring.
2. After propeller shaft insertion in rear final drive,

validate if properly locked.
torque.
Propeller Shaft U-Joint
Removing the Propeller Shaft U-Joint
Reinstall magnetic drain plug with a NEW sealing
ring. 1. Remove internal snap ring from bearing caps.
Tightening Torque
16 ± 2 Nm
Magnetic drain plug
(142 ± 18 lbf-in)
143
DRIVE SYSTEM
TYPICAL
TYPICAL
1. Snap ring 3. Using a suitable pusher, fully seat bearing cap
2. Support inner yoke in vice and drive other yoke on one side.
down with a soft hammer.
TYPICAL
TYPICAL 4. Install snap ring.

5. Complete installation for the other bearing
3. Support U-joint in vice and drive inner yoke caps.
down to remove remaining bearing caps.
4. Remove U-joint cross.
Installing the Propeller Shaft U-Joint
1. Install new U-joint in inner yoke.
2. Install bearing caps. Use a vise to push bear-
ing caps.
144
CHASSIS
09
145
CHASSIS
VEHICLE STABILITY SYSTEM (VSS)
09 CHASSIS
VEHICLE STABILITY
SYSTEM (VSS)
SERVICE PRODUCTS
BRP HEAVY DUTY CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................... 157

LOCTITE 243 (BLUE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................... 205
XPS ROADSTER WASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................... 220
XPS SYNTHETIC GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................... 207
XPS SYNTHETIC SUSPENSION GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................... 194
WARNING Subsystem Function

Torque wrench tightening specifications must Prevents the loss of steering
be strictly adhered to. control in normal riding
Locking devices must be replaced with new conditions as well as in
ones when removed (e.g.: locking tabs, elas- SCS
emergency avoidance
tic stop nuts, cotter pins, etc.). (Stability
maneuvers.
Control
It applies braking power to the
System)
NOTICE appropriate wheel. It may also
Hoses, cables or locking ties removed during reduce engine torque as
the procedure must be reinstalled as per fac- necessary.
tory standard. Prevents the wheels to lock while
ABS
braking.
GENERAL (Antilock
It reduces braking power to the
Braking
System Description (Features) appropriate wheel by modulating
System)
The VSS maintains vehicle control in normal riding brake pressure as necessary.
conditions as well as in emergency avoidance EBD
maneuvers. Allows the distribution between
(Electronic
front and rear brakes to be
The VSS uses the following subsystems to Brake
adjusted according to conditions.
achieve its goals. Distribution)
Optimizes rear wheel traction to
help keeping the vehicle on its
TCS
intended trajectory.
(Traction
It reduces engine torque as
Control
necessary.
System)
It may also apply brake on rear
wheel if necessary.
The VSS coordinates the SCS, ABS, EBD and

TCS to work together to allow maximum vehicle
control while accelerating, decelerating, turning
and braking.
146
CHASSIS
VSS
System Description (Components)
(Vehicle Stability
System) Vehicle Control Module (VCM)
The Vehicle Control Module (VCM) is the heart of
the vehicle stability system (VSS).
VCM
SCS ABS EBD TCS

(Stability (Antilock (Electronic (Traction
Control Braking Brake Control
System) System) Distribution) System)
Stability Control System (SCS)

The SCS helps to maintain control in normal riding
conditions as well as in emergency avoidance ma-
neuvers by modulating the brake fluid pressure to
the brake calipers. There are several possibilities
for braking modulation. It can, as needed, prevent
a front wheel from lifting by applying the brake on
the opposite wheel and reduce the engine torque
if necessary.
Anti-Lock Braking System (ABS)
The ABS prevents the wheels to lock while brak- The Vehicle Control Module (VCM) is the heart of
ing. The vehicle configuration allows a single the vehicle stability system (VSS). It contains 2 mi-
brake point at the right foot, to provide the optimal croprocessors, 2 hydraulic pumps, several sole-
amount of hydraulic brake pressure on all three noids and passageways to the 3 brake calipers.
wheel's brake discs, under a multitude of braking The VCM receives inputs from several sensors
and road conditions. The result is maximizing ve- and performs calculations to cycle the pump and
hicle control while allowing the wheels to remain solenoids to apply or relieve hydraulic pressure to
available to generate steering control force in re- or from the vehicle brake calipers. In addition the
sponse to the rider’s input. VCM has the ability to send a signal to the ECM to 09
Electronic Brake Distribution (EBD) reduce engine torque if necessary.
The EBD allows the distribution between front and
rear brakes to be adjusted according to conditions.
Based on inputs from the various sensors, it
achieves an efficient braking by reacting to vehicle
weigh transfer by reducing the rear braking pres-
sure as needed.
Traction Control System (TCS)
The TCS optimizes rear wheel traction to help
keep the vehicle on its intended course. It can re-
duce engine torque if necessary. It may also apply
brake on rear caliper if necessary.
The TCS will limit rear wheel spin.
At lower throttle opening, TCS will manage rear
wheel slip to allow maximum acceleration and
control.
147
CHASSIS
VSS Sensors
Sensor
Description Function
Acronym
Signals the VCM
when the PRS
switch is activated.
the VCM applies
changes to the
Pillion rider control
PRS
switch parameters,
mainly to reduce
maximum allowed
lateral acceleration
and yaw.
Signals the ECM
that the vehicle
has begun
Brake light
BLS braking. The ECM
switch
then broadcasts
the signal to the
VCM via CAN bus.
1. Wheel speed sensor (rear)
2. Wheel speed sensors (front) Signals the VCM
3. Vehicle control module (VCM) in case of a low
4. Steering angle sensor (SAS) Low pressure
5. Yaw rate sensor (YRS) LPS pressure situation
6. Pillion rider sensor (PRS) switch in the braking
7. Brake fluid level sensors (BFS) hydraulic system.
8. Brake light switch (BLS) and low pressure switch (LPS)
Signals the VCM

Sensor in the event of a
Description Function Brake fluid
Acronym BFS low brake fluid
level sensor
level in the dual
Determines the reservoir.
Wheel speed
VSS1 speed of the LH
sensor # 1
front wheel.
Determines the
Wheel speed
VSS2 speed of the RH
sensor # 2
front wheel.
Determines the
Wheel speed
VSS3 speed of the rear
sensor # 3
wheel.
Determines the
Steering angle of the front
SAS angle sensor wheels in relation
to the vehicle.
Measures lateral
and longitudinal
Yaw rate accelerations, as
YRS
sensor rotation speed
(yaw rate).
148
CHASSIS
VSS Inputs/Outputs
Input Usage Output
YRS
Longitudi
nal
accelera
tion
Lateral These sensor
accelera signals (or – Modulate
tion parameters) are brake fluid
used by the pressure to
VSS (3) VSS to perform proper
Front computations caliper.
brake and to then act – Engine
pressure by providing the torque
(inside proper reduction. The YRS measures lateral and longitudinal accel-
VCM) output(s). eration as well as vehicle rotation rate.
SAS
PRS
BLS thru
ECM
LPS This sensor is
used to monitor
proper VSS
system
BFS operation. They
are not used to
– Fault codes.
09
perform
computations.
The YRS and SAS are input sensors that, in addi-

tion to monitoring, broadcast their values to the
CAN bus to be used by other electronic modules. This VCM input helps to determine the direction
and velocity in which the vehicle mass is actually
Yaw Rate Sensor (YRS) traveling.
The YRS is located under the frame, at the middle
of vehicle between the frame side bars. The VCM calculates the acceleration, deceleration
and rotation of the vehicle. It determines the veloc-
ity and direction, calculates the force (weight) and
adjusts the VCM parameters accordingly.
Steering Angle Sensor (SAS)
The SAS is attached to the bottom of the right pit-
man arm.
149
CHASSIS
REAR WHEEL SPEED SENSOR
There are 3 wheel speed sensors on the vehicle,

The SAS informs the VCM of the handlebar posi- one for each wheel. The wheel speed sensors are
tion in relation to the chassis. hall effect type sensors that send a digital signal to
the VCM.
N O T E : To test, replace and reset the steering As the wheel rotates, the teeth on the encoder
angle sensor (SAS). Refer to Steering and wheel pass in front of the sensor. The output fre-
FRONT Wheels subsection. quency of the sensor is proportional to the wheel
Pillion Rider (Passenger) Switch rotation speed.
The Pillion Rider Switch (PRS) is a magnetic
switch located under the seat. A magnet installed
on the left footpeg activates the PRS when in low-
er position and informs the VCM.
The center of gravity and weight is much affected
by the presence of a passenger therefore, the
VSS behavior will change based on the addition of
the second rider.
Wheel Speed Sensor (VSS)
FRONT WHEELS
The inputs to the VCM from the wheel speed sen-

sors are major inputs to the initiation of ABS, EBD
and TCS.
FRONT WHEEL SPEED SENSOR
150
CHASSIS
Brake Fluid Level Sensor (BFS) point, the VSS checks the pressure in the system
and reacts accordingly.
If there is a loss of pressure (leak or air in the sys-
tem), the pedal would travel further than the pre-
defined stroke and activate the LPS function. This
will inform the VCM of the low pressure condition.
There is also an internal brake pressure sensor for
the front brake circuit in the VCM. Its pressure sig-
nal output can be viewed using the BRP diagnos-
tic software (BUDS2).
TROUBLESHOOTING
Install a battery charger on battery terminals
(under seat) for any tests that involve a prolonged
"key ON" period. If battery voltage gets too low,
The brake fluid level in the dual reservoir is moni- the VSS shuts off, some accessories are shut off
tored by one switch. Each reservoir section have by the ECM and test results can be altered.
magnets. The switch is positioned so that both
magnets can trigger the signal when any or both NOTICE
reservoirs fluid level are low. Never force a multimeter probe into an elec-
trical terminal.
The switche inform the VCM in the event of a low
fluid level in any section of the dual reservoir or an Troubleshooting Tips
open circuit or short circuit in the brake fluid level
sensor (BFS) connections. If the vehicle is in limp home mode and the appli-
cable indicator lights remain ON in the multifunc-
Brake Light Switch (BLS) tion gauge, the VSS does not work.
The brake light switch (BLS) also act as the low Start troubleshooting by checking fault codes us-
pressure switch (LPS). The switch is located close ing BUDS2. Make sure fuses J1 and J2 in fuse
to the master cylinder. It is activated by the brake box are good; follow the service actions in the fault
pedal. codes section. Refer to Diagnostic and fault 09
codes.
Carry out the tests in this subsection according to
the fault codes informations. Refer to Diagnostic
and fault codes subsection.
PROCEDURES
WARNING
The recommended tire pressure is critical for
optimal VSS operation. Use only recom-
mended tire dimensions and type.
YAW RATE SENSOR (YRS)

The BLS turns on the brake lights and supplies the
ECM a signal that the operator is applying the YRS Connector Location
brakes. The ECM sends the message to the VCM The YRS is located under the vehicle.
via CAN.
Under normal operation during a light to medium
braking, the brake lever does not activate the LPS
function.
The switch is positioned so that it will be activated
only when a predefined stroke is reached. At this
151
CHASSIS
Testing YRS CAN Lines

1. Read wiring resistance between diagnostic link
connector (DLC) and YRS.
YRS CAN Line Test

YRS
CAN DLC Result
Connector
High Pin 3 Pin 1 Close to 0
Low Pin 2 Pin 2 Ω
2. If continuity is not good, check wiring and con-

nectors from DLC to YRS connector.
3. If everything tested good, try a new YRS.
Removing the YRS
1. Lift and support front of vehicle. Refer to intro-
duction subsection.
Testing YRS Input Voltage 2. Disconnect the YRS connector.
1. Disconnect the YRS connector. 3. Remove YRS screws.
2. Press engine start button. Installing the YRS
3. Read voltage as follows.
YRS Input Voltage tTest cedure. However, pay attention to the following.
YRS NOTICE
Battery Result
Connector The YRS is very fragile. Do not drop or hit.
Handle with care. Replace if dropped or
Negative (-) Battery damaged.
Pin 4 post voltage
1. Tighten screws to specification.
If voltage is not good, check wiring and con-
nectors. Refer to wiring diagram. Tightening Torque
If voltage is good, carry out the Testing the
7 ± 1 Nm
YRS Ground Circuit procedure. YRS retaining screws
(62 ± 9 lbf-in)
Testing the YRS Ground Circuit
1. Check the ground circuit as per the following 2. Reset the YRS.
table. Resetting YRS
YRS Ground Circuit Test 1. Place vehicle on a flat level surface.
2. Connect vehicle to BRP diagnostic software
YRS Battery (BUDS2).
Result
Connector 3. In BUDS2, go to:
Positive (+) Battery – S e t t i n g s page
Pin 1 post voltage – V C M button.
– S e t t i n g s page
2. If ground circuit is not good, check wiring from 4. Have someone sit on the vehicle seat.
YRS connector to battery ground. 5. Click on I n i t i a l i z a t i o n - R e s e t L o n g i t u d i n a l
3. If continuity is good, continue with Testing the Offset.
YRS CAN Lines.
152
CHASSIS
PILLION RIDER (PASSENGER) SWITCH

(PRS) Continuity Test of PRS Sensor Wiring
PRS Location Resistance

Probe Connectors Reading At
The Pillion Rider Switch (PRS) is a reed switch lo-
21°C (70°F)
cated under the seat.
Testing the PRS Close to 0 Ω
PRS-1 VCM-10 (continuity)
1. Connect vehicle to the BRP diagnostic soft-
ware (BUDS2). Close to 0 Ω
2. In BUDS2, select the following: PRS-2 VCM-30 (continuity)
– M e a s u r e m e n t s page
– V C M button. 3. If resistance is not within specification, check
3. Open the left passenger footpeg. wiring and connectors, repair or replace as
necessary.
N O T E : The P i l l i o n R i d e r s w i t c h value should Removing the PRS
change in BUDS2.
Pivot upper body module.
If the pillion rider switch value does not Disconnect PRS connector.
change, carry out a Testing the PRS
Resistance. Installing the PRS
4. Retract the left passenger footpeg. The installation is the reverse of the removal pro-
NOTE: The pillion rider switch value should
change. Apply tape on wiring as shown.
Testing the PRS Resistance
1. Disconnect PRS connector. Refer to prs con-
nector location.
2. Test resistance as follows.
PRS Resistance Test
No Passenger With Passenger
09
Position Position
4400 ± 88 Ω 98 ± 2 Ω
If resistance is not within specification, confirm

magnet presence.
To confirm the magnet presence, repeat the
resistance test but take a magnet close to the
switch. Passenger mode is active when the
magnet is close.
Testing the PRS Circuit Continuity Brake Fluid Level Sensor (BFS)
1. Disconnect the PRS connector. BFS Location
2. Measure for continuity of the wiring from the
The Brake Fluid Level Sensor (BFS) is a reed
PRS connector and the VCM as per following
switch located in the brake fluid reservoir.
table. Refer to the appropriate wiring diagram
for details. BFS Connector Location
The Brake Fluid Level Sensor (BFS) connector is
located behind the brake fluid reservoir.
153
CHASSIS
Testing the BFS WHEEL SPEED SENSOR (WSS)

1. Disconnect BFS connector. Refer to BFs con-
nector location.
2. Test resistance as follows.
BFS Resistance Test
Float Up (Full) Float Down (Empty)
4400 ± 88 Ω 98 ± 2 Ω
3. If resistance is not within specification, confirm

magnet presence.
4. To confirm the magnet presence, repeat the
resistance test but take a magnet close to the
switch. Passenger mode is active when the
magnet is close.
Testing the BFS Circuit Continuity FRONT WHEEL SPEED SENSOR
1. Disconnect the BLS connector.

2. Measure for continuity of the wiring from the
BLS connector and the VCM as per following
table. Refer to wiring diagram for details.
Continuity Test of BFS Sensor Wiring

Resistance
Probe Connectors Reading At
21°C (70°F)
Close to 0 Ω
BFS-1 VCM-2 (continuity)
Close to 0 Ω
BFS-2 VCM-9 (continuity)
3. If resistance is not within specification, check

wiring and connectors, repair or replace as REAR WHEEL SPEED SENSOR
necessary.
Make sure that wheel sensors are securely fas-
Removing the BFS tened and undamaged.
Disconnect BFS connector, remove switch.
Testing the VSS with BUDS2
Installing the BFS 1. Connect vehicle to the BRP diagnostic soft-
The installation is the reverse of the removal ware (BUDS2).
procedure. 2. In BUDS2, select the following:
– V C M button.
3. Lift each wheel one at a time and manually ro-
tate wheel.
4. Look in BUDS2 to see if the corresponding
sensor needle moves.
Otherwise, perform the electrical tests.
154
CHASSIS
If one of the sensor gauges does not respond The problem can be related to a hydraulic func-
to wheel rotation. Refer to Testing VSS Wiring tion, check the following:
Continuity in this subsection. – Brake fluid level
Testing VSS Wiring Continuity – Brake line leaking, bent or pinched
– Brake caliper
1. Disconnect the wheel speed sensor connector – Master cylinder (including piston rod position).
to be tested.
2. Disconnect the VCM connector. The problem can be related to an electric function,
3. Set multimeter to Ω. check the following:
4. Measure wiring resistance as follows. – Fault codes
– VCM electrical connector
NOTICE – Wiring harness condition.
To avoid damaging the connector, probe only
the terminal tip. N O T E : If pins or terminals are not clean, check
VCM harness connector seal condition and ensure
VSS Wiring Continuity Test connector mechanism properly locks connector
seal against VCM.
Sensor VCM
Sensor Result Try disconnecting and reconnecting the VCM con-
Connect. Connect.
nector to see if it “cures” the problem.
1 Pin 19
Front LH As a final test, try a new VCM w i t h o u t disconnect-
2 Pin 8 ing brake lines from the old VCM. Proceed as
Close to 0
1 Pin 16 follows:
Front Ω
RH 2 Pin 4 (continui I M P O R T A N T : Disconnecting brake lines would
ty) require the system bleeding.
1 Pin 17
Rear 1. Connect VCM connector to a new VCM.
2 Pin 29 2. Press engine start button.
5. If continuity test failed, repair wiring or N O T E : It is normal that some fault codes appear
connectors. at this time.
6. If continuity test succeeded, try a new sensor. 09
7. If problem persists, try a new VCM. 3. If problem persists, the trouble is elsewhere.
4. If problem is now solved, the VCM in the ve-
VEHICLE CONTROL MODULE (VCM) hicle is faulty. Install the new VCM in the
vehicle.
WARNING
Never ride a vehicle with a VCM temporarily
installed.
VCM Connector Location

WARNING
The VCM motor and valves are powered from
the battery when the D.E.S.S. key is install on
the D.E.S.S. post. Always disconnect the bat-
TYPICAL tery prior to disconnecting VCM connector.
VCM Troubleshooting Lift and support front of vehicle.

A VCM failure is not likely to occur. These mod-
ules have proven to be very reliable. Prior to re- Connector can be accessed from the front RH side
placing a suspected VCM, take the following into by removing the VCM protector.
account.
155
CHASSIS
VCM Input Voltage Test

VCM Battery Result
Connector
Pin 1
Negative (-) Battery
Pin 25 post voltage
Pin 28
6. If voltage is not good, check wiring and con-

nectors from battery to VCM harness
connector.
7. If voltage is good, carry out the Testing the
VCM Ground Circuit.
Testing the VCM Ground Circuit
VCM PROTECTOR VCM Ground Circuit Test

VCM Battery Result
Connector
Pin 13 Positive (+) Battery
Pin 38 post voltage
1. If ground circuits are not good, check wiring

and connectors from VCM harness connector
to chassis ground located on the front part of
the frame.
2. If ground circuits are good, carry out the Test-
ing the VCM CAN Line Resistor.
Testing the VCM CAN Line Continuity
1. Read wiring resistance between diagnostic link
connector and VCM.
NOTICE
VCM CONNECTOR To avoid damaging the connector, probe only
the terminal tip.
Testing the VCM Input Voltage
1. Disconnect VCM connector. VCM CAN Line Test
2. Disconnect SAS connector.
3. Gently pull VCM connector out of the chassis CAN VCM DLC Result
to ease probing. High Pin 26 Pin 1
4. Turn vehicle ON. Close to 0
5. Test for input voltage as follows. Low Pin 14 Pin 2 Ω
NOTICE 2. If continuity is not good, check wiring and con-

To avoid damaging the connector, probe only nectors from diagnostic link connector (DLC) to
the tip of the terminal. VCM connector.
3. If everything tested good and VCM does not
work, try a new VCM.
156
CHASSIS
Removing the VCM 9. Pull assembly out of position to dislodge

grommet.
WARNING
10. Pull grommet out of VCM support and pull out
Cleanliness is critical when working with the VCM towards the RH side of vehicle. Discard
VCM and brake lines. All precautions must be grommet.
taken to prevent any foreign particle from en-
tering the brake system. Installing the VCM
N O T E : Keep the protective plugs on new VCM
N O T E : Before replacing the VCM, make sure until brake line installation.
electrical and hydraulic systems are in good
condition. The installation is the reverse of the removal pro-
1. Lift and support front of vehicle.
2. Disconnect battery. 1. Install N E W grommet.
3. Remove the VCM protector. 2. Make sure to reinstall brake lines as illustrated.
09
1. To LH front brake caliper
4. Detach lower and upper suspension arms from 2. To RH front brake caliper
3. To rear brake caliper
the vehicle.
5. Use cleaner to thoroughly clean the parts.
Blow compressed air to thoroughly dry the Tightening Torque
VCM, brake line fittings and the area around
the VCM. 8 ± 2 Nm
VCM nuts (71 ± 18 lbf-in)
BRP heavy duty cleaner
16 ± 2 Nm
Brake line fittings
(142 ± 18 lbf-in)
WARNING
Disconnect brake lines from the old VCM only 3. Reset the YRS.
just prior to installing the new VCM. The 4. Bleed the brake system.
shorter the time the brake lines are open, the
lesser the possibility of brake system WARNING
contamination. Brake bleeding must be performed to remove
any air trapped in the brake system.
6. Disconnect VCM connector.
7. Disconnect brake lines.
8. Loosen VCM nuts and remove the module 5. After bleeding, refer to DIAGNOSTIC and Fault
from the vehicle. Codes and do the following:
– Check and clear fault codes
157
CHASSIS
– Reset SAS
– Reset VCM variant if VCM is used.
158
CHASSIS
STEERING AND FRONT WHEELS
STEERING AND FRONT

WHEELS
SERVICE TOOLS
65MM SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036457) . . . . . . . . . . . . . . . . . . . 166–167

ALIGNMENT ADAPTOR B RYKER FRONT WHEELS . . . . (P/N 529036482) . . . . . . . . . . . . . . . . . . . . . . . 162
ALIGNMENT ADAPTOR C RYKER REAR WHEELS . . . . . (P/N 529036483) . . . . . . . . . . . . . . . . . . . . . . . 162
ALIGNMENT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036490) . . . . . . . . . . . . . . . . . . . . . . . 174
ALIGNMENT TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036475) . . . . . . . . . . . . . . . . . . . . . . . 162
BALL JOINT REMOVER SUPPORT . . . . . . . . . . . . . . . . . . (P/N 529036121) . . . . . . . . . . . . . . . . . . . . . . . 186
REAR WHEEL BEARING PUSHER . . . . . . . . . . . . . . . . . . . (P/N 529036246) . . . . . . . . . . . . . . . . . . . . . . . 186
RETAINING BEAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036477) . . . . . . . . . . . . . . . . . . . 226, 230
SPRING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036184) . . . . . . . . . . . . . . . . . . . 183, 193
STEERING COLUMN SPACER 8,34 . . . . . . . . . . . . . . . . . . (P/N 529036476) . . . . . . . . . . . . . . . . . . . . . . . 174
STEM PULLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036459) . . . . . . . . . . . . . . . . . . . . . . . 173
5 ± 0.5 N•m
(44 ± 4 lbf•in)
10 ± 2 N•m
(89 ± 18 lbf•in) 09
2.6 ± 0.1 N•m

(23 ± 1 lbf•in)
24 ± 1 N•m
(18 ± 1 lbf•ft)
5 ± 0.5 N•m
(44 ± 4 lbf•in)
2.5 ± 0.5 N•m 14 ± 1 N•m

(22 ± 4 lbf•in) (124 ± 9 lbf•in)
159
CHASSIS
18.5 ± 3.5 N•m

(164 ± 31 lbf•in)
NEW
6 ± 1 N•m
(53 ± 9 lbf•in)
NEW
37 ± 1 N•m
(27 ± 1 lbf•ft)
18.5 ± 3.5 N•m
NEW (164 ± 31 lbf•in)
NEW
37 ± 1 N•m
37 ± 1 N•m (27 ± 1 lbf•ft)
(27 ± 1 lbf•ft)
NEW
10 ± 2 N•m 300 ± 15 N•m
(89 ± 18 lbf•in) (221 ± 11 lbf•ft)
13.5 ± 1.5 N•m

(119 ± 13 lbf•in)
NEW
11.5 ± 0.5 N•m NEW
(102 ± 4 lbf•in)
160
CHASSIS
GENERAL measured at the leading and trailing edges of the

During assembly and installation, use the torque tires or wheels.
view.
Clean threads before applying a threadlocker. Re- 1 2 3
procedure.
WARNING
Locking devices when removed, must be re- 1. TOE = 0 (A=B)
placed (e.g.: locking tabs, elastic stop nuts, 2. TOE-OUT (A>B)
3. TOE-IN (A<B)
cotter pins, etc.).
Toe settings affect three major areas of perform-
NOTICE ance: tire wear, straight-line stability and
cornering.
Hoses, cables, or locking ties removed during
procedure must be reinstalled as per factory The wheels should point directly ahead when run-
standards. ning in a straight line. Excessive toe-in or toe-out
causes the tires to scrub, since they are always
Tire Pressure turned relative to the direction of travel. Too much
toe-in causes accelerated wear at the outer edges
Use the recommended cold inflation pressure for
of the tires, while too much toe-out causes wear at
optimum tire performance and wear. Under-infla-
the inner edges.
tion or over-inflation may cause uneven tread
wear patterns. Minimum tire wear and power loss are achieved
with zero toe. Toe settings have a major impact on
Recommended tire inflation pressure is found on
directional stability. A small amount of toe-in in-
the Tire Label located inside the right side service
sures that normal deflection of bushings, and oth-
cover.
er components is compensated for and the wheels 09
When weather temperature changes occur, tire in- travel down the road with close to zero toe. The il-
flation pressures also change. A drop of 6°C (10° lustrations above show the mechanisms involved.
F) can cause a corresponding drop of 1 psi (7 With the steering wheel centered, toe-in causes
kPa) in inflation pressure. Check tire pressures the wheels to tend to roll along paths that intersect
frequently and adjust them to the proper pressure each other. Under this condition, the wheels are at
odds with each other, and no turn results.
N O T E : The pressure difference between the left
and right side tire should not exceed 3.4 kPa (.5 Understanding Bump-Steer
lbf/in²). When the wheel on one side overcomes an ob-
stacle, suspension compression will shorten the
WHEEL ALIGNMENT tie rod causing toe out. In this way, slight toe-in en-
Theory of an Alignment hances straight-line stability. With toe-out, how-
ever, the front wheels are aligned so that
Understanding Toe suspension compression causes the wheel to as-
When a pair of wheels is set so that their leading sume a rolling direction that describes a turn.
edges are pointed slightly towards each other, the Thus, the vehicle will always be trying to enter a
wheel pair is said to have toe-in. If the leading turn, rather than maintaining a straight line of trav-
edges point away from each other, the pair is said el. Toe-out encourages the initiation of a turn,
to have toe-out. The amount of toe can be ex- while toe-in discourages it.
pressed in degrees as the angle to which the
wheels are out of parallel, or more commonly, as
the difference between the track widths is
161
CHASSIS
5. The BRP diagnostic software (BUDS2) up to

A A date.
6. Alignment tools.
Alignment tool
1 2 (P/N 529036475)
B B
Alignment adaptor B
RYKER Front wheels
(P/N 529036482)
Alignment adaptor C
RYKER rear wheels
1. TOE-IN
(P/N 529036483)
2. TOE becomes 0 due to bump steer
Alignment Procedure
A A Preparing the Workshop
1. Select a level flat surface.
2. Draw three lines of approximately 2 m (7 ft) on
3 4 the ground as per the following illustration.
B B A
B
1. 3. TOE = 0
2. 4. TOE-OUT due to bump steer
The amount of toe-out determines the severity of L1 L3 L2

the handling behavior. A. 315 cm (124 in)
B. 65 cm (25-1/2 in)
Understanding Rear Wheel Angle Deviation
The rear wheel angle cannot deviate much from Positioning the Vehicle
the center line of the frame with a properly aligned
engine. Rear wheel deviation is hardly noticeable 1. Position the vehicle perpendicularly between
by drivers if the front wheels are aligned to the lines L1 and L2.
frame as a reference. Removing the rear wheel for
maintenance will not change this value enough to
justify an alignment verification.
Vehicle Load
The effect of the passenger weight and rear cargo
load is negligible.
Prerequisites
1. Correct tire pressure.
2. Correct and identical preload adjustment on
both front shocks (when applicable).
3. No play in steering system.
4. No play in suspension system.
162
CHASSIS
Shim Minimum Thickness

10 mm
(0.4 in)
It may take more than one shim to reach the re-

quired thickness.
NOTICE
Make sure shim thickness is the same for
L1 L3 L2 front and rear adaptor.
2. Move vehicle forward and backward 1 - 2 m

(3.3 - 6.6 ft) to set the tires and suspension.
3. Align the center of the front hubs on the line
L3.
SHIM(S) LOCATION
L3 L2
4. Fully pull the park lever upwards to engage

and lock the P position.
09
Preparing the Vehicle
1. Inspect ball joints, suspension arm bushings
and tie-rod ends for play. Repair as needed be-
fore alignment is verified or adjusted.
2. Check and adjust tire pressure as per
specification.
3. Make sure the front shock preload is correctly
adjusted according to specifications (when
applicable).
4. Lock the steering column.
5. Remove all RED locking clips.
Toe Measurement
1. Install a laser in each adaptor tools.
Ryker 900 Rally edition
Due to rear wheel configuration, install shims
between the rear adaptor tool (C) and laser.
LASER BEAM RESULT WITH APPROPRIATE SHIM(S)
163
CHASSIS
ADAPTOR B
NOTICE
Make sure the laser are correctly calibrated.
Calibrated means that the 2 laser lines need to

be at 90 degrees. If not, loosen the 2 set
screws on the laser support and using a car-
penter square, do the proper adjustment to ob-
tain the required angle (90°).
4. Connect the laser units to a power source.
LASER BEAM RESULT WITH WRONG SHIM(S)
5. Point the rear laser perpendicularly with the
ground.
All models 6. Point the laser of the front right wheel towards
2. Insert the alignment adaptor C into the rear the rear of the vehicle.
hub. 7. Measure the distance "A" between both laser
lines.
ADAPTOR C
3. Insert an alignment adaptor B into each front

hub.
8. Compare this measure with the measure A in

the next table. Make sure to select the proper
vehicle.
Measure A
765 ± 20 mm
(30-1/8 ± 3/4 in)
164
CHASSIS
9. If the measurement is out of the specification, 1. If the measurement is out of the specifica-
adjust the tie-rod length of the front r i g h t tion, adjust the tie-rod length of the front l e f t
wheel. wheel.
10. Remove the alignment adaptor and the laser 17. When alignment is completed, connect the ve-
unit from the rear wheel. hicle to the BRP diagnostic software (BUDS2)
11. Turn both laser units of front wheels towards and reset the steering angle sensor (SAS).
the rear of the vehicle.
12. At the line L1, measure and record the dis- Rear Wheel Alignment
tance "B" between both laser lines. No rear wheel alignment is required.
Resetting the SAS

Inflate tires to recommended pressure.
If SAS is to be reset without steering alignment:
– Select a reference point (an object, a line, etc.)
B in front of the vehicle.
– By pushing the rear of the vehicle, move
t h e v e h i c l e f o r w a r d ( a p p r o x i m a t e l y 3 to 6 m
(10 to 20 ft))) t o c o n f i r m t h a t w h e e l s a r e
s t r a i g h t . The vehicle should roll straight with-
out veering off to the right or left.
L1 L3 L2 – Repeat until wheels are straight ahead.
13. Turn both laser units towards the front of the
vehicle.
14. At the line L2, measure and record the dis-
tance "C" between both laser lines.
C
09
1. Lock the steering column. See procedure in

L1 L3 L2 this subsection.
15. With the above measurements, calculate the 2. Without moving vehicle or handlebar or sitting
toe by s u b t r a c t i n g t h e d i s t a n c e C f r o m t h e on vehicle, connect vehicle to the BRP diag-
d i s t a n c e B . A negative answer indicates toe- nostic software (BUDS2) and reset the steering
out; a positive answer indicates toe-in. angle sensor (SAS).
16. Compare this result with the measure in the
next table. Make sure to select the proper
PROCEDURES
vehicle. FRONT WHEELS
Measure B - C Removing the Front Wheel

1. Place the vehicle on a level surface.
Ryker 900 0 to 16 mm 2. Lift and support the front of the vehicle using
Rally edition (0 to 5/8 in) the following locations.
–4 to 16 mm
All other Ryker
(–5/32 to 5/8 in)
165
CHASSIS
3. Turn the handlebar and lock the wheel hub

with a locking device (such as a long Allen key
or a tempered steel rod).
6. Remove the wheel from the vehicle.
4. Remove the RED locking clip.
1. RED locking clip

3. Conical washer
4. Wheel
Installing Front Wheels

5. Remove the center lock wheel nut and the con- NOTICE
ical washer.
The installation instruction and tightening tor-
65mm socket que values must be strictly adhered to. Fail-
(P/N 529036457) ure to do so can lead to rim damage.

NOTICE
The front right wheel nut has left threads. You 1. Align the three dowel pins of the rim with the
must turned the nut clockwise to unscrew it. brake disk holes.
Always refer to the decal on the nut. NOTICE
All contact surfaces of the wheel, wheel hub,
brake disc and the thread in the wheel hub
must be free of abrasion, sand, dust or chips.
Do not use fluids of any kind to wash the sur-
faces, use only dry soft cloth.
166
CHASSIS
2. Install the conical washer and the center lock

wheel nut. Tightening torque
NOTICE Center lock wheel 300 ± 15 Nm
The front right wheel nut has left threads. You nut (221 ± 11 lbf-ft)
must turned the nut counterclockwise to tight-
en it. Always refer to the decal on the nut. 4. Install the RED locking clip. The folded end
must point inside the drive axle.
WARNING
Failure to install the RED locking clip may
cause the loss of a wheel if the center lock
wheel nut becomes loose.
09
1. Fo lded e nd poi nting i nside the driv e axl e
5. Remove locking device from the wheel hub.

3. Tighten the center lock wheel nut to
specification.
65mm socket
(P/N 529036457)
NOTICE
Never use impact tools to tighten wheel nuts.
FRONT TIRES
NOTICE
Never untighten the nut to align the RED Tire Damage
locking clip hole. Tighten the nut to the nomi- Check all tires for:
nal value, then tighten further to align the – Cuts, slits and cracks in the tires.
hole. – Bumps or bulges in the side of the tire or the
tread.
– Nails or other foreign objects in the side of the
tire or tread.
167
CHASSIS
– Air leaks (hissing sound) caused by an ill-fitting Rotating Front Tires

rim or a faulty tire valve. Rotate front tires when tread depth reaches 4 mm
If any of the above occurs, have the tire repaired (5/32 in). This will maximize tire life.
or replaced. Replacing Front Tires
Tire Tread Wear WARNING
1. Check minimum tread depth by using the The VSS on the vehicle has been calibrated
tread-wear indicators (hard rubber bars to perform best with a tire of a specific size,
molded at the base of the tread; 1 in figure be- material, and tread pattern. Replacing a tire
low). Check in three locations across the tire with one not approved by BRP can cause the
tread: VSS to be ineffective.
– Outer edge
– Center To replace a front tire, carry out the following
– Inside edge. steps:
2. The tread-wear indicators will appear across 1. Remove front wheel from the vehicle.
the treads that have been worn down to the 2. Using an automotive tire changer (rim clamp
minimum tread depth. When at least one type), remove the old tire and install the new
tread-wear indicator appears across the tread, one.
have the tire replaced.
3. The rear tire owns 2 types of wear indicator, WARNING
one for the regular use and another for the use Tires used on this vehicle are designed to ro-
on a wet surface. Regular tread-wear limit indi- tate in one direction only. Do not switch the
cators are indicated by a triangle symbol and left and right front wheels or tire direction of
the ones for the wet surface use are indicated rotation will be reversed.
by a water droplet symbol.
N O T E : Refer to manufacturer's instructions for
WARNING tire changer operation.
It is not recommended to use the vehicle on a
wet road if the tread-wear limit indicators for 3. Remove the old balancing weight (s) from the
wet surface use are reached or near to be rim.
reached. Replace the tire for your safety. 4. Clean the inner side of wheel with alcohol to re-
move grease and dust.
5. Balance wheel using a wheel balancer.
2 1 1 2
N O T E : Refer to manufacturer's instructions for
wheel balancer operation.
6. Install new balancing weight (s) inside wheel.

Position them in the center of the flat inner sur-
3 3 face of the rim.
4 4
NOTICE
Improperly positioned weights can cause in-
REAR TIRE SHOWN terference with the lower ball joint stud.
1. Tread-wear limit indicators for wet surface use
2. Tread-wear limit indicator symbols for wet surface use
3. Regular tread-wear limit indicators 7. Reinstall wheel.
4. Regular tread-wear limit indicator symbols
WARNING
4. It is normal to see uneven wear on tires de-
pending on how the vehicle is driven and road When installing new tires, always observe a
conditions. The front tires external or internal break-in period of 300 km (200 mi).
edges and the rear tire center tread will wear New tires will not operate at their maximum
unevenly depending on if the vehicle is driven efficiency until their break-in is completed.
smoothly or aggressively. Braking, steering and VSS performance may
be reduced,.
168
CHASSIS
Mirrors Air Deflector

Removing the Mirror Support Ryker 900 Rally Edition
1. Loosen the mirror support screw about 10 to Removing the Air Deflector
13 mm (3/8 to 1/2 in).
NOTICE
To avoid losing parts, do not remove the
screw completely.
AUSTRALIAN AND RUSSIAN M ODELS
A. 10 to 13 mm (3/8 to 1/2 in)
2. Hit the screw to push it inward and release the

support retainer mechanism.
3. Pull on the mirror support to remove it.
Installing the Mirror Support
1. Fully push the support against the handlebar.
2. Position the mark on the support perpendicu-
larly with the ground.
ALL O THER COUNTRIES
09
90°
Installing the Air Deflector
3. Hold the support and tighten the screw. cedure. However, pay attention to the following.
Tightening Torque Insert the location tab into the handlebar hole.
Mirror support 5 ± 0.5 Nm

screw (44 ± 4 lbf-in)
4. Adjust the mirror.
169
CHASSIS
Handlebar Grip
Removing the Handlebar Grip 3. Remove both switch housing screws.
Remove grips by pulling while using compressed
air, which will inflate or loosen the fit between the
grip and handlebar.
Installing the Handlebar Grip
Insert the handlebar grip on handlebar while blow-
ing compressed air to inflate or loosen the fit be-
tween grip and handlebar.
Left Hand Multifunction Switch
Removing the Left Hand Multifunction Switch
1. Remove the left side fairing and the upper
fairing.
Installing the Left Hand Multifunction Switch

1. Insert the location tab of the housing into the
handlebar hole.
2. Tighten housing using specification and this
sequence.
Tightening Torque
5 ± 0.5 Nm
Housing screws
2. Unplug the left hand multifunction switch (44 ± 4 lbf-in)
connector.
170
CHASSIS
Installing the Right Hand Multifunction Switch

Right Hand Multifunction Switch procedure. However, pay attention to the
Removing the Right Hand Multifunction Switch following.
1. Remove the left side fairing and the upper 2. Insert the location tab of the housing into the
fairing. handlebar hole.
3. Tighten housing using specification and this
sequence.
Tightening Ttorque
5 ± 0.5 Nm (44 ± 4 lbf-
Housing screws
in)
09
2. Unplug the right hand multifunction switch
connector.
HANDLEBAR
Adjusting the Handlebar
WARNING
Make sure the engine is turned off and the
engine stop switch is on the STOP position
before performing any control components
adjustments.
3. Remove switch housing screws. 1. Sitting on the vehicle, engine off, lift the locking
lever to unlock the handlebar.
171
CHASSIS
– Multifunction switches.
2. Lift the locking lever to unlock the handlebar.
2. Displace the handlebar back and forth until a

comfortable position is obtained.
3. When done, reposition the locking lever in its
original position to lock the handlebar in place. 3. Remove the both handlebar clamps.
WARNING
Be sure that the locking lever is well posi-
tioned. It should be equal with the handlebar
retaining clamps.
✔ ✗
Adjusting the Locking Lever Clamping

Strength
Turn the locking lever screw counterclockwise to 4. Remove the handlebar.
increase the clamping strength and clockwise to 5. Install and center the new handlebar.
decrease it. 6. Secure it with clamps. Do not torque yet.
7. Reinstall all other removed parts.
8. Finalize the positioning of the handlebar and
tighten clamp screws to specification.
Tightening Torque
10 ± 2 Nm
Steering clamp screws
(89 ± 18 lbf-in)
Separating the Handlebar Stem From the

Steering Column
1. Move handlebar forwards.
Replacing the Handlebar

1. Remove:
– Mirrors
– Air deflectors (if equipped)
– Handlebar grips
172
CHASSIS
1
2
2. Remove the rubber plug. Step 1. Insert the puller

Step 2. Screw the puller in
6. Pull up the handlebar to remove the handlebar

stem from the steering column.
7. To reinstall the handlebar on the steering col-
umn, insert the handlebar completely in the
steering column.
8. Insert the handlebar stem screw.
9. Center the handlebar (rotation movement).
10. Tighten the screw to specification.
Tightening Torque
24 ± 1 Nm
Handlebar stem screw (18 ± 1 lbf-ft)
3. Remove the handlebar stem screw. 11. Move the handlebar rearwards and turn it com-
pletely side to side to verify there is not tension
in both multifunction switch harnesses. Adjust
09
harnesses evenly not too tight or too loose.
12. Reinstall the rubber plug.
13. Position handlebar and lock it in place.
THROTTLE HANDLE
Removing the Throttle Handle
Remove the right hand multifunction switch.
4. Install the puller into the handlebar stem.

5. Screw the puller to separate the handlebar
from the steering column.
Stem puller
Disconnect the TAS connector and remove the
(P/N 529036459)
harness.
Installing the Throttle Handle
173
CHASSIS
Make sure to insert the spring end in the location 5. Loosen the upper bolts attaching the left and
hole. right upper frames together.
7. Free the upper end of the steering column then
remove the column from the vehicle.
Installing the Steering Column
Before installing the lower clamp and the round
half-housing, lock the steering column.
Steering Column NOTICE

Make sure the pitman arm is pressed against
Locking the Steering Column
the tool.
1. Remove the front service cover.
2. Position the handlebar straight. TIE-ROD
3. Lock the steering column.
Removing a Tie-Rod
Alignment screw 1. Remove wheel.
(P/N 529036490) 2. Remove the front service cover.
3. At pitman arm and knuckle, remove:
Steering column – Flange nuts

spacer 8,34 – Hardened washers.
(P/N 529036476)
2 AT LH KNUCKLE
1. Flange nut
1. Countersunk head screw M6 x 25 x 1.0 2. Hardened washer
2. Steering column spacer 8,34 3. Knuckle
4. Remove tie-rod from the vehicle.

Removing the Steering Column
Inspecting Tie-Rod
1. Separate the steering stem from the steering
column.. Inspect tie-rod ends for wear or excessive play. If
2. Detach the left tie-rod end and the intermediate excessive, replace tie-rod end.
rod from the bottom of the steering column. Installing a Tie-Rod
3. Remove the lower clamp and the round half-
housing.
4. Remove the following body components:
1. Adjust tie-rod length.
– Left and right side fairings
– Upper fairing
– Fuel tank cover.
174
CHASSIS
Intermediate Rod
A Removing the Intermediate Rod
1. Remove the front service cover.
2. On both side of the intermediate rod, remove:
– Intermediate rod nut
A. Starting length – Hardened washers.
Tie-Rod
Starting length - 410.9 ± 10 mm
dimension “A” (16.2 ± .4 in)
2
3
2
1
1. Intermediate rod nut

2. Hardened washer
3. Pitman arm
1. Pitman arm side
2. Knuckle side
1. B. Unengaged threads
3. Remove intermediate rod from the vehicle.
Inspecting the Intermediate Rod
Tie-Rod Inspect intermediate rod ends for wear or exces-
sive play. If excessive, replace intermediate rod.
Unengaged threads - 12 mm
dimension “B”* (.47 in) Installing the Intermediate Rod
* Dimension “B” to be approximately equal upon
assembly.
cedure. However, pay attention to the following. 09
1. Tighten the intermediate rod nuts to
2. Tighten tie-rod lock nuts finger tight. specifications.
3. Install tie-rod on steering knuckle. Follow in-
stallation sequence as depicted in exploded Tightening Torque
view.
Intermediate rod 37 ± 1 Nm
4. Torque tie-rod retaining nut.
retaining nuts (27 ± 1 lbf-ft)
Tightening Torque
2. Check front wheels alignment.
37 ± 1 Nm
Tie-rod retaining nut KNUCKLE
(27 ± 1 lbf-ft)
Removing the Knuckle
5. Tighten tie-rod end lock nuts. 1. Place vehicle on a level surface.
2. Apply parking brake.
Tightening Torque 3. Loosen wheel lug nuts.
4. Lift the front of vehicle on jack-stands.
18.5 ± 3.5 Nm
Tie-rod end lock nuts 5. Remove wheel.
(164 ± 31 lbf-in)
6. Remove brake disc.
7. Remove wheel speed sensor.
6. Align front wheels.
175
CHASSIS
1. Wheel speed sensor

2. Wheel speed sensor screw
8. Remove fender supports. 11. Detach the upper suspension arm from the
knuckle.
NOTICE
Pay attention not pull too hard or let the fend-
er hang by the wires.
12. Remove wheel axle and wheel bearing only if

1 necessary.
1. Fender support bolts

Installing the Knuckle
9. Remove tie-rod end from knuckle. cedure. However, pay attention to the following.
1. Install and tighten n e w ball joint nuts to
1 specification.
Tightening Torque
85 ± 10 Nm
Upper ball joint nut
(63 ± 7 lbf-ft)
48 ± 6 Nm
2 Lower ball joint nut
(35 ± 4 lbf-ft)
2. Install tie-rod ends.

3. Perform a steering alignment.
1. Tie-rod end Upper Ball Joint
2. Knuckle
Removing Upper Ball Joint
10. Remove the pinch bolt that retain the lower ball 1. Remove wheel.
joint. 2. Remove brake disc.
176
CHASSIS
3. Detach the upper suspension arm from the

knuckle.
4. Remove the upper suspension arm.
Installing Upper Ball Joint

5. Remove retaining ring.

1. Tighten n e w ball joint nuts to specification. 09
Tightening Torque
85 ± 10 Nm
Upper ball joint nuts
(63 ± 7 lbf-ft)
2. Install tie-rod ends.

3. Align front wheels.
Wheel Axle
Removing a Wheel Axle
NOTICE
Each time the wheel axle is removed, both
wheel bearings must be replaced.
6. Remove the upper ball joint using a pry bar.
1. Extract the wheel axle using a press.
177
CHASSIS
1. Support the inner race of the inner bearing. 3. Using a chisel and a hammer, push out the
2. Place a metal plate on the end of the wheel bearings.
axle.
3. Push the wheel axle out of the knuckle. NOTICE
Pay attention not damage the encoded wheel
Installing a Wheel Axle
located between both wheel bearings.
1. Install both wheel bearings. See procedure in
this subsection.
2. Before pressing wheel hub, ensure it is per- NOTICE
fectly aligned. Support the knuckle properly to avoid damag-
ing it. Do not use ears to support it.
NOTICE
If the wheel hub is not aligned, wheel bearing Installing Wheel Bearing
will be damaged and its replacement
NOTICE
necessary.
Always install the outer bearing first, the en-
coded wheel then the inner bearing.
3. Install the knuckle and all other removed parts.
WHEEL BEARING
Inspecting Wheel Bearing
1. Lift and support the front of vehicle on jack- 2
stands.
2. Hold the wheel at the top and bottom and at-
tempt to move it back and forth to check for 1
looseness and lateral play in the bearing. 3
3. Rotate wheel and check for smoothness of
rotation.
If there is any play or roughness of rotation, re-
place the wheel bearing.
BEARINGS INSTALLATION ORDER
N O T E : First, check if ball joints are loose. If nec-
essary repair all defective parts before checking 1. Clean all grease from outer and inner surfaces
the wheel bearing condition. Be careful not to mis- of knuckle.
take play in a ball joint for a bad wheel bearing. 2. Support the inner side of the knuckle on a
press.
Removing Wheel Bearing 3. Install the outer bearing by pushing on the in-
1. Remove the knuckle. ner and outer races in the same time using a
2. Press out the wheel axle. flat tool.
178
CHASSIS
4. Turn knuckle up side down and install the en-

coded wheel on the inner race of the bearing. 3. Remove nuts located at the bottom of the SAS.
5. Install the inner bearing by pushing on the in-
ner and outer races in the same time using a
flat tool.
4. Remove the SAS.
6. Install the wheel axle, see procedure in this 09

subsection.
7. Reinstall the knuckle on the vehicle.
8. Carry out the steering angle sensor reset. See
the procedure in this subsection.
Steering Angle Sensor (SAS)
Removing the SAS
1. Remove front service cover and front fascia.
2. Disconnect the SAS connector.
Installing the SAS

1. Make sure to install SAS connector towards
the battery.
2. Reset the SAS using the BRP diagnostic soft-
ware (BUDS2).
179
CHASSIS
Adjusting the Suspension

Suspension Adjustment Guidelines
Suspension adjustment and loading can have an
effect on your vehicle handling and comfort. 1
1
2
WARNING 3
4
2
Suspension adjustment could affect vehicle
handling.
Always take time to familiarize yourself with
the vehicle's behavior after any suspension
adjustment has been made.
Choice of suspension adjustments vary with driv-

er’s weight, vehicle load, personal preference, rid-
ing speed and field condition.
SPRING PRELOAD
The best way to set up the suspension, is to start
from factory settings, then customize each adjust- 1. Position #1
ment one at a time. 2. Position #4
Front and rear adjustments are interrelated. It may Rear Suspension

be necessary to readjust the rear shock absorbers
after adjusting front shock absorbers for instance. SPRING PRELOAD
Test run the vehicle under the same conditions; Model Factory settings
trail, speed, load, etc.
Ryker 600 ACE
Change one adjustment and retest. Not adjustable
Ryker 900 ACE
Proceed methodically until you are satisfied. 239 ± 1 mm
Ryker Rally 900 ACE
(9.4 ± .039 in)
Suspension Factory Settings
Front Suspension 227 ± 1 mm
Ryker Sport 900 ACE
(9 ± .039 in)
SPRING PRELOAD
Factory settings COMPRESSION DAMPING
Model
Model Factory settings
Ryker 600 ACE
Not adjustable
Ryker 900 ACE Ryker Rally 900 ACE Position 2
Ryker Rally 900 ACE Between position 2 and 3
Ryker Sport 900 ACE Position 3
COMPRESSION DAMPING
Model Factory settings
Ryker Rally 900 ACE Position 2
180
CHASSIS
Result on big
Position Setting
bumps
Softer
2 1 Soft compression
damping
Firmer
4 Hard compression
damping
1. Distance to measure
2. Adjusting ring
Spring Preload Adjustment

Shorten the spring for a firmer ride, when riding on 1. Position #1
a rough paved road or when riding with a passen- 2. Position #2
ger or more cargo than usual. 3. Position #3
4. Position #4
Lengthen the spring for a softer ride and smooth
riding condition. WARNING
Factory settings are suitable for almost all Make sure compression damping setting is
the same on both front shock absorbers.
conditions. 09
Take into consideration that an increase in ground
clearance can affect the handling of the vehicle.
WARNING
The front shocks adjustments must always be
set to the same position.
Spring length should be equal on both sides.
Never adjust one shock only.
Uneven adjustment can cause poor handling
and loss of stability, which could lead to an
accident.
1. Lift the vehicle.

2. Adjust spring preload by turning the adjuster
ring.
Shock Damping Adjustment

Compression damping controls how the shock ab-
sorber reacts when riding.
181
CHASSIS
FRONT SUSPENSION
FRONT SUSPENSION
SERVICE TOOLS
65MM SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036457) . . . . . . . . . . . . . . . . . . . 166–167

STEM PULLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036459) . . . . . . . . . . . . . . . . . . . . . . . 173
50 ± 2 N•m
NEW (37 ± 1 lbf•ft) NEW
50 ± 2 N•m
(37 ± 1 lbf•ft)
NEW
50 ± 2 N•m
(37 ± 1 lbf•ft)
NEW
61 ± 9 N•m 50 ± 2 N•m
(45 ± 7 lbf•ft) (37 ± 1 lbf•ft) NEW
NEW
10 ± 2N•m
(89 ± 18 lbf•in)
NEW
NEW
48 ± 6 N•m
(35 ± 4 lbf•ft)
50 ± 2 N•m
NEW NEW
10 ± 2N•m 10 ± 2N•m
(89 ± 18 lbf•in) (89 ± 18 lbf•in)
182
CHASSIS
FRONT SUSPENSION
GENERAL
During assembly and installation, use the torque
view.
procedure. 1. Spring compressor hooks
WARNING 2. Tighten the spring compressor tool screw until

Torque wrench tightening specifications must the spring is sufficiently compressed to remove
be strictly adhered to. spring stopper.
Locking devices when removed (e.g.: locking 3. Release the spring compressor tool screw.
tabs, elastic stop nuts, cotter pins, etc.) must 4. Remove spring from shock absorber.
be replaced. Inspecting the Shock Absorber
1. Examine shock for leaks.
NOTICE 2. Extend and compress the piston at least 5
Hoses, cables and locking ties removed dur- complete strokes with its rod upward.
ing a procedure must be reinstalled as per 3. Ensure the rod moves smoothly and with uni-
factory standards. form resistance over its entire stroke.
N O T E : During compression motion, it is normal

PROCEDURES to feel only a small resistance.
SHOCK ABSORBER
4. Pay attention to the following conditions that
Removing the Shock Absorber will denote a defective shock:
1. Lift and support front of vehicle.
– A very weak rebound.
– A skip or a hang back when reversing
3. Remove shock absorber screws.
stroke at mid travel.
– Seizing or binding condition except at ex-
treme end of either stroke.
09
– Oil leakage.
– A gurgling noise, after completing one full
compression and extension stroke.
5. Check piston rod for excessive wear or pitting.
6. Inspect the spring for damage. Replace if
necessary.
7. On both ends, check the bushings for exces-
sive wear or other damages.
8. Replace shock absorber or spring if any faults
are present.
Assembling and Installing the Shock Absorber
Disassembling the Shock Absorber To assemble and install the shock absorber, re-
1. Position the shock absorber in the tool and in- verse the disassembly and removal procedures.
stall the spring compressor hooks.
UPPER SUSPENSION ARM
Spring compressor Inspecting the Upper Suspension Arm
(P/N 529036184)
1. Check upper suspension arms for bending or
other damage. Replace suspension arms if
necessary.
183
CHASSIS
FRONT SUSPENSION
2. Move upper suspension arm from side to side 3. Perform the steering alignment.
and up and down. There should be no notice-
able play in bushings. UPPER BALL JOINT
3. If necessary, remove suspension arm and in- Refer to steering and front wheels subsection.
spect pivot bushings and sleeves for wear or LOWER SUSPENSION ARM
damages. Replace bushings and/or sleeves if
necessary. Inspecting the Lower Suspension Arm
Removing the Upper Suspension Arm 1. Check lower suspension arms for bending or
other damage. Replace suspension arms if
1. Place vehicle on a level surface. necessary.
2. Engage park position lever. 2. Move lower suspension arm from side to side
3. Remove front service cover, front fascia and and up and down. There should be no notice-
rocker panel. able play in bushings.
4. Lift and support the front of the vehicle. 3. If necessary, remove suspension arm and in-
5. Remove wheel. spect pivot bushings and sleeves for wear or
6. Remove electrical wiring and brake hose from damages. Replace bushings and/or sleeves if
suspension arm. necessary.
Removing the Lower Suspension Arm
1. Place vehicle on a level surface.
2. Engage park position lever.
3. Adjust foot peg to the rearmost position.
5. Remove battery.
6. Lift and support the front of the vehicle.
7. Remove wheel.
8. Remove the upper suspension arm.

Installing the Upper Suspension Arm
1. To ease suspension arm insertion onto the
chassis mounts, suspension arm bushings
may be lubricated using soapy water.
2. Refer to exploded view for appropriate tighten-
ing torques.
184
CHASSIS
FRONT SUSPENSION
09
9. Remove radiator mounting screws and set

aside radiator, Properly secure the radiator to
keep it out of the way during the procedure.
10. Remove lower suspension arm screws.
N O T E : For LH side, set aside the voltage regula-
tor and on RH side the ABS module cover to have
better access to the lower suspension arm
screws.
11. Remove the lower suspension arm.
185
CHASSIS
FRONT SUSPENSION
Installing the Lower Suspension Arm

1. Suspension arm bushings may be lubricated
using soapy water to ease installation onto the
chassis mounts.
ing torques.
3. Perform the steering alignment.
LOWER BALL JOINT
Inspecting the Lower Ball Joint
Inspect ball joint end for damage. Ensure it is mov-
ing freely without play. Replace ball joints as 6. Remove the lower ball joint.
required.
Rear wheel bearing
Removing the Lower Ball Joint pusher
1. Place the vehicle on a level surface and apply (P/N 529036246)
parking brake.
2. Lift and support the front of vehicle. Ball joint remover
3. Remove wheel. support
4. Remove the lower ball joint retaining screw (P/N 529036121)
and discard elastic nut.
TYPICAL BALL JOINT REMOVAL

5. Lift up the upper suspension arm.
1. Tighten C-clamp and press the ball joint out
N O T E : Properly secure the suspension arm to of the suspension arm.
keep it out of the way during the procedure. Installing the Lower Ball Joint
cedure, however pay attention to the following.
1. Install the C-clamp, the ball joint installer, the
rear wheel bearing pusher and the socket of
35 mm (1-3/8 in) as shown.
NOTICE
Always push on the ball joint edge, never on
center surface.
186
CHASSIS
FRONT SUSPENSION
Installing the Pivot Bushings

Installation is the reverse of the removal
procedure.
STABILIZER BAR
Removing the Stabilizer Bar
1. Remove LH lower suspension arm.
TYPICAL BALL JOINT INSTALLATION
2. Tighten C-clamp and press the ball joint into

lower suspension arm.
ing torques.
PIVOT BUSHINGS
09
The following procedure is the same for all sus-
pension arms.
Removing the Pivot Bushings
Remove the suspension arm.
Using a press or a drift, remove pivot bushings.
3. Turn stabilizer bar downward.

4. Remove stabilizer bar with bushings from
vehicle.
187
CHASSIS
FRONT SUSPENSION
Installing the Stabilizer Bar

Installation is the reverse of the removal proce-
dure. However, pay attention to the following.
1. Before installing stabilizer bar, verify if all ball
joints on link rods move smoothly and freely.
Replace link rod if necessary.
2. Check stabilizer bar bushings for cracks or oth-
er damages. Replace if necessary.
3. Apply tightening torques specified in exploded
view.
4. Install all other removed parts.
LINK ROD
Removing the Link Rod
Lift the front of vehicle.
Remove screws securing link rods to stabilizer bar
and chassis.
Installing the Link Rod

Installation is the reverse of the removal
procedure.
Apply tightening torque as specified in exploded
view.
188
CHASSIS
REAR SUSPENSION
REAR SUSPENSION
SERVICE TOOLS
65MM SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036457) . . . . . . . . . . . . . . . . . . . 166–167

STEM PULLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036459) . . . . . . . . . . . . . . . . . . . . . . . 173
SERVICE PRODUCTS

LOCTITE 243 (BLUE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................... 205
09
189
CHASSIS
REAR SUSPENSION
Ryker 900 Rally

Edition
31.5 ± 3.5 N•m

(23 ± 3 lbf•ft)
NEW
31.5 ± 3.5 N•m

Synthetic (23 ± 3 lbf•ft)
suspension NEW
grease
NEW NEW
50 ± 5 N•m
Synthetic (37 ± 4 lbf•ft)
suspension
grease Synthetic
suspension
NEW grease
105 ± 15 N•m 105 ± 15 N•m
NEW (77 ± 11 lbf•ft) (77 ± 11 lbf•ft)
NEW
105 ± 15 N•m NEW
(77 ± 11 lbf•ft)
NEW
Synthetic
NEW suspension
grease
105 ± 15 N•m
(77 ± 11 lbf•ft)
190
CHASSIS
REAR SUSPENSION
GENERAL
During assembly and installation, use the torque
view.
procedure.
WARNING
be strictly adhered to. 1. Solenoid valve connector
tabs, elastic stop nuts, cotter pins, etc.) must NOTICE
be replaced with new ones.
Be careful not to power the gauge by the sol-
enoid valve connector in order to avoid per-
NOTICE manent damage to gauge.
Hoses, cables and locking ties removed dur-
ing a procedure must be reinstalled as per 4. Connect solenoid valve connector pin 1 to a 20
factory standards. A suitable fused jumper and then directly to the
positive battery post.
PROCEDURES 5. Connect solenoid valve connector pin 2 directly
to the negative battery post.
ACS SOLENOID VALVE 6. Verify that air exits from side port to confirm
The ACS solenoid valve is identified S R V in the proper solenoid operation.
wiring diagram.
ACS Solenoid Valve Location
The ACS solenoid valve is located on the RH side
of the vehicle near the shock absorber.
09
If air exits from side port:

– Check input voltage at solenoid valve (PIN-1).
– Check ground circuit continuity at solenoid
valve (PIN-2).
– Check connector and terminal condition.
Testing the ACS Solenoid Valve Operation
If no air exits from side port:
1. Manually adjust air suspension pressure to 6
bar (87 lbf/in²). – Replace ACS solenoid valve.
2. Remove side panels. Replacing the ACS Solenoid Valve
3. Disconnect the solenoid valve connector.
1. Release the suspension air pressure.
2. Remove side panels.
3. Disconnect the solenoid valve connector.
191
CHASSIS
REAR SUSPENSION
NOTICE
Do not let reservoir hang at the end of the
hose.
4. Disconnect the pneumatic hoses.
All Models
2. Install a strap under the seat.
5. Remove the ACS manifold retaining screws.
3. Loosen the shock absorber front bolt and pivot

arm front bolt.
1. ACS manifold retaining screws
6. Remove the ACS manifold from vehicle.

7. Check the air system for leakage.
SHOCK ABSORBER
Removing the Shock Absorber
Models with Remote Reservoir 1. Pivot arm front bolt
2. Shock absorber front bolt
1. Remove the screw securing the clamp of the
shock absorber reservoir support. Set reservoir 4. Remove the muffler.
aside. 5. Slightly lift the rear of vehicle to allow the re-
moval of the pivot arm front bolt.
192
CHASSIS
REAR SUSPENSION
6. Continue to lift the vehicle until the front of the 2. Extend and compress the piston at least 5
pivot arm can be removed from the frame complete strokes with its rod upward.
bracket. 3. Check that rod moves smoothly and with uni-
7. Remove the link arm central bolt. form resistance over its entire stroke.
N O T E : During compression motion, it is normal
to only feel a small resistance.
4. Pay attention to the following conditions that

will denote a defective shock:
– Oil leakage.
8. Remove rear shock absorber with pivot arm 5. Replace if any faults are present.
and link arm from vehicle.
9. Detach the shock absorber from the pivot arm Shock Absorber Removed from Vehicle
and the link arm. 1. Examine shock for leaks.
2. Extend and compress the piston at least 5
Disassembling the Shock Absorber
complete strokes with its rod upward.
Shock Absorber with Adjustment Rings 3. Check that rod moves smoothly and with uni-
1. Unscrew the adjustment rings. form resistance over its entire stroke.
2. Remove the spring stopper.
3. Remove spring from shock absorber. N O T E : During compression motion, it is normal
to feel a small resistance only.
Shock Absorber with Adjustment Cams
1. Position the shock absorber in the tool and in- 4. Pay attention to the following conditions that
stall the spring compressor hooks. will denote a defective shock: 09
Spring compressor
(P/N 529036184)
– Oil leakage.
5. Replace if any faults are present.
Shock Absorber Installed on Vehicle
1. On models with ACS suspension, manually ad-
1. Spring compressor hooks just air suspension pressure to 2 ± 0.2 bar (30
± 3 lbf/in²).
2. Tighten the spring compressor tool screw until 2. From the rear, press down the vehicle as much
the spring is sufficiently compressed to remove as possible and release it to let suspension re-
spring stopper. turn upward.
3. Release the spring compressor tool screw. 3. If the suspension bounces freely or returns too
4. Remove spring from shock absorber. quickly:
Inspecting the Shock Absorber – Remove and inspect shock absorber.
1. Examine shock for leaks.
193
CHASSIS
REAR SUSPENSION
Assembling the Shock Absorber

The assembly is the reverse of the disassembly
following.
1. When installing spring stopper and cap, make
sure to install opening at 180°.
3. Tighten all retaining bolts as per exploded

view.
Swing Arm
Removing the Swing Arm
1. Remove rocker panels.
1. Stopper opening
2. Cap opening 2. Remove brake hose and electrical wiring from
swing arm.
Shock absorber with adjusting cam
2. Position cam on position 1 or accordingly with N O T E : Do not disconnect the brake hose from
operator preferences. the caliper.
Installing the Shock Absorber 3. Remove speed sensor.
The assembly is the reverse of the disassembly
following.
1. Inspect link arm upper bushings, replace as
necessary.
N O T E : Make sure there is no cable interfering

with the rest of the vehicle or the surrounding
2. Lubricate needle bearings and n e w link arm equipment for the following steps.
central bolt before reassembly.
XPS synthetic suspension grease 5. Remove following fasteners:
194
CHASSIS
REAR SUSPENSION
RYKER 90 0 RALLY EDITION
9. Remove swing arm.
ALL OTHER MODELS

09
6. Remove the link arm central bolt.
Inspecting the Swing Arm

1. Check swing arm for cracks, bending or other
damages.
2. Check if bearings turn smoothly and freely.
3. Replace all damaged parts.
Replacing the Swing Arm Bearings
1. Using a blind hole puller, remove swing arm
7. Remove rear final drive and propeller shaft. bearings.
8. Remove the following fasteners: 2. Discard bearings.
3. The assembly is the reverse of the disassem-
bly procedure.
195
CHASSIS
REAR SUSPENSION
Installing the Swing Arm

procedure.
Refer to the exploded view for tightening torques.
196
CHASSIS
BRAKES
BRAKES
SERVICE PRODUCTS

LOCTITE 243 (BLUE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................... 205
16 ± 2 N•m
(142 ± 18 lbf•in)
28.5 ± 1.5 N•m

9 ± 1 N•m (21 ± 1 lbf•ft)
(80 ± 9 lbf•in)
8 ± 1 N•m
NEW
50 ± 4 N•m
(37 ± 3 lbf•ft)
09

FRONT BRAKES
197
CHASSIS
BRAKES
85 ± 5 N•m
(63 ± 2 lbf•ft)
NEW
NEW
Synthetic grease
8 ± 1 N•m
(71 ± 9 lbf•in)
NEW
85 ± 5 N•m
(63 ± 2 lbf•ft)
NEW 28.5 ± 1.5 N•m

50 ± 4 N•m (21 ± 1 lbf•ft)
(37 ± 3 lbf•ft)
16 ± 2 N•m
(142 ± 18 lbf•in)

REAR BRAKES
198
CHASSIS
BRAKES
Synthetic grease
3.5 ± 0.5 N•m
(31 ± 4 lbf•in) 8 ± 1 N•m
(71 ± 9 lbf•in)
11 ± 1 N•m
(97 ± 9 lbf•in)
8 ± 1 N•m
(71 ± 9 lbf•in)
NEW
15 ± 2 N•m
(133 ± 18 lbf•in)
NEW
NEW
NEW
24.5 ± 3.5 N•m
09
16 ± 2 N•m
(142 ± 18 lbf•in) NEW
NEW
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
16 ± 2 N•m
(142 ± 18 lbf•in)
BRAKE PEDAL
199
CHASSIS
BRAKES
17.15 ± 2.45 N•m 17.15 ± 2.45 N•m

17.15 ± 2.45 N•m (152 ± 22 lbf•in) (152 ± 22 lbf•in) 5.4 ± 1.5 N•m
(152 ± 22 lbf•in) + (48 ± 13 lbf•in)
5.4 ± 1.5 N•m Brake grease
(48 ± 13 lbf•in)
17.15 ± 2.45 N•m

(152 ± 22 lbf•in)
+
Brake grease
Brake grease
+
22 ± 2.5 N•m
(16 ± 2 lbf•ft)
Brake grease
+
22 ± 2.5 N•m
(16 ± 2 lbf•ft)
FRONT AND REAR CALIPERS
200
CHASSIS
BRAKES
GENERAL Anti-Lock Braking System (ABS)

This subsection covers the maintenance and pro- The ABS prevents the wheels to lock while brak-
cedures related to the braking system mechanical ing. The vehicle configuration allows a single
components. For ABS related components, refer brake point at the right foot, to provide the optimal
to Vehicle Stability System (VSS). amount of hydraulic brake pressure on all brake
discs, under a multitude of braking conditions. The
During assembly and installation, use the torque result is maximizing vehicle control while allowing
values and service products as in the exploded the wheels to remain available to generate steer-
views. ing control force in response to the rider’s input.
Clean threads before applying a threadlocker. Re- Disc Brake Configurations
tion at the beginning of this manual for complete Number of Disc Brakes
procedure.
Front 2
WARNING
Rear 1
be strictly adhered to. Brake Control and Circuit Configuration
tabs, elastic stop nuts, cotter pins, etc.) must Brake Control
be replaced.
Brake pedal Controls front and rear
brakes
WARNING
Never use thread sealant or Teflon tape on Fault Codes
brake fittings or bleeders. Brake system dam- For any replacement of parts that involves brake
age and failure may occurs. bleeding, it is important to reset the fault codes us-
ing the BRP diagnostic software (BUDS2).
WARNING System Components Description
Avoid brake system contamination. If re- Refer to Vehicle Stability System (VSS)
quired, clean components prior to removal. subsection.
09
NOTICE INSPECTION
Avoid spilling brake fluid on plastic, rubber or Brake System Pressure Validation
painted parts. Protect these parts with a rag NOTICE
when servicing brake system. Do not pump up the brake pedal repeatedly
before doing the validation.
NOTICE
Hoses, cables and locking ties removed dur- 1. Connect the vehicle to the BRP Diagnostic
ing a procedure must be reinstalled as per Software (BUDS2).
factory standards. 2. Go to:
N O T E : Install a battery charger on battery termi- – V C M button
nals for any tests that involve a prolonged key ON – V C M - B a s i c tab
period. If battery voltage gets too low, some ac- 3. Press slowly on brake pedal until Low Pres-
cessories are shut off by the ECM. sure Switch value indicate true.
System Description 4. If B r a k e P r e s s u r e S e n s o r value is above 5
515 kPa (800 lbf/in²), the validation is
A disc brake system with twin-piston on front successful.
wheels and single-piston sliding calipers on rear 5. If B r a k e P r e s s u r e S e n s o r value is below 5
wheel are used. 515 kPa (800 lbf/in²), perform the following 3
times:
201
CHASSIS
BRAKES
– Apply brakes two to three times to ensure Verifying the Brake Fluid Level
good contact between the brake pads and Use only DOT 4 brake fluid from a sealed
brake disks. container.
– SLOWLY depress the brake pedal until
L o w P r e s s u r e S w i t c h indicator turns on. Check the brake fluid level as follows:
– Take note of the B r a k e P r e s s u r e S e n s o r 1. Park the vehicle on a firm, level surface.
value. 2. Slide the RH footpeg in order to be able to see
6. Calculate the average of the 3 B r a k e P r e s - the level marks on the rear of the master cylin-
s u r e S e n s o r values previously noted. der reservoir.
7. If the average is E Q U A L O R A B O V E 5 515 3. Check the brake fluid level in the reservoir. In
kPa (800 lbf/in²), the brake system pressure is both chambers, the fluid must be above the
conform. Clear fault codes. MIN mark.
8. If the average is B E L O W 5 515 kPa (800 lbf/
in²), repeat the Complete Brake Fluid Bleeding 2
Procedure.
TROUBLESHOOTING
Always refer to the appropriate wiring diagram
when troubleshooting an electrical circuit.
Install a power pack before any tests that involve 1
prolonged "key ON". If system voltage is too low, 1. Brake fluid MIN. level mark
some accessories will be shut off and test results 2. Brake fluid MAX. level mark
can be altered. The use of a battery charger can
create interferences during tests. 4. Add fluid as required.
NOTICE NOTICE
Never force a multimeter probe into an elec- Low brake fluid may indicate leaks or worn
trical terminal. brake pads. Check the brake system.
Troubleshooting Tips Adding Brake Fluid

Start troubleshooting by checking fault codes us- 1. Slide the RH footpeg fully rearward.
ing the BRP diagnostic software (BUDS2). Make 2. Clean the filler cap and the top of the reservoir.
sure fuses are good; follow the service actions in
the fault codes section. WARNING
Clean the filler cap and its surrounding area
Carry out the tests in this subsection according to before removing it in order to avoid brake flu-
the fault codes informations. id system contamination.
PROCEDURES
3. Remove the filler cap, the anti friction washer
BRAKE FLUID
and the diaphragm.
Recommended Brake Fluid
Always use brake fluid meeting the specification
DOT 4 only.
WARNING
To avoid serious damage to the brake
system:
– Use only DOT 4 brake fluid from a sealed
container.
– Do not mix different fluids for topping off.
202
CHASSIS
BRAKES
Bleeding the Brake Fluid

WARNING
Failure to correctly bleed the braking system
may reduce its performance and lead to a
loss of control.
Anytime the brake system is opened, the bleeding

procedure must be performed.
1. Ensure brake fluid is present in the entire sys-
tem by topping off the master cylinder and:
– Open the bleeder of the rear caliper until
fluid drips out and close it.
– Open the bleeder of the front RH caliper un-
til fluid drips out and close it.
– Open the bleeder of the front LH caliper un-
til fluid drips out and close it.
1. Filler cap ware (BUDS2) and go to:
2. Anti friction washer
3. Diaphragm – F u n c t i o n s page
– V C M button
4. Add fluid to MAX level.
– F u n c t i o n s tab
N O T E : Replacing brake pads will increase brake – Routines - Execute Bleeding
fluid level. If replaced when at MAX level, brake 3. Follow the on-screen instructions.
fluid spills may occur.
CALIPER
NOTICE Removing the Caliper
Brake fluid can damage painted surfaces or Front Caliper
plastic parts. Wipe up any spills. 1. Remove front wheel.
2. Remove and discard caliper screws. 09
5. Reinstall the filler cap, the anti friction washer
and the diaphragm. N O T E : If the caliper is replaced, loosen brake
6. Reposition the footpeg and the brake pedal as hose first. See procedure below. Otherwise, omit
described in the Driver's Footpegs and Brake the next steps concerning the brake hose.
Pedal section.
Verifying the Brake System
The front and rear brakes are hydraulic disc types.
These brakes are self- adjusting and do not re-
quire adjustment.
WARNING
The brake pedal requires an adjustment each
time the RH footpeg is moved.
To keep brakes in good condition, check the fol-

lowing as per the Maintenance Schedule:
– Entire brake system for fluid leaks
– Brake pedal for spongy feel
– Brake discs for excessive wear and surface NOTICE
condition
– Brake pads for wear, damage or looseness. Do not let caliper hang by the hose and do
not stretch or twist the hose.
203
CHASSIS
BRAKES
3. Install a drain pan under caliper to catch brake Front Caliper

fluid. NOTICE
4. Loosen the Banjo fitting. Disconnect brake
hose and discard sealing washers. To ensure good clamping of calipers screws,
it is imperative to clean knuckle threads using
a metric tap M10 x 1.5.
5. Remove the caliper from the vehicle.

Rear Caliper
Tighten caliper screws to specification.
1. Loosen caliper screws.
N O T E : If the caliper is replaced, remove caliper Tightening Torque

from wheel. See procedure below. Otherwise, omit 50 ± 4 Nm
the next steps concerning the brake hose. Caliper screw
(37 ± 3 lbf-ft)
2. Install a drain pan under caliper to catch brake
fluid. Rear Caliper
3. Loosen the Banjo fitting. Tighten caliper screws to specification.
4. Disconnect brake hose and discard sealing
washers. Tightening Torque
5. Remove caliper.
50 ± 4 Nm
Caliper screw
NOTICE (37 ± 3 lbf-ft)
Do not let caliper hang by the hose and do
not stretch or twist the hose. BRAKE PADS
Inspecting the Brake Pad
Inspecting the Caliper
Measure brake pad lining thickness.
Check piston (s) for scratches, rust or other dam-
ages. If so, replace caliper. Brake Pad Thickness
Installing the Caliper Service limit 0.5 mm (.02 in)
NOTICE
1. Install N E W caliper screws. Brake pads must always be replaced in pairs.
2. If hoses were disconnected:
– Install N E W sealing washers. Replacing Front Brake Pad
– Tighten Banjo fitting to specification. 1. Remove caliper.
2. Remove and discard brake pads retaining
Tightening Torque screw and retaining clip.
28.5 ± 1.5 Nm
Banjo fitting
(21 ± 1 lbf-ft)
204
CHASSIS
BRAKES
5. Remove and discard brake pads.

6. Using a flat screwdriver, depress pistons into
their bores.
7. Install N E W brake pads.
8. Apply a threadlocker product on threads of
brake pad screw.
Loctite 243 (blue)
N O T E : If new brake pad screw is used, the

threads are coated with a self-locking product, do
not apply threadlocker product on threads.
3. Using a C-clamp , depress pistons into their 9. Install brake pad screw. Do not tighten yet.
bores. 10. Reinstall caliper.
4. Remove brake pads. 11. Tighten brake pad screw to specification.
5. Check the condition of pistons pins. Replace
caliper as required. Tightening Torque
6. Install N E W brake pads.
7. Install caliper. 17.15 ± 2.45 Nm
Brake pad screws
8. Check brake fluid level and adjust if needed. (152 ± 22 lbf-in)
9. Ride the vehicle a few minutes to make sure
the repair is successful. 12. Apply brake a few times.
13. Ride the vehicle a few minutes to make sure
WARNING the repair is successful.
When installing new brake pads, always ob-
serve a break-in period of 300 km (200 mi). WARNING
During this time, the brakes and the VSS will When installing new brake pads, always ob-
not operate at their maximum efficiency. You serve a break-in period of 300 km (200 mi).
could lose control and crash – use extra During this time, the brakes and the VSS will
caution. not operate at their maximum efficiency. You
Replacing the Rear Brake Pad
could lose control and crash – use extra 09
caution.
1. Remove caliper.
2. Remove and discard retaining clip securing BRAKE DISC
brake pad retaining screw.
3. Unscrew and remove brake pad retaining Inspecting the Brake Disc
screw. With a caliper or a micrometer, verify the brake
disc thickness.
Minimum Brake Disc Thickness
Front and rear 5 mm (.197 in)
Using a dial gauge, verify the brake disc warpage.
Maximum Brake Disc Warpage
Front and rear 0.2 mm (.01 in)
Removing the Brake Disc

Front Brake Disc
1. Remove caliper.
4. Check brake pad retaining screw for wear. Re-
place as required.
205
CHASSIS
BRAKES
NOTICE
Do not let caliper hang by the hose and do
not stretch or twist the hose.
2. Remove brake disc.

Rear Brake Disc
2. Remove and discard brake disc screws.
Tightening Torque
85 ± 3 Nm
Brake disc screws (63 ± 2 lbf-ft)
3. Install all other removed parts.

BRAKE PEDAL
Removing the Brake Pedal
3. Remove brake disc. 1. Remove the right rocker panel.
2. Remove cap.
Installing the Brake Disc
Position the brake disk so that directional arrow
points forward.
3. Remove retaining screw and spring.
Front Brake Disc

procedure.
Rear Brake Disc
1. Install N E W brake disc screws.
2. Tighten brake disc screws to specification as
per tightening sequence.
206
CHASSIS
BRAKES
4. Retract the RH driver footrest in upper position

then pull out the brake pedal to the vehicle has
shown. 4. Remove bolts retaining the master cylinder to
the frame.
Installing the Brake Pedal

5. Carefully remove master cylinder from vehicle.
09
cedure. However, pay attention to the following. N O T E : Be sure to identify each hose position for
reinstallation.
1. Apply grease on splines.
6. Remove Banjo fittings and discard sealing
XPS synthetic grease washers.
2. Tighten brake pedal retaining screw. Refer to

exploded view for appropriate tightening
torque.
MASTER CYLINDER
Removing the Tandem Master Cylinder
1. Remove the right rocker panel.
2. Place a container under the master cylinder to
catch brake fluid.
3. Remove jam nut from master cylinder.
7. Remove spring pin retaining brake fluid reser-

voir to master cylinder and discard rubber
seals.
207
CHASSIS
BRAKES
2. Remove and replace the brake light switch with

Inspecting the Master Cylinder a new one.
1. Check bellow for cracks.
2. Check rod for wear and scratches.
3. Check master cylinder housing for leaks or
damage.
Installing the Master Cylinder
1. Install N E W sealing washers and N E W seals
for the brake fluid reservoir.
2. Tighten brake hoses, jam nuts and master cyl-
inder retaining bolts to specification.
Tightening Torque
Brake hose screw 28.5 ± 1.5 Nm
(banjo fitting) (21 ± 1 lbf-ft) Tightening Torque
15 ± 2 Nm 11 ± 1 Nm
Jam nut (133 ± 18 lbf-in) Brake light switch
(97 ± 9 lbf-in)
Master cylinder 24.5 ± 3.5 Nm
retaining bolt (18 ± 3 lbf-ft) 3. Connect brake light switch connector.
4. Perform the Adjusting the Brake Light Switch /
Low Pressure Switch task.
3. Refill and bleed brake system.
Adjusting the Brake Light Switch / Low
BRAKE LIGHT SWITCH (BLS) Pressure Switch (BLS/LPS)
Replacing the Brake Light Switch 1. Connect the vehicle to the BRP diagnostic soft-
1. From the underneath of the vehicle, disconnect ware (BUDS2) and go to:
brake light switch connector. – M e a s u r e m e n t s page
– V C M button
– V C M - B a s i c tab
2. Untighten the upper and lower jam nuts of the
BLS/LPS.
208
CHASSIS
BRAKES
1. Upper jam nut

2. Lower jam nut 6. Tighten the upper and lower jam nuts to
specification.
3. Hand tighten the upper jam nut until the brake
light switch value indicates 1 in BUDS2.
7. Perform the Inspecting the Adjustment of the

Brake Light Switch / Low Pressure Switch
4. Carefully untighten the upper jam nut 3/4 turn.
(BLS/LPS) task. 09
Tightening Torque
Brake light switch 11 ± 1 Nm
upper and lower jam (97 ± 9 lbf-in)
nuts
Inspecting the Adjustment of the Brake Light

Switch / Low Pressure Switch (BLS/LPS)
ware (BUDS2) and go to:
– V C M button
5. Hand tighten the lower jam nut and ensure the – V C M - B a s i c tab
upper jam nut does not turn. 2. Install a dial gauge indicator on the master cyl-
inder rod.
209
CHASSIS
BRAKES
3. Slowly push the brake pedal and monitor the

dial gauge and the indications in BUDS2.
4. When the brake light switch value indicates 1
in BUDS2:
– If the dial gauge indicates lower than 1.06
mm (.042 in) displacement, perform the Ad-
justing the Brake Light Switch / Low Pres-
sure Switch task
– If the dial gauge indicates 1.06 mm (.042
in) to 1.37 mm (.054 in)displacement, no
action necessary, switch adjustment is
acceptable.
– If the dial gauge indicates higher than 1.37
mm (.054 in) displacement, perform the Ad-
justing the Brake Light Switch / Low Pres-
sure Switch task
WHEEL SPEED SENSOR (WSS)
Refer to Vehicle Stability System (VSS).
Vehicle Control Module (VCM)
Refer to Vehicle Stability System (VSS)
subsection.
210
CHASSIS
BODY
BODY
SERVICE TOOLS
65MM SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036457) . . . . . . . . . . . . . . . . . . . 166–167

STEM PULLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036459) . . . . . . . . . . . . . . . . . . . . . . . 173
SERVICE PRODUCTS

LOCTITE 243 (BLUE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................... 205
09
211
CHASSIS
BODY
Ryker Series
8
6
4 9
11
3
12
10
13
1
2
1. Front fascia 8. Seat (Rally Edition)

2. Front service cover 9. Upper fairing
3. Front fender support 10. Side fairing
4. Front fender 11. Glove box cover
5. Seat (STD) 12. Front fairing
6. Rear upper fender (Rally Edition) 13. Left service cover
7. Rear frame (Rally Edition)
212
CHASSIS
BODY
6
5
1
2
1. Rocker panel 5. Rear fender

2.
3.
Upper frame
Rear fender support trim
6.
7.
Seat trim (STD)
Fuel tank cover
09
4. Rear fender trim 8. Fuel filler door
213
CHASSIS
BODY
1.6 ± 0.1 N•m

(14 ± 1 lbf•in)
Rally Edition
1.6 ± 0.1 N•m

(14 ± 1 lbf•in)
3.5 ± 0.5 N•m

(31 ± 4 lbf•in)
Rally Edition 1.6 ± 0.1 N•m Rally Edition

(14 ± 1 lbf•in)
FRONT FASCIA AND SERVICE COVER
214
CHASSIS
BODY
0.6 ± 0.1 N•m

(5 ± 1 lbf•in)
0.4 ± 0.1 N•m

(4 ± 1 lbf•in)
0.6 ± 0.1 N•m

(5 ± 1 lbf•in)
09
CONSOLE COMPONENTS
215
CHASSIS
BODY
NEW
5.5 ± 0.5 N•m
(49 ± 4 lbf•in)
5/5
5.5 ± 0.5 N•m
5.5 ± 0.5 N•m (49 ± 4 lbf•in)
(49 ± 4 lbf•in)
NEW
0.6 ± 0.1 N•m

(5 ± 1 lbf•in)
2/5
1/5
5.5 ± 0.5 N•m

(49 ± 4 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
3/5
4/5
5.5 ± 0.5 N•m

(49 ± 4 lbf•in)
2.8 ± 0.2 N•m

(25 ± 2 lbf•in)
NEW
0.4 ± 0.1 N•m 2.8 ± 0.2 N•m
(4 ± 1 lbf•in) (25 ± 2 lbf•in)
Outside Canada and USA

UPPER FRAME AND FOOTRESTS
216
CHASSIS
BODY
Ryker 600 and Ryker 900
1.5 ± 0.1 N•m Outside Canada and USA

(13 ± 1 lbf•in)
1.5 ± 0.1 N•m

(13 ± 1 lbf•in)
10 ± 2 N•m 2.5 ± 0.5 N•m

(89 ± 18 lbf•in) (22 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in) 09
1.5 ± 0.5 N•m
Canada and USA (13 ± 4 lbf•in)
50 ± 4 N•m
(37 ± 3 lbf•ft)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
Outside Canada and USA
2.5 ± 0.5 N•m

(22 ± 4 lbf•in) 2.5 ± 0.5 N•m
(22 ± 4 lbf•in)
REAR FENDER AND SEAT
217
CHASSIS
BODY
Ryker Sport and Ryker Rally
17 ± 1 N•m
(150 ± 9 lbf•in)
5.5 ± 0.5 N•m

(49 ± 4 lbf•in)
5.5 ± 0.5 N•m

(49 ± 4 lbf•in)
Canada and USA 1.5 ± 0.5 N•m

(13 ± 4 lbf•in)
50 ± 4 N•m
(37 ± 3 lbf•ft)
2.5 ± 0.5 N•m

Outside Canada and USA (22 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
2.5 ± 0.5 N•m
(22 ± 4 lbf•in)
REAR FENDER AND SEAT
218
CHASSIS
BODY
Rally Edition
NEW
1.6 ± 0.1 N•m

(14 ± 1 lbf•in)
1.6 ± 0.1 N•m

(14 ± 1 lbf•in)
1.6 ± 0.1 N•m

(14 ± 1 lbf•in) 09
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft) 24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)

FRONT FENDER
219
CHASSIS
BODY
GENERAL This paint finish may require more frequent

Vehicle Care cleaning.
Cleaning the Vehicle Vehicle Protection

D o n o t u s e h i g h - p r e s s u r e w a s h e r s (like the Apply non-abrasive wax to plastic parts.
ones found in car washes) as they may damage
certain parts of the vehicle.
NOTICE
Do not wax or polish matte surfaces (includ-
NOTICE ing matte paint finishes).
Do not clean the windshield with alkaline or
acid cleaner, gasoline or solvent to avoid Surface Recommendation
windshield damage.
Glossy paint Apply only non-abrasive wax,
finishes safe for clear coat paints
NOTICE
Matte finishes Do not apply wax
For matte finishes, do not use wax, detail
spray, or other products used on regular
paint. Do not wash with abrasive materials. NOTICE
Do not use mechanical cleaners or polishers, Do not polish windshield with any plastic
and do not rub the surfaces vigorously. cleaner/polisher.
To clean the vehicle: WARNING

1. Rinse the vehicle thoroughly with water to re- Do not apply a vinyl or plastic protector on
move loose dirt. the seats as the surface will become slippery
2. Using a soft, clean cloth, wash the vehicle with and the operator or the passenger may slip
water mixed with a mild detergent, such as off the vehicle.
soap specially formulated for motorcycles or
automobiles. Procedures
N O T E : Using warm water works well to remove N O T E : The procedures are the same for LH and
bugs in the windshield and front panels. RH side unless otherwise specified.
3. While washing the vehicle, check for grease or DECALS
oil. You can use service product or a mild auto-
motive degreaser. Thoroughly follow the man- Removing Decal
ufacturer's instructions. 1. Using a heat gun (low heat setting) warm up
one end of decal for a few seconds until decal
XPS Roadster wash can roll off when rubbing with your finger.
2. Pull decal slowly and when necessary apply
4. Dry the vehicle with a chamois or a soft towel. more heat to ease removal on the area that
Vehicles with Matte Finishes has to be peeled off.
3. If decal tears while pulling off, it has to be
NOTICE heated for a few seconds longer. If decal tends
Do not use wax, detail spray, or other prod- to stretch while pulling off, stop heating and
ucts used on regular paint. Do not wash with wait a few seconds to let it cool, then peel it off.
abrasive materials. Do not use mechanical
Installing a Decal
cleaners or polishers, and do not rub the sur-
faces vigorously. Using isopropyl alcohol, clean the surface and dry
thoroughly.
Hand-wash with a soft wash mitt and a mild clean- Apply a soapy water solution to new decal and
ing product safe for matte paint. To remove foreign carefully position it. Using a sponge or a
substances such as insects, use a soft applicator
and a mild solvent. Saturate and soak area before
cleaning. Rub lightly.
220
CHASSIS
BODY
squeegee, remove the air bubbles and water

working from the center toward the edges. Allow
to air dry.
NOTICE
Do not apply isopropyl alcohol or solvent di-
rectly on decals.
SERVICE COVERS
Lateral Service Covers
Right Service Cover
Closing the Right Service Cover

Close the cover and lock it using the quarter-turn
screw.
Left Service Cover
The right service cover gives access to:

– Safety card
– CVT air filter
– Engine oil dipstick.
Opening the Right Service Cover 09
1. Turn the quarter-turn screw counterclockwise. The left service cover must be removed to servic-
ing the engine air filter.
Removing the Left Service Cover
1. Release both clips, located underneath the left
service cover, that retain it in place.
2. Tilt the service cover.
2. Remove the cover from the vehicle.
221
CHASSIS
BODY
1. Slide forward
Installing the Left Service Cover 2. Lift up
The installation is the reverse of the removal Installing the Front Service Cover
procedure.
1. Slide front service cover back in place.
Front Service Cover 2. Insert service cover rear tabs into vehicle sup-
The front service cover must be removed to reach ports slots.
the following items:
– Battery
– Fuse box
– Coolant reservoir
– Diagnostic connector
– Engine oil filter.
STD and Sport Models
Removing the Front Service Cover
1. On each side of the service cover, insert a fin-
ger into the front lateral opening and lift the re-
taining tab to unlock the cover.
1 1. Rear tabs of the front service cover

2. LH vehicle support
3. Clip the front of the service cover.

4. Pull on the cover to make sure is it properly
latched.
Rally Models
Removing the Front Service Cover
1. Unscrew both 1/4– turn screws to release the
front service cover.
1. Locking tab
2. Hold the tabs and slide the cover forward.

3. Remove service cover from vehicle.
222
CHASSIS
BODY
2. Lift the front of the cover and slide it forward. 3. Unhook rear end of fascia.
Installing the Front Service Cover

1. Slide front service cover back in place.
2. Insert service cover rear tabs into vehicle sup-
ports slots.
09
1. Rear tabs of the front service cover
2. LH vehicle support
3. Lock the front service cover using both 1/4–

turn screws.
FRONT FASCIA CROSSCUT - TOP VIEW
Removing the Front Fascia

Installing the Front Fascia
1. Remove:
– Rocker panels procedure.
– Front service cover.
Refer to the exploded view for proper tightening
2. Remove the screws. torque.
ROCKER PANELS
Removing the Rocker Panels
Remove the plastic rivets.
223
CHASSIS
BODY
UPPER BODY MODULE
Pivoting the Upper Body Module

1. Drain the fuel tank.
2. Remove:
– Rocker panels
– Front service cover
– The front fascia.
3. Remove the following screws.
Unhook rear end of the panel.
CROSSCUT - TOP VIEW
Installing the Rocker Panels

procedure.
224
CHASSIS
BODY
NOTICE
Pay attention not to damage upper frame
finish.
6. Turn handlebar towards right.

7. Loosen the steering column lower bracket
screws.
09
4. Loosen the following screw.
8. Lift the rear of the upper body module.
NOTICE
Lift slowly and make sure to not stretch the
fuel line on the RH side.
5. Secure the fuel tank to the plastic frame with a

strap.
225
CHASSIS
BODY
9. Place the beam to secure the upper body

module.
Retaining beam
(P/N 529036477)
Refer to Installing the Upper Body Module to

set the module back in place.
Removing the Upper Body Module
1. Drain the fuel tank.
2. Perform the Pivoting the Upper Body Module
procedure but do not pivot.
3. Open the fuel cap cover and remove its retain-
ing screws.
226
CHASSIS
BODY
4. Open the glove box cover. 6. Remove the fuel cap cover.
09
5. Remove the upper fairing. 7. Remove the side fairings.
227
CHASSIS
BODY
8. Remove the glove box.
9. Unplug the gauge connector.
228
CHASSIS
BODY
10. Remove the fuel tank trim.
09
11. Unplug the following connectors.
229
CHASSIS
BODY
13. Place the beam to secure the upper body

module.
12. Lift the rear of the upper body module.
Retaining beam
NOTICE (P/N 529036477)
Lift slowly and make sure not to stretch the
fuel line on the RH side.
230
CHASSIS
BODY
14. Disconnect the fuel rail.

15. Disconnect the fuel vapor hose from the throt-
tle body.
09
16. Disconnect the following connectors.
17. Cut locking ties and remove the main harness

from the upper body module.
18. Remove both tie rod ends from steering col-
umn pitman arm.
19. Remove steering column lower bracket.
231
CHASSIS
BODY
DRIVER SEAT
Removing and Installing the Driver Seat
1. Pivot the upper body. Refer to procedure in this
subsection.
2. Push on the seat tabs from under the plastic
frame.
20. Remove upper body module pivot screws.
3. To install the seat, use 4 paper clips to

squeeze seat tabs.
21. Using a strap attached to the steering column,

under the handlebar, slowly lift the upper body
module.
Installing the Upper Body Module

following.
2. Lock the steering column prior to tighten the 4. Position the seat and press firmly.
lower bracket screws. Refer to Locking the
Steering Column in the Steering Column and
Front Wheels subsection.
3. Install new nuts where required.
4. Refer to appropriate exploded view for tighten-
ing sequence and torques.
232
CHASSIS
BODY
GLOVE BOX COVER

Removing the Glove Box Cover
5. Ensure seat tabs are properly inserted into the

plastic frame openings.
09
SEAT CROSSCUT - SIDE VIEW
Installing the Glove Box Cover

procedure.
233
CHASSIS
BODY
FOOTRESTS
Removing Footrests
4. Remove the rear fender trim.
To remove brake component from the RH footrest

refer to the Brake subsection.
Installing Footrests
Refer to appropriate exploded view for tightening
torque.
Rear Fender
Removing the Fender
1. Remove the rear wheel.
2. Remove and disconnect lights from the rear
fender.
5. Remove the rear fender screws.
3. Remove screws securing the front of the

fender.
6. Remove the rear fender.
234
CHASSIS
BODY
Installing the Rear Fender

procedure.
Refer to appropriate exploded view for tightening
torque.
09
235
CHASSIS
FRAME
FRAME
10 ± 2 N•m
(89 ± 18 lbf•in)
NEW
10 ± 2 N•m 10 ± 2 N•m
(89 ± 18 lbf•in) (89 ± 18 lbf•in)
NEW NEW
236
CHASSIS
FRAME
GENERAL After insert installation, ensure insert can hold the

During assembly/installation, use the torque val- torque applied to the screw it retains. Otherwise,
ues and service products as in the exploded view. install a new insert.
Clean threads before applying a threadlocker. Re- Replacing the Frame

fer to Self-Locking Fasteners and Loctite Applica- Blind threaded inserts are not installed on a re-
tion at the beginning of this manual for complete placement frame. Make sure to order enough in-
procedure. serts when replacing frame.
WARNING Frame Care

Torque wrench tightening specifications must 1. Clean the frame with appropriate cleaners and
be strictly adhered to. rinse thoroughly.
Locking devices when removed (e.g.: locking 2. Touch up all areas where paint has been
tabs, elastic stop nuts, cotter pins, etc.) must scratched or chipped off.
be replaced. 3. Spray all bare metal parts of vehicle with metal
protector.
NOTICE
Hoses, cables or locking ties removed during
a procedure must be reinstalled as per fac-
tory standards.
PROCEDURES
FRAME
Inspecting the Frame
Inspect the frame and subassemblies for:
– Cracks
– Bends
– Twisting
– Buckling
– Paint condition 09
– Any other damages.
Repair or replace as required.
Arc Welding on Frame
NOTICE
Arc welding on frame is not recommended.
Components may be damaged.
Replacing Frame Insert

To install a new blind threaded insert, use a blind
threaded insert installer available at any automo-
tive parts retailer.
TYPICAL
237
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
238
TECHNICAL SPECIFICATIONS
10
239
Technical Specifications
Ryker
10 Technical Specifications
Ryker
Cooling System
Liquid cooled, radiator with cooling

Type
fan (temperature controlled)
Ethyl glycol/water mix (50% coolant,

50% water).
Use the Extended life pre-mixed
Type
coolant sold by BRP or
coolant specifically designed for
Coolant aluminum engines
2.2 l
600 ACE
(.58 gal (liq.,US))
Capacity
2.45 l
900 ACE
(.65 gal (liq.,US))
Turn on @ 101 °C (214 °F)

Radiator fan
Turn off @ 97 °C (207 °F)
110 kPa
Radiator cap opening pressure
(16 lbf/in²)
Electrical System
Type Maintenance free SLA
Model Yuasa YTX14L
Battery Voltage 12 V
Nominal rating 12 A•h
Recommended charging rate 2A•h
CA/US H4, 12V 55/60W

Headlight LOW: projector LED
Other
countries HIGH: H4, 12V 55/60W
Lights (turn indicators, brake, position, license plate) LED
Reverse light Australia LED
240
Ryker
Electrical System
F1: Horn / Hazard 7.5 A

F2: Headlamps 20 A
F3: USB / ACC 5A

F4: Cooling Fan 15 A
F5: Fuel pump / Engine 20 A
F6: Not used Not used

F7: Electronic module 10 A
F8: Start button / Cluster 15 A
Fuse box
J1: VCM pump 40 A
J2: VCM valves 25 A

J3: Not used Not used
J4: Main 30 A
J5: Battery 50 A
RY1 Main
RY2 Cooling fan
RY3 Headlamps
Fuel System
400 kPa
Fuel delivery system Operating pressure
(58 lbf/in²)
Fuel pump Type Electrical module in fuel tank
North America 87 (R+M)/2

10
Minimum Octane rating
Outside North America 91 RON
Fuel
Recommended Octane North America 91 (R+M)/2
rating
Outside North America 95 RON
20 l
Fuel tank capacity Normal
(5.28 gal (liq.,US))
± 3.8 l
Fuel remaining when low fuel light turns ON
(1 gal (liq.,US))
600 ACE 1100 RPM± 50 (not adjustable)

Idle speed
900 ACE 850 RPM± 50 (not adjustable)
241
Ryker
Drive System
Continuously Variable Transmission

Transmission
(CVT)
Engagement RPM 1800 RPM
Final drive Drive shaft with bevel gears
335 ml
Capacity
(.35 qt (liq.,US))
Final drive oil Recommended XPS 75W90 Synthetic gear oil
If the recommended XPS oil is not Use a 75W90 gear oil that meets the
available API GL-5 specification
Rear gear ratio 3.15 : 1
Gearbox Forward and reverse positions
500 ml
Capacity
(.53 qt (liq.,US))
General purpose 5W40 Synthetic blend oil

Recommended 10W50 Synthetic oil
XPS products Warm
or
temperature
75W140 Synthetic gear oil
Gearbox oil
Use a 4-stroke SAE engine oil
meeting or exceeding the following
If the General purpose lubricant industry specifications:
recommended API service classification SN or
XPS gearbox oil JASO MA2
is not available
Warm Use a 75W140 gear oil that meets the
temperature API GL-5 specification.
Steering
Type Pitman arm
4 435 mm
Turning radius
(174.6 in)
0° ± 0.2°
Total toe-in (vehicle on ground) (see steering and front wheels
subsection
Camber angle 0° ± 0.5°
17 mm
Tie-rod maximum length unengaged threads
(11/16 in) maximum
410.9 mm
Tie-rod nominal length (c/c ball joints)
(16.2 in)
242
Ryker
Front Suspension
Double suspension arms with

Suspension type
stabilizer bar
Ryker 600 137 mm
Ryker 900 (5.39 in)
Suspension travel
Ryker 900 162 mm
Rally Edition (6.38 in)
Qty 2
Ryker 600
Oil type
Shock absorber Ryker 900
Type
Ryker 900
HPG shocks
Rally Edition
Ryker 600 190.1 ± 3 mm

Ryker 900 (7.48 ± .12 in)
Spring free length
Ryker 900 202.3 ± 3 mm
Rally Edition (7.96 ± .12 in)
Ryker 600
No adjustment
Ryker 900
Spring preload adjustment
Ryker 900
Threaded rings
Rally Edition
Rear Suspension
Suspension type Single swing arm
Ryker 600 150 mm

Ryker 900 (5.91 in)
Suspension travel
Ryker 900 175 mm
10
Qty 1
Ryker 600
SACHS twin tube coil-over
Shock absorber Ryker 900
Type
Ryker 900
HPG shocks with piggyback reservoir.
Rally Edition
Ryker 600 261.2 ± 3 mm

Ryker 900 (10.28 ± .12 in)
Spring free length
Ryker 900 249.9 ± 3 mm
Rally Edition (9.84 ± .12 in)
Ryker 600
Cam 5 positions
Ryker 900
Preload adjustment type
Ryker 900
Threaded ring
Rally Edition
243
Ryker
Brakes
Foot-actuated. Fully integrated
Type hydraulic 3-wheel braking system with
ABS and EBD
Dual 270 mm
(11 in) discs,
Front brake
Nissin floating caliper with 2 x 27 mm
pistons
Single 220 mm
Rear brake (9 in) disc
with 1 32 mm piston floating caliper
Type DOT 4
87.6 ml
Capacity (Front)
Brake fluid (3 fl oz (US))
49.5 ml
Capacity (Rear)
(1.7 fl oz (US))
Caliper Floating
Brake pad material Organic
0.5 mm
Minimum brake pad thickness
(.02 in)
5 mm
Minimum brake disc thickness
(.197 in)
0.2 mm
Maximum brake disc warpage
(.01 in)
Tires and Wheels

TIRES
Ryker 600
Kenda KR390 145/60R16 M/C 66T
Ryker 900
Front
Ryker 900
Kenda KR392 145/60R16 M/C 66T
Type (use only radial tires Rally Edition
recommended by BRP) Ryker 600
Kenda KR391 205/45R16 M/C 77T
Ryker 900
Rear
Ryker 900
Kenda KR393 205/55R15 M/C 81T
Rally Edition
Recommended tire inflation pressure

is found on the Tire Label located
inside the right side service cover.
Pressure
N O T E : The pressure difference
between the left and right side tire
should not exceed 3.4 kPa (.5 lbf/in²)
244
Ryker
Tires and Wheels

1.6 mm
Front
(.063 in)
Minimum tire thread depth
1.6 mm
Rear
(.063 in)
WHEELS
Ryker 600
Cast aluminum wheels
Ryker 900
Type
Ryker 900
Machined aluminum wheels
Rally Edition
406 x 114 mm
Front
(16 x 4.5 in)
Ryker 600 406 x 165 mm

Rim size
Ryker 900 (16 x 6.5 in)
Rear
Ryker 900 381 x 165 mm
Rally Edition (15 x 6.5 in) x
300 ± 15 Nm
Center lock wheel nuts
(221 ± 11 lbf-ft)
Dimensions
2 352 mm
Overall length
(92.6 in)
1 509 mm
Overall width
(59.4 in)
1 062 mm
Overall height
(41.8 in)
10
Ryker 600 599 mm
Ryker 900 (23.6 in)
Seat height
Ryker 900 615 mm
1 709 mm
Wheelbase
(67.3 in)
1 360 mm
Front wheel track
(53.5 in)
104 mm
Ryker 600
(4.1 in)
102 mm
Ground clearance, front and under engine Ryker 900
(4 in)
Ryker 900 112 mm

245
Ryker
Weight and Loading Capacity
270 kg
Ryker 600
(594 lb)
280 kg
Dry weight Ryker 900
(616 lb)
Ryker 900 285 kg

Rally Edition (627 lb)
2 kg
Glove box
(4.4 lb)
Ryker 900 10 kg
Rear fender
Rally Edition (22 lb)
Total vehicle load allowed (including driver, passenger, all other loads 207 kg
and added accessories) (456 lb)
489 kg
600 ACE
(1,078 lb)
Gross vehicle weight rating (GVWR)
499 kg
900 ACE
(1,100 lb)
239 kg
600 ACE
(527 lb)
Front
248 kg
900 ACE
(547 lb)
Gross axle weight rating (GAWR)
250 kg
600 ACE
(551 lb)
Rear
251 kg
900 ACE
(553 lb)
246
WIRING DIAGRAM INFORMATION
11
247
Wiring Diagram Information
11 Wiring Diagram Information
Wiring Diagram Line Line

Function Definition
Color Type
Information
Data
General communica
Wiring Diagram Location tion between
The wiring diagrams are found in the Wiring Dia- Gree Thin Communica modules
grams Booklet. n dotted tion using a
protocol
Wiring Diagram With Colored Lines (CAN, LIN, &
The wiring diagram on the Knowledge Center is in other)
color.
Controls a
Color Definition circuit by
Brow providing an
N O T E : To find the color of the wire on the ve- Thick Power control
n on/off control
hicle, skip to Wire Colors and Sizes in this to activate the
subsection. circuit
The following colors refer to the color of the line Alternative
drawn in the wiring diagram. Yel current exiting
Thick AC Volts
low the magneto
Line Line
Type Function Definition A ground that
Color
Permanent is in
Unswitched Hot at all Thick ground
Thick permanent
12 V times contact
Red Black
Sensor Module
reference A ground that
Thin 3.3 and 5 V (analog/
voltage Thin is controlled
digital)
by a module
ground
Or
Thick 55 - 60 V High voltage
ange
Wire Colors and Sizes
Variable
Blue Thin Analog signal
voltage
Pulsed or
Cyan Thin Digital signal constant
digital (on/off)
Condition
must be met 1. Wire color
Pink Thick 12V switched
to activate 2. Wire gauge (AWG)
circuit
The first color of a wire is the main color, second
color is the stripe.
Example: YE/BK is a YELLOW wire with a BLACK
stripe.
248
COLOR CODE Troubleshooting

Diagnostic Tips
OR
BG — BEIGE OG —
ANGE I M P O R T A N T : When trying to solve an electri-
cal problem, check the following:
BK — BLACK RD — RED – The ignition switch is turned ON.
BU — BLUE VT — VIOLET – The engine RUN/STOP switch is in RUN
position.
BN — BROWN WH — WHITE – The battery condition as well as its cables and
connections.
YEL – The system fuse condition of the related circuit
GN — GREEN YE —
LOW using an ohmmeter.
GY — GRAY PK — PINK – Ensure a positive electrical connection of the
fuse to the fuse holder contacts.
LT prefix means a "light" color. E.g: LT GN = – Examine related circuit harness and
Light green. connections.
Wiring Diagram Codes Install a power pack before any tests that involve
prolonged "key ON". If system voltage is too low,
Splices in Wiring Harness some accessories will be shut off and test results
Splices in wiring harness are indicated on the wir- can be altered. The use of a battery charger can
ing diagram as follows. create interferences during tests.
1 2 Pay particular attention to electrical connectors

and ensure that pins are not out of their housings,
loose, or damaged. The troubleshooting proce-
JT - RD/BU dures may not cover problems resulting from one
of these causes.
1. JT: Splice indication Ensure all terminals are properly crimped on wires
2. Spliced wire color and connector housings are properly fastened.
When replacing any electric or electronic part (s),
Following a Circuit always check electrical connections. Make sure
To follow a circuit, search in the ection of the wir- that they are clean, corrosion-free, tight and make
ing diagram shown in the wiring diagram index. good contact. The voltage and current might be
too weak to go through dirty or corroded connector
In this example, the voltage comes f r o m the Fuse pins or terminals.
4 (F4L) in the Left Block Fuse (LBF) - pin B5.
If a fault is intermittent and cannot be found
through static continuity checks, it may indicate:
– A loose connection 11
– A bad splice in a harness
– A pin that is unlocked in a connector and barely
making contact
– An intermittent electronic component within a
module.
Do the following:
N O T E : The arrow indicates the direction of the
power in the circuit. – Try moving the harness and connectors to sim-
ulate vehicle vibration as you carry out your
checks with the multimeter.
– Try spraying water to the harness, connectors
or sensors to simulate riding under the rain or
249
high humidity as you carry out your checks with power components or for supplying multiple cir-
the multimeter. cuits. Take this into account when troubleshooting
the electrical system.
IMPORTANT: In an electrical circuit, the bat-
tery usually provides power to a switch, which then Pay attention to ground wires. They could become
supplies the electric component when the switch loose or corroded which causes them to act as an
contacts are closed (low power circuits). Therefore additional load in a circuit, dropping voltage and
the switch opens and closes the positive side of reducing current to components. Some compo-
the circuit. In circuits controlled by the ECM and nents may be grounded through their outer casing
other modules, the battery supplies the electric and mounting hardware. This should also be
component, and the ECM or the module acts as considered.
the switch which completes the circuit to ground. A
relay acts as a remote switching device for higher
Simplifying Electrical System Tests
For complex systems where there are electronic modules, sensors, actuators, relays etc., it is often ben-
eficial for diagnosing problems to divide up the system into some basic smaller subsystems, to help nar-
row down where the problem lies.
Connect the vehicle to the BRP diagnostic software (BUDS2) to check for fault codes.
Common Subsystem Guideline

Power and – Battery – Check if a group of components or systems stopped
Grounds – Fuses working or if nothing works (lights, gauge, etc.).
– Relays – Start from the power source (battery) and move
– Connections outwards towards the modules, checking for voltage
at each connection.
– Check grounds and battery (+) using a voltmeter.
– Disconnect and test wiring.
Inputs and Outputs – Sensors – View measurements in BUDS2
– Gauges – Activate all possible items and monitor response.
– Actuators – Disconnect and test wiring.
– Motors
Communication – Between Modules – View measurements in BUDS2
and with BUDS2 – Disconnect and test wiring.
For ALL wiring tests, you need to check for:
Possible Problem Common Cause
– Open circuit – Loose terminals, broken wires.

– Shorts to ground (battery -) – Wires rubbed through, water in connectors.
– Shorts to battery (+) – Corroded wires and terminals.
– Shorts to other circuits
– Higher resistance than desired
250
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
251
www.brp.com
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Vehicle Service Manual

Includes Safety, Use and Maintenance

2023 Ryker Series

CALIFORNIA PROPOSITION 65 WARNING

™®Trademarks of BRP or its affiliates.

FAULT CODES ...................................................................................................................... 62

CHARGING SYSTEM OUTPUT ................................................................................................ 99

STABILIZER BAR................................................................................................................. 187

WIRING DIAGRAM CODES ................................................................................................... 249

65mm socket D.E.S.S. Post Remover Pressure gauge

Page:138, 166–167 Page:111

Alignment adaptor B RYKER Diagnostic cable

Page:59 Rear wheel bearing pusher

Page:77–78 Steering column spacer 8,34

Optional extension cableDo not

BRP heavy duty cleaner

Extended life pre-mixed coolant

Loctite 243 (blue)

Loctite 767 (anti-seize lubricant)

XPS Roadster wash

XPS synthetic grease

XPS synthetic suspension

Safety Notice CAUTION

We have provided you with some of the most im-

Vehicle Information Engine Identification Number (EIN)

Vehicle Identification Number (V.I.N.)

Bombardier Recreational Products Inc. DATE: XXXXX

Bombardier Recreational Products Inc

XXXX dB(A) - XXXXX min-1

TYPICAL - VEHICLE SERIAL NUMBER L ABEL

900 ACE ENGINE

EPA Compliance Label (North

TYPICAL - UNDER THE SEAT, AFFIX ON THE LEFT LOWER

VEHICLE EMISSION CONTROL INFORMATION VEHICLE EMISSION CONTROL INFORMATION

Exhaust Emission Système de contrôle

Compliance Labels (Australian Models)

APPROVAL No: xxxxx CATEGORY LEM2

TYPICAL - AUSTRALIA ADR LABEL

Lifting and Supporting

Lift the front of vehicle.

Lower vehicle and ensure it is supported safely

Manual Information In order to avoid a poor assembly, tighten screws,

FAS FASTENER GRADE/TORQUE

135 Nm 170 Nm 200 Nm

Threadlocker Application for Uncovered Holes

Self-Locking Fasteners Procedure

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

Use a metal brush or a tap to properly clean a

Loctite® Application Procedure

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

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

1. Clean bolts and nuts with solvent. Standard Thread Repair

1. Clean shaft external contact surface.

4. DO NOT use antiseize Loctite or any similar

Threadlocker Application for Case-In

1. Proper strength Loctite

1. Clean inner housing diameter and outer gasket

4. Install according to standard procedure.

N O T E : Normally used on worn-out housings to