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The BRP Can-Am Commander 800R & 1000 service manuals for do-it-yourselfers. This manual covers the following BRP made Can-Am side-by-side vehicles: Commander 800R STD 6CEA, 6CEB, 6CEC; Commander 800R DPS 6TEA, 6TEB; Commander 800R XT 6DEA, 6DEB, 6DEC; Commander 1000 STD 6AEA, GAEB; Commander 1000 DPS 6PEA; Commander 1000 XT 6BEA, 6BEB, 6BED, 6BEE, 6BEF, 6BEG, 6BEH; Commander 1000 XT-P 6EEA, 6EEB, 6EEC; Commander 1000 LTD 6GEA, 6GEB, 6GED.

Contents:

Engine, CVT And Gearbox

Engine Removal And Installation

Air Intake System

Exhaust System

Lubrication System

Cooling System

Magneto System

Intake Manifold

Top End

Timing Chain

Bottom End

Continuously Variable Transmission (CVT)

Gearbox And 4×4 Coupling Unit

Shifter

Wiring Diagrams

General System

ACS System

DPS System

CE System

Free BRP Can-Am Repair Manuals

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User Manual: 2011-2012_Can-Am_Commander_1000LTD

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Page Count: 671

This service manual covers the 2

This service manual covers the 2011/2012 Can-Am Commander Series.
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file:///C|/Manuals/Midwest%20Manuals/index%20searchable%20BRP.html[10/21/2011 9:03:04 AM]

This service manual covers the 2

file:///C|/Manuals/Midwest%20Manuals/index%20searchable%20BRP.html[11/15/2010 1:58:50 PM]

2011
Shop Manual

Commander™ 800R/1000
Series

can-am

TABLE OF CONTENTS

01

MAINTENANCE (cont'd)
03 - PERIODIC MAINTENANCE PROCEDURES (cont'd)
PROCEDURES (cont'd)
FRONT SUSPENSION ARM INSPECTION.......................... . .............................. . .. .. ..
BRAKE SYSTEM INSPECTION AND CLEANING.. .. ...... . ....... .. ................................ .. ...
BRAKE FLUID REPLACEMENT.. ... .... .. . .. .. .. ...... .. ............ .. .. . .. .. ... .... ..... ... ........ .. ...
PASSENGER HANDHOLD CONDITION.... .. ...... .. .... .. .................... . ............ .. .. .... .. .. .
TOW HITCH INSPECTION... .. .... .... .. ......... .. ... .... . ........ .... .. .. .................. . ...........
04 - PRESEASON PREPARATION............. .. .......... . ............... ... ..... .. .... .............. ............
05 - STORAGE PROCEDURE................. .......... ............ ...... ...... .. .. ....... ........... .. .... ... ... ..
GENERAL ................ .................. ....... . ........ . .................... . ................. .... .. .. .. .
PROCEDURES ... ... .. .. . ...... .......... ... ..... ..... .. .. .............................. ....... ....... .......
FUEL SySTEM.. .. ..... . . .. . .. ..... . .............. ... .. . .. . ......... .. .. . ... . .. . .... . . . ... . ..... . ...... . ..
ENGINE ......... . .................... . ........................... . ...... . .. . ... . ..........................
ELECTRICAL SySTEM....... . .............. . .. . ........... . ....................................... . ......
DRIVE SySTEM.. . .. .. . .. .. . . .. . . ..... . .. .. .. . .. . ... . .... . . .. ..... . ...... . .. .. .................... .. ......
CHASSIS . .. ....... . .. . ..... . .... .. .... .. .. . .. . .. . ........ . .. . .. .. . . .. . ... .. ............ . .... .. . .....•.....
06 - SPECIAL PROCEDURES.............. ... ... .. .. .. ... .. ....... .. ..... ... ................ .. ..... . ............ ...
GENERAL .. ....... ... .............. . ......... ..... .. ................... ......................... . .......... ..
ROLLED OVER VEHiCLE .. . . .. . . .. . . .. .. . .. .. .. ... . . . ... . ..... . .............. . .. . ........................
SUBMERGED VEHiCLE........ ........ . . .................... . ...... ........ .. .... .. ................ . .....

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27
29
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31
33
33
33
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34
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35
35
35
35

02 ENGINE. CVT AND GEARBOX
01 - ENGINE REMOVAL AND INSTALLATION ..................................................................
GENERAL ............ ........ . .. ... ..... .... .. . ........................................................... ...
PROCEDURES ... ................ . .. .. ......... .. ...... ........... . ........ ... .... .... . ........ ....... .... ...
ENGINE REMOVAL.......................... . .. . .......... ... ........................ .. ..................
ENGINE INSTALLATION.......... . .......................... ..... . . .... . . . .. .. ... .... . ............. . .. .. .
ENG INE MOUNTS. . ........................ .. .. ............. ... ... ..... .. ...... . ..... .. ............. . ....
02 - AIR INTAKE SySTEM.......................... .. ......... . .. ... .... .. .............. ....... ... .... .............
GENERAL .... ,..................................................................... ........................ ..
PROCEDURES ...... ............ . .................... ........................................................
AIR FILTER . . .. .. . ... .. . .. .. . ... . .. . ..... . . ... . .. .. . ........ . ......... . ....................... ,............
AIR FILTER HOUSiNG .............. .. .. . ...... . ................... . .. . ... ,. .. .. . . ...... . ...... .. . . .......
03 - EXHAUST SySTEM ............. ....•..... ....................•.........................• ... . .. .... ... •... . ... .
GENERAL . ... .. . .. .. .. .. .. . ... .. ... .. ... ... .. .. .. .. .. .. .. . ... ... ... ... .... ... .. ........ ....... ... .... ........
PROCEDURES . .. ............. ........ ................ ....... .. .. .... .... ... ... . .... ............ .. ... ... .....
SPARK ARRESTER.............................. . ............. . ........ . ......... . . . . . .. . . . ....... .. .... ..
MUFFLER..... .. .. . ............................. .. . .... . ...... .. . .... . ...... .. ..... . .... .. . .......... .. ...
"Y" EXHAU ST PiPE ........ .. . . .... .. .. . ... . . . .. . ... . ..... . .. . .. ... . .. . ...... .. .. . ...... ....... . ..........
HEAD PIPE (FRONT CyLINDER)...... .. ...... ......... ... ..... ........ .. .... .. .. . .. .. .. ..... .............
HEAD PIPE (REAR CYLINDER) .. . ......... . ........... . . ..... . ... . .... .. ..... .. ............ . ... . .. . .. .. ..
04 - LUBRICATION SySTEM..... . ........................................................................... . ... ..
GENERAL .. ... ............ .......................................................... ... .... ............... ...
INSPECTION ... .. ...... ...... ... .. ....... . .. . ... ... ....... . .... .. .... ..... . .. ........ .. . ... .... ... ...........
ENGINE OIL PRESSURE............ . . . ........... . . . . ..... . ......... . ..... .. .. . .. . .. . .. .. .. . .. .. .. . ... . ..
TROUBLESHOOTING .............................. . .................. ... .................. . ........ .. .. ...
PROCEDURES ............. ... .. ..... ... .. .. .. ...............................................................
OIL COOLER . . . . .. . .. . ... ... . . . .. . . ..... .. . . .. .. .... . .... , . . . ...... . ..... . .. ,.. . .. ... ....... .. ............
OIL PRESSURE SWITCH (OPS)............... .. . ......................... ... .. .. ... .. ... ....... ..........
ENGINE OIL PRESSURE REGULATOR............................................................. .. ....
OIL PUMP .. .. .. .. .. . . .................. .. .. . ..... . ...... . ..... .. . . .................. . ..... ........ . . . . .. .
ENGINE OIL STRAINER. .. . . .. ... .. .. . .. . . .. ... . ..... . . ... . .. . .. ....... .. ................... . ... . ........
REED VALVE.. ..................................... . ...... .... .. . ..... .. .... . .. ... ... .. ......... . . . .... . ..

II

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54
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55
57
58

TABLE OF CONTENTS

02 ENGINE. CVT AND GEARBOX (cont'd)
05 - COOLING SySTEM.............................................. ... .. ... .. ......... .. ... .. .................... 59
GENERAL ... ......... ... .. .... ......... . .. .. ...... ..... ... ........ .... .................. . .......... ... .... ...
PROCEDURES . ............ . . . .. . .. .. ...... . ... .. .. .. .... . .. . ... ... ..... . ...... ... . . ... . .. .......... . ..... . ..
THERMOSTAT. . ... . .. . ... ........... .... .. ... ........... ... ................... ... . .. . .... . .... .. .. . ... . . .
RADIATOR................................................................................................
COOLANT TEMPERATURE SENSOR (CTS) ..............................................................
RADIATOR COOLING FAN RELAY (Rl) ..................... . .............................................
RADIATOR COOLING FAN .. . ...... .... ..... . . . .... .. ........ .. .......... ... .................. .. . .. .. ....
WATER PUMP HOUSiNG ... .. .. ..... ...... .. .. ..... . ....... . .. .. . .. . . ... . . ...... ...... . .. . ........ . .. ... .
WATER PUMP IMPELLER ..... ............ ....... ....... ........ ... . ...... ..... .............. ..... . .... . .
WATER PUMP SHAFT AND SEALS... ...... ... ......... ...... .... . . ... . ...... ............. .. ..... .......
06 - MAGNETO SySTEM . .. ... .. . ...... . ........ . ...... . ..... .. .... . .... . . . . .. . ... ......•......•.. . . ..... .. •.. ... ..
GENERAL ...... .. ........ . .. .. .... ... ..... . ...... . . .. ... . . . . . .............. . ... .... .... ... .. ... ....... .. .. . ..
PROCEDURES... .. ..... ....... . . .... .. .. ... . .... . .. . .. . .. . . .. . . .. . ..... . .. . ... . . . .. ... . . . .. . .. .. .. . ...... ...
MAGNETO COVER ..... . . .. ....................... .. . .... .......... . .. ..... ............ ..................
STATOR . . ... .... .... .. . ... . . .... . .... ....•.. .... . .... ...... ......•.... . . .. ... . . ... .... ...... .... .. . ... . .. .
ROTOR ............................•......•..................................... •...... •. ............•.....
SPRAG CLUTCH. ..... ......... . ................ ........ .... .. ... . . ....... .......... ... .... .... ... .... ... .
SPRAG CLUTCH GEAR.. . ... . . . ....... ...... . .. . ... . ...... ... ........ . ...... . ..................... .. . ....
STARTER DRIVE GEARS........ . ...... .. . .. . . .. .. ............... ... . ..... . .. .. .. . ...... ............... ...

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07 - TOP END........ .......... ................. .......................... ............... .. .. .... ... .......... .... .... 91
GENERAL . ... ..... .. . . . ... ...... ................... ......... . .. .... .... . .......... . .... .. ....... . ............
INSPECTION. ...... .. .. ...... .. .. ....... ..... ....... ..... . ....... .. . .... .. . .......... . ...... ..... .... ... . ....
LEAK TEST. . . . .. . . .. . . . . . .. . . . .. .. . . •.. . . . ... . .. . ... . . . . . . . . .. . .. . .•. ..... . .. .. . .• . . . . . .•.. ... . . . . . . .. . . . .
PROCEDURES...............................................................................................
INTAKE MANIFOLD.. . . . .. ............. ... ... .. .... ... .. ..... .. .. .. ................ ...... .................
VALVE COVER ....... . . . .............. . ...... •.... . . . .. ..•.... .....•.... ..•.. .......... ... .. .. ...... . ... . .
ROCKER ARM ..................... ...... ................ . ...............................................
CYLINDER HEAD . .. ... .................. ...... . ........... . ... .............. ... ....... ....... .... .......
CAMSHAFT. . . .. . .. . . . . . . .. . . . .. . . . . . . . . . . . . . .. . .. . . . . . . . .. . . . . .. . . ... . . . ... . . . . ... . . . . . .. . .. . . . . . .. . . . ..
VALVE SPRINGS . .... .. ...... .... ..... .. ... . ... . .. .. . .. ..... .. . .. .......... ..............................
VALVES ...............•.........•...............•.................. . . .• . ...•...... .... ... . ................
VALVE GUiDES ...... .. .................................... . ........ . .....................................
CyLINDER...... . .. . . .. . . . . ........................................................ .... . .. ..... . ... . ... . .
PISTON ............ .. . ....• . ...•... . . ......... .. ........• . . . .. . ... ... . ..... . ........... . . .• . ... . .........
PISTON RINGS................ . . ....... .... .. . ..... . ..... ... .. .. . . .............. . ........................

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08 - TIMING CHAIN .. ...... ............ . .. ... . .. .... ... ......... ... .. ...... ..... ........... .. .. .................... 119
GENERAL ........ .. . . ............. ... ........... .......... ...... .... ..... . . . ...... .. ....... ......... . ..... . .
TROUBLESHOOTING . .. ... .. ... .. . ...................... . ................................................
PROCEDURES ......... . .. ... .. . ...... .. .............. . ............. . .. . ........ . . . . . .... . ......... .. ... ....
TIMING CHAIN TENSIONERS .. ......... ... . ..... ..... ... . ....... ... ......... ... ........... . ... ... .. .. ..
CAMSHAFT TIMING GEARS . . ............. .. .. .. ......... ... .. .. . .. .... . .. . .... .. ... .. .. .. . . . . .... . ....
TIMING CHAIN ................. . .......... . ..... .. ....... .......... . .. . ............... ...... . .... . . .. .. . .
TIMING CHAIN GUIDE (TENSIONER SIDE) .... ...... .... ...................................... ... . .....

09 - BOTTOM END ... . .. .. ............ ... .. ... . ... . ...... . ..... ... ... .... ... . ..... .... ...... .... .. .... .. . ... . .. ....
GENERAL ............ ... ....................................................................................
PROCEDURES . ......... .. ... ........ ..... . .. ....... •.......................................................
ENGINE DRIVE SHAFT ....................................... . .................. . .......................
PTO COVER OIL SEAL .. ......... ... ................................. ... ........... .... ............. ....
PTO COVER. .. . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . .. .. .. . .. . . . . . . . . .. . . . . . . . . . . . • . . . . . . . . . . .. . . .• . . . . .. . . . . . .
DRIVE GEARS ......... . .... . .... . .. .............•... . . .. . .• . .... .. .. . . ....... . ... . ... . .....• . ..... . ... . .
CRANKCASE .... . ...... .. .... . ... .. ..... .. ..... . ....... . ......................... . .. . ....... . .. . .. . .. ....
CRANKSHAFT.. .... . ..... .. . .. .... . ..... .. ..... .................................... .................... . .

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III

TABLE OF CONTENTS

02 ENGINE, CVT AND GEARBOX (cont'd)
10 - CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ...................................... .. .. .. .......
GENERAL............ ..... . .. .... ............ ... ..... ....... ....... ........ . ....... . ........... . ............
PROCEDURES ............. .. ... ...... .. ....................................•.............•........ .... .....
CVT COVER... . . . . .. .. . ..... .. . ... . .. ..... . .. . . .. ... .. .... . .... .... ..... ... . .... . .... .... ..... . ...... . .. .
DRIVE BELT....................... .. ........................................................ . ............
DRIVE PULLEy. .. ... ..... ........ .... ... . ......................................................... ...... .
DRIVEN PULLEy ............. ......... ................. . ..... . .... .... ................ . ..................
CVT AIR GUiDE ..... . . ............................................. ... ...................................
11 - GEARBOX AND 4X4 COUPLING UNIT .... .... ............................................................
GENERAL ...................................................... .. .... .. ......... . .................... .. .. ...
GEARBOX OVERViEW ........................................ .. .........................................
TROUBLESHOOTING ............ . ..... .......... ......... ..... . . ......... .. ............... . . ...... .. .. ...
PROCEDURES ........................................................... ... .. .... . .................... ... ..
VSS (VEHICLE SPEED SENSOR) ........................................................................
GBPS (G EARBOX POSITION SENSOR) ........................................................... ......
4WD INDICATOR SWiTCH ..............................................................................
ACTUATOR .............................. . .. . .............................................. . ... ... .......
GEARBOX OIL SEALS .................................... . ......... . .......... . ................. .. ......
GEARBOX.................. .... . ................ . .... . ... .. .............................. ... ...... . ......
12 - SHIFTER . . ........ ............... ........... . ........................ ... ........................................
GENERAL ........................... .. ...................... .. .............. ....... .......... .. ......... .. ..
PROCEDURES ............................................................ ..... . . ...........................
SHIFT LEVER . ..................... .......... ........................ . ...................... ...... .......
SHIFTER CABLE ...... .. ............ . .................................................................. ..
SHIFT PLATE .................................................................................... . ........

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03 ELECTRONIC MANAGEMENT SYSTEM
01 - ENGINE MANAGEMENT SYSTEM (EMS) ................................................................
GENERAL .. .... ............... . ..... .. ......................................................................
SYSTEM DESCRiPTION... ..... ... ........... .. .............. .. ... ........... . ... ................ .. .... .
02 - COMMUNICATION TOOLS AND B.U.D.S ................................................. .. ..............
GENERAL................................................. ... .... .. ........... ....... ...... ... . ..... ........
TROUBLESHOOTING ..... . ............................................................. .. ................
DIAGNOSTIC TiPS .......................................................................................
PROCEDURES ... ............... . ..... .... ... .. .. ...... .... . . .... ...... . ............................ ........
MPI-2 ..................................................................................... . ...............
B.U.D.S. SOFTWARE ............................................................................... .... .
03 - DIAGNOSTIC SYSTEM AND FAULT CODES .............................................................
GENERAL ...................................................................................................
DIAGNOSTIC SYSTEM .......... . ..................... .. .. . .................... . ..... . .... ..............
FAULT CODES ............. ..... ............ ...... .. ... . . ....... . . .. .... ............ ..... . ......... . .....
SPECIFIC FAULTS .............. . ............................................................. .. ..........

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04 FUEL SYSTEM
01 -INTELLIGENT THROTTLE CONTROL (iTC) ................................................................
GENERAL .............................................................. .. ................... . ........ ...... .
SYSTEM DESCRiPTION ..................................................................... .. .. ... . ....
SYSTEM MAIN FEATURES . .. ........... .. ..... .... . ..... ............... . ..... .. ......... . ..............
SYSTEM OTHER FEATURES ............................................................................
PROCEDURES .. .. ..... .. .. ...... ...... ...... . ......... ... ..................................................
SPORT/NORMAL SWiTCH ................... .... .............. .............. . .. . .. . . ..... ..............
SEAT BELT SWiTCH............................................................. ... .. . . .................
OVERRIDE SWITCH ................................................ ...... ........... .. ... . _... . . ..... __
THROTILE ACCELERATOR SENSOR (TAS)..... . ....................................... .. ..............
IV

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TABLE OF CONTENTS

04 FUEL SYSTEM (cont'd)
02 - ELECTRONIC FUEL INJECTION (EFI) ..................... ... ............ .................................. 225
GENERAL ........... . ......... . ...................... ... ............................ . .................... .. .
SYSTEM DESCRiPTION .... . ......... . .... ... ................ ..... ........ . ..... . ........ . ..............
ADJUSTMENT ....................................................................... . ............. .. . .... .
IDLE SPEED .. ................. ... ... .... ....................... ..... .... ... ......... ... ....... ....... .. .
TROUBLESHOOTING .....................................................................................
DIAGNOSTIC TiPS . . .. .... ..... . . ...... . ..... . ........................... . .... ... ...... . .. . ..............
PROCEDURES ...................................................................... ... ............ . ........
ENGINE CONTROL MODULE (ECM).......... .. . ...... .. ..... ......... .. ........................ .. .....
FUEL INJECTOR .........................................................................................
FUEL RAIL ...............................................................................................
THROTILE BODy .... . .. . .. . ..... . .. . ........ ..... ................... .. .... .. ....... .. ......... . .........
THROTILE POSITION SENSOR (TPS) ............... : ...................... ... ..... .. ...................
CRANKSHAFT POSITION SENSOR (CPS) . ...................................................... . .... ...
MANIFOLD AIR PRESSURE AND TEMPERATURE SENSOR (MAPTS) .................................
CTS (COOLANT TEMPERATURE SENSOR) ...... . .. . ...... .. ................. . •... . ... . .....•..........

03 - FUEL TANK AND FUEL PUMP.................................... . ....................... . .................
GENERAL ...................................................................................................
SYSTEM DESCRIPTION .................. ... ........... . .... ... . . ................ , .............. . .......
INSPECTION . . ............. . .. . .... . ......... . ............... . ...... . ........... , .... , .... , .................
FUEL TANK LEAK TEST ............................ .. . .. ................................ .. ...............
FUEL PUMP PRESSURE TEST ................................................. ... ... .. ..... .. ..........
TROUBLESHOOTING ............................................................ . . , .......... . .......... .
FUEL SYSTEM DIAGNOSTIC FLOW CHART............................................................
PROCEDURES . .. . ......... ... . ..................................... , ......... . ..... .. ... .. . , ...............
FUEL HOSE AND OETIKER CLAMPS ..................................... .. ............................
FUEL TANK .... . .. . .... .. ..................... , ............. , ............................................
FUEL PUMP... . ....... ..... . ................ . .. ......................... . .. . ............... . .. .. ... .....
FUEL LEVEL SENDER . ........................................... . ....................... ....... ........
FUEL TANK VENT VALVE ................................................................................

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05 ELECTRICAL SYSTEM
01 - POWER DiSTRIBUTION.............................................................................. .... .. .. 265
GENERAL ... . .................... . .................... .. , ....... ... . . ............. , ....•......•... . ....•....
POWER DISTRIBUTION DIAGRAM ............................... ,.. ..... ....................... .. .....
FUSE BOX 1 .. .. . ...... . ........ . ............. .. ....................... ... .... .... ..... ..................
FUSE BOX 2 ................................. .. ............. ...... . .. .. ......... .. ..... ... ...............
02 - CONTROLLER AREA NETWORK (CAN) . .. . ......•.... . . , .. . .• ..... . , ...... , ... . , . . ..•.. ....•. ,...........
GENERAL. ... ... .... .... ..... ... . ..... .. . .... .... .. ........... ................ ............ ..................
SYSTEM DESCRiPTION................. . ...............................................................

03 - IGNITION SySTEM...........................................................................................
GENERAL ................................................. , .... ...... .............. . .... . ...................
SYSTEM DESCRiPTION. .. .. . .. . . . .. ....... ............... .... .. ................ .. . .... . .............. ..
TROUBLESHOOTING .. . .. . .. . .... . ..... . . .. .. . . .. .... ..... .. . ...... . ..... .... . ..... . . .... . .. .. .. .........
DIAGNOSTIC GUiDELINES ......... ... .... . .... ... . ..... ........... . ................................ .. ..
PROCEDURES ......... . ...............•.... . . , .. . . , .................. , .... .. , ... ..... ............ , .........
IGNITION SWiTCH......... . .... . .. .... .. . .... ..... ..... . .. . ......... . ....... . .. . . .. . .................. ..
IGN ITION COIL .. . . . . .... ..... .... . ....... .. ........... .... . ... .... .. .......... . .. .. ..... .. .. ........ . ...
SPARK PLUG . . .. ... .. .. ... . .. . . . .... .. ... ... .... . ..... .. .... . ................................ . ...........

04 - CHARGING SySTEM............................................................................. ............
GENERAL ................... . . .. ..•.......... . , ....•...... , .......... ... .... ... .. . , ....•. , . ....... , .........
SYSTEM DESCRiPTION .... .. .. ... .. . . . .. . . . .. . . .................. . . .. . .. . .... . .. . . . . . .. ... .. .. .. ... ... .
INSPECTION ..................................................................................... .. ... ... . ..
CHARGING SYSTEM OUTPUT ................................................................... .. .....

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V

TABLE OF CONTENTS

05 ELECTRICAL SYSTEM (cont'd)
04 - CHARGING SYSTEM (cont'd)
TROUBLESHOOTING . .. . ..... . .. ... .. .. . . . ...... .. . .. . . .......... . . ... .... . . ... ...... . .... ... ............
PROCEDURES ........ . ....... . ............ . . . . ........ . .... . . . . . .. . .. .. . .. . . . . ... .. . . ...... . ... ... ... ......
VOLTAG E REGULATOR/RECTIFIER.. ...... . ........... ... ..................... .. .... . ...... . ... .. . .. ...
BADERY .. ......... .. .......... . . . ........ . ..... .. ...... .... . ... . .. . ... . ... .. ... .. ..... .. ................
05 - STARTING SySTEM........ ... .... . ...... .......... . ... . ........ .. .. .. .. .. ... .. ... ... .. ... .. ...... ... .. . .. .. .
GENERAL .............. . ....................... .. . .. ....................... .. ....... . ... ... ... . .. . .... .. . .. .
SYSTEM DESCR iPTION..... .. . .. ... . . .. .. .. . .. . ... . ...... . .. . . . ... . ......... .. . . ... .. ........ . ... . .. .. .
TROUBLESHOOTING .. . . .. . . .. .. ....... . .... .. .. . .. .. . .. .. .. . .. ......... . . .. . . . .. ... ... .... . ........... ..
DIAG NOSTIC GU iDELI NES .......... .. ......... .. ... .... ..... . .. .. ... .. ........ .. ... .. ..... . .. .. . . ... . . .
PROCEDURES ... . .. ... . .. . . .. ..... .. ... . .. .. . . . . . . ... .. ........ ... .. .. . . ... . .... . ........ . ... . .... . ... . .. . .
D2 DIODE (STARTER SOLE NOID). . ... . .. .. . .... .. . . ... . ..... .. . ... .... ..... . . ........ .. .. .. ... .. . . ... ..
START BUDON ..... .... ......... .. . .. .. . ... . . ...... ... .. .. . . ... .. . . ... .. . . .. . .. . . . . . ..... .. . .... . ... ....
STARTER SOLENOID. .. . .. . ... ... ... . . .... .... . .. . ... . . . .... . ... . .. .. ... . .. . .................... ... . .. ..
ELECTRIC STARTER .. . . .. . .. ..... .. ... .. . . .. . .. . .. . .. . ......... . .. .. .. . .. . .. . .. . .... . ... . ... . . .... .... . .
06- DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.1 .. .. .. ...... .... .. .. .... .. .... .. ........ .. .. .. ....
GE NERAL ...... .. . . ... . .. .. . .... ...... .. ........ .. ....... .. .......... . ..... . . . .. . ....... .. . ... ... ... . .. .. .. .
SYSTEM DESCR IPTION .. . ........... . ... ... ... .. ..... ... .. .. . . . . . . .... .. . .... . .... .. ....... .. .... ..... .
TROUBLESHOOT)NG .. . ...... .... ... . .. . ..... . ..... . ....... ..... .. ....... .. ... . . .. . .. ... . . .... .......... .
DIAGNOSTIC TiPS.. . . .. . . .. . . ... .. .. . ... . . .. .. . . . ... . . .. .. .. .. . . .. . ...... . .. . . . . . . .. .......... . . ... .. . ..
PROCEDURES . ....... .. . .. . .. . . .. ...... .. .. .... . .. . ... .... . .. .... . •. .. . . . . .. . . .. . . ....... . . . . .... .... •. ....
KEY PROGRAMMING ....... . . . .... ... . .... .. .... .. . ........ .. .. . .. . .. ... . . ... .. .. .... ... ........... .. ..
07 - LIGHTS, GAUGE AND ACCESSORIES...... .. ...... .. .... .. ...... . .... .. .......... ...... ........ ... .. .... .
GENERAL . . . .. . . . ..... .. . ..... . .... . ... .. ..... ..... .. . . .. .. .. .... . . .. ..... .. ... . . . .... . .. .. .. .. .... . . ... ... .
TROUBLESHOOTING .... . ........ .... .... .... .. ... ... ... ...... .. . .. . ...... . ... ...... . . .. . ... .. . . . .. . . . ...
DIAGNOSTIC TiPS. . ..... . ..... . .. .. ... . . . . .... .. .. .. . .... . ..... .. .. . .. .. .. . . . .... . ... . . .. . . ..... .. . . . ...
PROCEDURES .... . .. . ... . ............ . ... . .......... . ... . . .. ...... .. ..... .. ... . .. ... ........... . .. ..... . ...
CONSOLE SWiTCHES .. . ....... . .... . .. .. . .. . . . .. .. .. . . .. .. . .. .. .. . . ... . .. . . . .. . .. .. . . .. . . .. .. .. . .... . . .
MULTIFUNCTION GAUGE (LCD AND ANALOG/DIGITAL) ....................... . .......... ..... ... .....
12 VOLT POWER OUTLET . ..... . .......... . . . ...... . . . ... . ..... ........... .. .. .. . . .... . . . ... . ...........
HEADLIGHTS ............ . ... . . . .... . .. . . . ...... . . .. . . ... . .. . . .. . . ... . .. ..... . .. . . . ...... .. . . . ... ... .. ...
TAI LLIGHTS/BRAKE LIGHTS. .................. .. ........... . . .. ... . .......... .. .. . .. . .. .. .... ..... ..... .
WiNCH ......... . ..... .. . . .. . .. . .. . ... .. . .. . .. . .... ... .. . ... .. . ... ...... . . ..... . . .. .. . .. ... .. . ...... . .... .
TURN SIGNALS/HAZARD(EC MOD ELS ONLY).. .. .. .... ....... .. .. ...... .... . .... ....... ... ............
HORN (EC MODELS ONLYI .. . .... .. ........ .. .. . .... ... ... ........... ..... .. .. .. .. .......... ... ... .. ...

274
274
274
274
277
277
277
277
277
278
278
278
279
280
283
283
283
283
283
283
283
285
285
285
285
285
285
286
288
289
291
292
293
294

06 DRIVE SYSTEM
01 - FRONT DRiVE .. .. ... .. ... .. ... .. .. ..... .. ... . .. . .... ........ ... ............ . ... ... .... . .. ......... ... ..........
GENERAL . .. . . .. . .... . ... . .. . ....... . ... .. .. .. ... ..... . .. .... .. . .. . .. . . .. ... .. . . .. . . . . .. ... . .. ..............
SYSTEM DESCRiPTION .... . ......... . .............. . . . .. .. .. .... . . ... .. . ...... .. ... . ........ .... . ... .. .
PROCEDURES .. . . .. . ... .. . .. . . .. ....... . ..... . .................. .. ..................... .. ..... ... .. . .. ... . .
WHE EL HUB . . . . . .... . . .. . .... ..... ...... . . . ....... .......... . ...... .. .......... ... ........... .. ...... ...
FRONT DRIVE SHAFT . . . . .. .. . .. . . .. . ... . .. . .. .. .... . .. .... . .... ... .. ............ .... ...... .... . .. . ... ..
DRIVE SHAFT BOOT... .. . .. ..... . ..... .. .... .. ... ... . . .. . . .. .... . ... .. .. . .. ..... .. . .. ....... .. .. .. .. ....
FRONT DIFFERENTIAL .... . .... .. .......... . ............... . ......... .. . . ..... . ... .. ...... . ....... .... . .
FRONT PROPELLER SHAFT.. . . ...... .. .. ........... .. ..... . ..... . ...... . ...... .. ............ .. ... ... ...
PROPELLER SHAFT U-JOINTS .. .. .. ... . .... .... .... .. . .. . . .. ........ . .... .. .......... .. ........ .. . .. . ..
02 - REAR DRiVE.... ... ........ . ... ...... ........ .... .. .. ... ...... . .... ... ... . .. ... ... .... ... . .. ...... . ... .. ........
GENERAL .. .... ......... . .. .. .... .... . ........... ........ . .. . . .... .. ..... .. . .. . .. . . . .. . .. .. .. . ... . . .........
PROCEDURES .... . . .... . . ...... ...... . ... .. ..... .. ................ . .... . .... . ............. . .... . ... . . .. . .. .
WHEEL HUB. . .. . . . . . . . .. . .. .... .. . . . .... . .. ... . .. .. ....... . .... . .. . ... . .. . . . .... . ..... .. ... . ... .. ... . . . .
DRIVE SHAFT . . .. . ...... . .. . . . .... .. ... . . . .... ... . . .. .. . . .. .. .... . . .. .. . . ... . . ... . .... . . . . . . .. ...........
DR IVE SHAFT BOOT....... . .......... . ............... .. .. ............. ... .. .... . ... . ... .. . .. .. .. .... . .. .
PROPELLER SHAFT . . ...... .... ... .. . .... .... ........ .. .............. . .................. .. . .. . . . ... . ....
VI

295
298
298
298
298
299
299
300
303
303
305
308
308
308
309
309
310

TABLE OF CONTENTS

06 DRIVE SYSTEM (cant'd)
02 - REAR DRIVE (cant' d)
PROCEDURES (cant' d)
PROPELLER SHAFT U-JOINTS ...... . . . . ...... . ... ... ..................... . ........................... . . 310
REAR FINAL DR iVE..... .. .. .. ..... . .. . .... .. . . .................... .. ........... . ... ..... . . . . ........... . 311

07 CHASSIS
01 - WHEELS AND TIRES .... .. ........... .. ............... .. .. . ........ ............. .. ....... .. ... .. ....... .. ....
GENERAL .. ... ..... ......... ....................................... .. .. . .. .. .. ..... . .. .. .. ... .. .. ...........
PROCEDURES .. ...... . .. . ....... ....... . ..... .... .. .. .. .. . .. •... .. . •.... .. •. . ..•. .. . ..... ... .. . •.... .. •... .
TIRES ............. ... . .. . . ..... . . .. .. . . .. . . .... .. . . ... .. .. .. . . ...................... .. ..... .. .......... . .
WHEELS ... ... . ...... . .. ....... .. . .. . . ......... .. . .. . .... .................... .. .. ..... ..... .... ....... . . .
02 - STEERING SYSTEM .. ...... ... ........ . .. . ... ... .. •... ....... ... .. ..... ... .... .. ...•. . ... . •. ..... .. •. .. ... ...
GENERAL .. ... ... .. . ......... ...• ..... .. . ... .. ... •...... •..... .. .. ... ... .. .. .. . ..... . .. ..• .... ... ... ........
ADJUSTMENT ... ........... .... .... ....... .. .. . .... .. ..... ............ .. ...... .... . .. . .... .. ...... . ..... ..
STEERING ALIGNMENT ..... . ..... .. . . ...... .. .............. .. .. ... . . ..... . . .. .. .. . .. .. ..... .. ..... . .. ..
TROUBLESHOOTING ....................... . ....... .. .. .......... ... ...... ... .. . ... ..... ... ... .. .. .. .. . ..
DIAGNOSTI C TiPS . . ... . ... ........... . ......... .. . ... . .. .. .. . .. . .. .. .. . ... ......... .. .. . ....... . .... . . ..
PROCEDURES ... .. ....... .. . ...... .. ...... ..... ............. .... . .. ..• ..... . •.. ... .... ..• .•. . ... .. ... . ... ..
STEERING WHEEL .. ... . .. ................. .... . . .. .. .. . .. . .. .. .. . . . . ....... .. . .. . ... .. . .. ... ... .. .. . . ..
STEERING COLUMN . .. .. ... . . . .... . . .. . . .. . . . ........... . . .. .. .. . .. ... . .. . . .. .. ... . .. .. . .. .... . . ...... .
RACK AND PiNION . .. ... . .. . ... . .. . .... . . . .. . .. ..... . .... ... ............... . . . . . .. . . . ........... . .... .. .
TIE-ROD ENDS .......... . .... . .. ... . ... ... . ..... ........... .. .... . ...... . ... . . . . . . .. . ... .. .. .. ... ... .... .
KNUCKLES . . . .......... .. . . ... .... . ... . . . . . . .. . ....... .. ... ... ... . . . . ... . .• . ... . . . .. . . . . •. .. .. . .. •. ......
WHEEL BEARINGS. .. ... . ... .. .. . ...... .. ... .. ...... . . . .. . . . . ... .. . .. . .. . .. . .. . ... . .... . .. . .... .. .. .. . . .
03 - FRONT SUSPENSiON ......... ... ....... .. ... .. .... . .... .. . ... .......... . ....... .... . .. .. .. .. ...... .. .... . ...
GE NERAL ..... .. .. ... ... . .. .. ........... .... .. .. ......... . .. ... . .. ... .. . .. . .. .... ... ............... ... .... ..
PROCEDURES .. ... .... .... . ...... .. ........ .... . .. •. ... ..... ...... .. .. . •.. ... ... ...•.. ... ......... ..... . ...
SHOCK ABSORBER. ... .. . ... . .. . .. ...... . ..... . . ... . . .. . . . . . . ... .. . .. ... ..... .. ..... .. . . . . ... .. . ... . . ..
SHOCK ABSORBER BUSHINGS . . .. .... . ............ . ...... . ................ .. .. . ... .. ......... .. ..... ..
SPRINGS . . . ........ . ... . ... . ... ......... . ...... .. .. . .. .. ...... . . . .. .. .. . . .. . .. . .. .. ........... .. .... .... .
LOWER SUSPENSION ARM .. ... ...... . . . .... . ... . .. . .. . . . . . . .. . . . .... . .......... . . .. .. . ... . . . . . .. . ....
UPPER SUSPE NSION ARM .... .. ... .... ........ .. .. ... ........ .... .. .. ............ . ............. .... .. .
SUSPENSION ARM BUSH INGS .. . ........... . ............ ............... . ..... .. . .. . .. ......... . ..... ..
BALL JOINTS . .. .. .. ... . . .. ............ . ....... . ... . . . ... . . ... . .. ... . .. . . . . . ....... ... ..... .. ..... . ......
04 - REAR SUSPENSiON .... . ....... . .. .. . . . . . . . . .. . . ... . • . . . . . .• . . . . .. . ... . .. . . . . . . . .. . . . . . . . . ... . . . .. .. . . .. . . . ..
GENERAL ...... . ... ... . .. .. .... .. . .... ... .. . .... .. ... .... ... .. .... ... ..... .. .. .. .. .. ... . ....... .. .. .. ... .. ..
PROCEDURES ... ..... . .... .. .. .. . .. ...... .. .. .. . ....... .. ..... ... ...... . ....... .. .. . ... ....................
SHOCK ABSO RBE RS . .. .. . .. .. .......... . .............. . ..... . .... ... . . ..... . ..... .. .. .... .. . ... .. ... . . .
SHOCK ABSORBE R BUS HINGS . . ..... . .. . . . ..... .. . ....... . .. .............. . .. .... .. . ...... . .... .. . .. ..
SPRINGS . . ...... . .. . .. .. .. .. .. . .. .. . .. . .. . . .. . .. . .. . .. . . . . ... .. . . .. .. .. . ..... . . .. ...... . . . .. . ..... .. .. . . .
ANTI-SWAY BAR.. . .. . ... . . .. .. ...... ...... . ..... . .... . ...... . ...... . ........ . ..... .. . . ..... . ............
TRAILING ARM . .. .. . ....... . ................................. .... ....... .. .. .. .... ....... .. .. ...........
05 - BRAKES. .. .. .... .. ..... ........ .. ........ ......... . .... . .. .. ..... . .. .. .... ... ... .. .. . ... . .. . ... . .. ... .... .... . ..
GENERAL ........... ... . ..... .. .. ....... .. .......... .. ... ... .. .. ..... .. ..... ........ . .... ... ... ... ..... ... . .
INSPECTION ... .. . ... .. .. ... ...... ........ .. .... . .. . ........... ... ... ....... ... ....... .... ........ ....... . ..
BRAKE SYSTEM PRESSU RE VALIDATION ............... . .. .. . .. . .. .. . ... ... .. .. . ...... .. ... . . . .. ... .. .
PROCEDURES .......... . ...................... ...... ... ..... . ... .. ... ... ... .... .. .. . .. . ....... ... ....... ...
BRAKE LIG HT SWiTCH ..... . .... . .. . ..... . ... . .... .. . .. . .. . ....... .......... . ..... .. ............... . . .. .
MASTER CyLINDER......... .. . . .... . . .. . .. . . .. . . .... . ... . ......... . ..... .. .... . .. .. . ... ........ . .......
CALIPER. . ... . .. ..... .. . .. ..... . .. . ... . .... . ......... ... .. .. . .. .. .. . .. .. .. . . ....... .... .. . .. ... ... .. .. ...
BRAKE PADS ..... . . ... ......... . . . . . .... . .. . . . . .. .. . . .. . ... . .. . ... . . .. . .. . .. . ... . .. . . .... .. ... ... .......
BRAKE DiSC ... .. . . . . . .. . ... . . . .... . .. . . . . . .. . .. . ... . ...... .. . . ... ............. . ... . ..... .. .. . ...... . .. . .

315
315
315
315
317
319
321
321
32 1
323
323
323
323
323
325
325
326
326
329
330
330
330
331
331
331
332
333
333
335
336
336
336
337
337
338
338
341
343
343
343
344
344
345
347
347
348

VII

TABLE OF CONTENTS

07 CHASSIS (cont'dl
06 - BODY. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . ... . . . . . . . . . ... . . . . .. . . .. . ... . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . ... . . . . .... . . . . . . ..
GENERAL ....................... . .... . ........................... . .................. . .......................
PROCEDURES ..............................................................................................
PLASTIC RiVET............... . .... . .... . ... . .. . .. .. ....... ... . . .... . .. ... . . . . . .. .... ... .... . ....... . . . ..
DECALS ........ . ................................................................. . .......................
UPPER CONSOLE. . .... . ..................................... . .. .. .. ... .. ........ . .. .. ..... .. ......... ..
LOWER CONSOLE.. ... . .... . ....... . .................... . ................................... . .. .. .. . . ..
LATERAL CONSOLE PANELS.. . .. . .. .... . .. . ...... ..... . .. ...... . . .. .... .... .......... . . .. .... ..... . . . .
GLOVE BOX REMOVAL AND INSTALLATION ...........................................................
07 - CARGO BOX .... .. ..... ... ...... . ................ . ........ .. ... .. ... . .. . ....... . ... ....... .... ... . ....... . .....
GENERAL .. . .. ..... ....... .. .. .. .. . . .. . .. . .................. . ... ..... .. . . . . . .... .. .. .. . ...... . ... . ......... .
ADJUSTMENT ... . .. . .... . ................................................................................ .
CARGO BOX ADJUSTMENTS. .. .. . . ... .. .. . ...... . .... . ..... . . . . ..... . .. . .. . ...... . ... . .. ... .. . .. . .. ...
PROCEDURES . .. . .. . . ... . . .. .. .. .. . . .... .. . . .. .. ..... .. . .. ...... . .... . .... .. . .. .. . .. .. .. .... ... ....... . . . ..
CARGO BOX GAS SHOCK .. ... .... ...... . ... . .. . .. .. .. . ......... .. ..................... . . .... ... ..... . ..
CARGO BOX ... . . ..... ...... . .. . .......... . .. . . . .. ......... . ... . ....... .... ...... .. ....... .. .... .. ... ....
08 - FRAME.. .... . .... .. . .. . .. . ..... .. .. . ... .. .. . ... . .. ..... . .. .... .. ... .. .. ..... .. . .. . .... ... ...... .. ... ..... .... .. .
GENERAL ..... . .. . ...... . .... .. ..... . .. ...... ... ... .......... ..... ..... . .. . .. . ............... .. .... . .. .. ....
PROCEDURES ...... .. ............. . .............. . ........ ............... . .. ...... . . .. ..... . .... . .. .. . .... .
CAGE ... . .. .. . .. . .. . .. . .. . ...... . ........ ... . .. . ...... . .. .. . .. ..... .. . ................. . .. ..... . ... '" .. . .
FRAME ...................... . ..... . . .... ...... . ... . ....... . ............ . .... . ............................

349
359
359
359
359
359
359
360
361
363
369
369
369
371
371
371
373
376
376
376
377

08 TECHNICAL SPECIFICATIONS
01 - COMMANDER 800R AND 1000 ............................................................................. 379

09 WIRING DIAGRAM
01 - WIRING DIAGRAM INFORMATION.............................................................. .. ........
GENERAL ....... . . .... . .... . . ........ . . . .......... .. ... .. . ........ .. ... ... .. ..... . ............. . ... .........
WIRING DIAGRAM LOCATION..........................................................................
WIR ING DIAGRAM CODES....... . .. ... .. . ........ . .. . .. . ....... . . .... .. .. . .............................
02 - CONNECTOR INFORMATION ........... .......... ...... ...... ... .. ..... . .. ... . ... .. .. ... . ..... . .. .... ......
GENERAL .. . .. . .. ... . ... . . . . .. . . ..... . . .... . .... .. . ... ........ ... .... ...... ... ......... . . . . . ... . . .... . ... . ..
DEUTSCH CONNECTORS . .. .... .... . .. . . . .. .... .. .... ... . .. .. ..... .............. ..... . ... . . .... ...... ..
PACKARD CONNECTORS ....... .... ....... . .. . ........ .. ...... . .. . . ....................................
PACKARD CONNECTOR (MULTIFUNCTION GAUGE) ............ .. ... ... ............ .... ....... ........
MOLEX CONNECTOR.. . . .. .. ...... . .. ... .. . . . ..........................................................
FURUKAWA CONN ECTOR... .. ... .. . . . . ... ....... ....... .. ...... ....... . . . .. . ................... . ......
BATIERY AND STARTER CABLE TERMINALS .......... .. ..............................................

VIII

389
389
389
389
391
391
391
393
394
395
398
398

SAFETY NOTICE

SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair the 2011 Can-Am'" Commander SSV as described in the model list in the
INTRODUCTION
This edition was primarily published to be used by
mechanical technicians who are already familiar
with all service procedures relating to BRP products. Mechanical technicians should attend training courses given by BRPTI.
Please note that the instructions will apply only
if proper hand tools and special service tools are
used.
The contents of this manual depicts parts and/or
procedures applicable to a particular product at
the time of writing. Service and warranty bulletins
may be published to update the content of this
manual. Dealer modifications that were carried
out after manufacturing of the product, whether
or not authorized by BRP, are not included.
In addition, the sole purpose of the illustrations
throughout the manual, is to assist identification
of the general configuration of the parts. They are
not to be interpreted as technical drawings or exact replicas of the parts.
The use of BRP parts is most strongly recommended when considering replacement of any
component. Dealer and/or distributor assistance
should be sought in case of doubt.

Although the mere reading of such information
does not eliminate the hazard, your understanding of the information provided will promote its
correct use. Always use common shop safety
practices.
It is understood that this manual may be translated into another language. In the event of any
discrepancy, the English version shall prevail.
BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents of this publication. We strongly recommend
that any services be carried out and/or verified by
a highly skilled professional mechanic. It is understood that certain modifications may render use of
the vehicle illegal under existing federal, provincial
and state regulations.

The engines and the corresponding components
identified in this document should not be utilized
on product(s) other than those mentioned in this
document.
This manual emphasizes particular information
which, is denoted by the following wording and
symbols:

A

WARNING

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

A

CAUTION Indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.

'Nnilllj Indicates an instruction which, if not
followed, could result in severe damage to vehicle components or other property.
NOTE: Indicates supplementary information required to fully complete an instruction.
!mr2011"{)()2

IX

INTRODUCTION

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

ENGINE
TYPE

MODEL NUMBER

Com mander BOOR

BlO

6CBA, 6CBC,
6DBA, 6DBD

1010

6ABA, 6ABC,
6BBA,6BBB,
6BBC,6BBD,
6BBE, 6B BF, 6EBA,
6EBC, 6CBA, 6CBC

Commander 1000

The information and component/system descriptions conta ined 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 instal l them
on products previously manufactured.
Due to late changes, there may be some differences between the manufactured product and the
description and/or specifications in this document.

VIN Decal Description

3

2

~34X:2V000123l- 1

TYPICAL -

VEHICLE IDENTIFICATION NUMBER LABEL

1. VIN (Vehicle Identification Number)

2. Model number
3. Manufacturing date

ENGINE IDENTIFICATION
NUMBER (EIN)

BRP reserves the right at any time to discontinue
or change specifications, designs, features, models or equipment without incurring obl igation.

VEHICLE INFORMATION
VEHICLE IDENTIFICATION
NUMBER (VIN)

TYPICAL - RH SlOE OF ENGINE
1. Engine Identification Number (EIN)

LIFTING AND SUPPORTING THE
VEHICLE
Front of Vehicle
1. Place vehicle on a flat non slippery ground.
TYPICAL
1. VIN (Vehicle Identification Number) location

The VIN (Veh icle Identification Number) decal is located under the glove box on the passenger side.

x

2. Ensure vehicle shift lever is set t o PARK.
3. Install an hydraulic jack under front skid plate.
4. Lift front of vehicle and install a jack stand on
each side under frame section in front of the lip
for center skid plate.

tmr2011-OO2

INTRODUCTION

1. Front of vehicle
2. Hydraulic jack
3. Jack stand

4. Lip for center skid plate
5. Center skid plate

5. Lower hydraulic lift and ensure vehicle is supported safely onto both jack stands.

Rear of Vehicle

1. Rear of vehicle

2 . Jack stand
3. Frame section

6. Lower hydraulic lift and ensure vehicle is supported safely onto both jack stands .

HOISTING THE VEHICLE

1. Place vehicle on a flat non sli ppery ground.

The vehicle may be lifted off the ground by the
cage using a hoist and a lifting strap.

2. Activate 4WD mode.

iN'JlMj

3. Ensure vehicle shift lever is set to PARK.
4. Install a hydraulic jack under the trailer hitch.

1. Hydraulic jack
2. Trailer hitch

The lifting strap must be wrapped
around the horizontal side tubes at the top of
the cage, NOT fore and aft. Lifting vehicle by
the fore and aft tubes of the cage can cause
damage.

1. Lifting strap around horizontal side tubes (top)
2. Hoist hook

5. Lift rear of vehicle and install a jack stand on
each side under frame section in front of rear
wheel.

Imr201 J.{)02

XI

INTRODUCTION

A

WARNING

- Ensure hoist and lifting strap are rated for
lifting the total vehicle weight. Refer to applicable manufactures instructions.
- Ensure lifting strap is in good condition before lifting vehicle.
- Do not allow anyone in the vehicle or under
any portion of the vehicle while it is suspended by a hoist.
- Do not perform any work on the vehicle
while it is suspended by a hoist.

TRANSPORTING THE VEHICLE
If the vehicle needs to be transported. it should be
carried inside a full size pick-up box or on a flatbed
trailer of the appropriate size and capacity.

,,,,,Ji(ljj

Do not tow this vehicle - towing can
seriously damage the vehicle's drive system.

When contacting a towing or transporting service,
be sure to ask for tie-down straps, a flatbed trailer,
loading ramp or power ramp to safely lift and secure the vehicle. Ensure the vehicle is properly
transported as specified in this section.

'1![,Ji(ljj Avoid using chains to tie down the
vehicle - they may damage the surface finish
or plastic components.
To load the vehicle for transport, proceed as follows:
1. Set gear shift lever to NEUTRAL (N).
2. Remove the key from the ignition switch.
3. If the vehicle is equipped with a winch, use the
winch to roll the vehicle onto the transport vehicle.
4. If the vehicle is not equipped with a winch, proceed as follows:
4.1

Put a strap around the lower arm of each
front suspension.
4.2 Attach the straps to the winch cable of the
towing vehicle.

4.3 Pull the vehicle on the flatbed trailer with
the winch.

7. Firmly attach the rear wheels tie-down straps to
both sides of the rear of the trailer with ratchets.
B. Ensure that both the front and rear wheels are
firmly secured to the trailer.

ENGINE EMISSIONS
INFORMATION
MANUFACTURER'S
RESPONSIBILITY
Manufacturers of engines must determine the
exhaust emission levels for each engine horsepower family and certify these engines w ith
the United States of America Environmental
Protection Agency (EPA). An emissions control
information label, showing emission levels and
engine specifications, must be placed on each
vehicle at the time of manufacture.

DEALER RESPONSIBILITY
When servicing any vehicle that carry an emissions control information label, adjustments must
be kept within published factory specifications.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory
specifications.
Exceptions include manufacturer's prescribed
changes, such as altitude adjustments.

OWNER RESPONSIBILITY
The owner/operator is required to have eng in e
maintenance performed to maintain emission
levels within prescribed certification standards.
The owner/operator is not to, and should not allow anyone else to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory
specifications.

NOTE: Be sure to leave the gear shift lever in
NEUTRAL IN)

EPA EMISSION REGULATIONS

5. 1ie down the front wheels to the front of the
trailer using tire towing straps.
6. Pass a tie-down strap inside each rear wheel.

Vehicles manufactured by BRP are certified to the
EPA standards as conforming to the requirements
of the regulations for the control of air pollution
emitted from new vehicle engines. This certifica-

XII

tmr201 1-002

INTRODUCTION

tion is contingent on certain adjustments being
set to factory standards. For this reason, the
factory procedure for servicing the product must
be strictly followed and, whenever practicable,
returned to the original intent of the design.
The responsibilities listed above are general and
in no way a complete listing of the rules and regulations pertaining to the EPA requirements on exhaust emissions. For more detailed information
on this subject, you may contact the following locations:
FOR ALL COURIER SERVICES:
U.S. Environmental Protection Agency
Office of Transportation and Air Quality
131 0 L Street NW
Washington D.C. 20005
REGULAR US POSTAL MAIL:
1200 Pennsylvania Ave. NW
Mail Code 6403J
Washington D.C. 20460
INTERNET: http://www.epa.gov/otaq/
E-MAIL: otaqpublicweb@epa.gov

MANUAL INFORMATION

MANUAL PROCEDURES
Many of the procedures in this manual are interrelated. Before undertaking any task, you should
read and thoroughly understand the entire section
or subsection in which the procedure is contained .

A

WARNING

Unless otherwise specified, the engine
should be turned OFF and cold for all maintenance and repair procedures.
A number of procedures throughout the book require the use of special tools. Before starting any
procedure, be sure that you have on hand all required tools, or their approved equivalents.
The use of RIGHT and LEFT indications in the text
are always referenced to the driving position (sitting on the vehicle).

lmr2011-002

TYPICAL

1. Lefr

2. Right

This manual uses technical terms which may be
different from the ones of the PARTS CATAL OGs.
When ordering parts always refer to the specific
model PARTS CATALOGS.

'ill'J'lIi" Most fasteners are metric, and most
components are built with parts dimensioned
using the metric system. Consult the appropriate PARTS CATALOGto obtain and use the correct parts and fasteners. Mismatched or incorrect fasteners could cause damage to the vehicle.

MANUAL LAYOUT
This manual is divided into many major sections as
can be seen in the main table of contents at the
beginning of the manual.
Each section is divided into various SUbsections,
and again, each subsection has one or more divisions.
Illustrations and photos show the typical construction of various assemblies and, in all cases, may
not reproduce the full detail or exact shape of the
parts used in a particular model vehicle. However,
they represent parts which have the same or a
similar function.

XIII

INTRODUCTION

TYPICAL PAGE
06 ENGINE
Page h ead ing
___________________~S:"b~':Section
'~"~;o:o~o:'~~~~~.Ej_- indicates section
and subsection.

Subsection title

--I---'MIA,GNETO

Indicates applicable -~--+ M"d.l'
models.
~------------------------~

Drop represe nts a
• .~~----------~~- service product
- ./'"
to be applied.

Exploded view assists

you in identifying parts

"¥:.

-L--l~

and t heir related
positions.

Model

.~,
- - -I
,

".~----------f~f-

I
I
l ___ I

Dotted box contains
parts applicable to a
specific model.
Bold face number
is used to ident ify
a part referred to

the text

NEW indicates that the

part must be replaced -!---L----~[lml--J
with a new one.

Illustration number --+----)~cO::=.____
for publishing process.

____ ____ I--- -- --------.J

___________ I - ------------....J

Document number for
publishi ng process. -t::::::::~_~::_'d
_~

Page numbe r

Specific torq ue applicable to this installation.
CAUTION: Pay attenti on to torque specifications.
So m e of t hese are in Ibf·in instead of Ibf·tt.
Use appropri ate torque w rench.

X IV

tmr201H)(12

INTRODUCTION

TYPICAL PAGE

Section 03 ENGINE
Su bsection 09 (MAGNETO SYSTEM )

Tittle in bold
indicates category --l-~'G,ErYERj~L
of information to be
NOTE: The following
carried out.

procedures can be dol'l€

wit hout removi ng the e ng ine

D un ng assembly/Insta llat ion, use the torque va lues and service products as In the exploded
views

Reference to a
specific section
or subsection.

"TYPICAL"
indicates a genera l
view w hi ch may
not rep resent exact
detai ls.

th iS m anual for co mp le te procedure.

.&.
Torque

wrench

WARNING
tightening

specifications

must be strictly adhered to.
Lock ing dovices (e.g.: loc kin g tab s, e lastic
stop nuts, self-locking fas ten el S, etc.) m ust

I

be repl aced with new ones.

I

PROCEOURES
Indicates component
procedures apply to.

NOTE: To ,emove Stalling pulley bolts. hold mag ·
neto flywheel Wllh a socket as shown

Ca ll-ou t s pertaining
to above ill ustration.

FLYWHEEL
Magneto Flywheel Cleani ng
Clean al l melal compon ents 'n a non -ferrous metal
c leaner

Indicates specific
procedure to be
carried out.

CAUTION: Clean magneto fl yw he e l usin g on ly
a clean cloth.

Illust ration always
fo llows text to which
it app lies

--+----}••,.<'oc,'o Flywheel Remova l
Remove muf fl er. refe r to the srllAUST SYSTEM
sect ion

Rem ove ac oust ic pa ne l
Remove rewortd starter
Remove sta rtlng pu lley

Remove the conneC/lIlg flange reraining the
rewind starter to the engine /lo(Js.ng

Itali c bold face typesett ing indicates a
procedure app licable
to a specif ic
model(s)

Bold face numbe r fo ll OWing part
name refers to expl oded view
at begi nning of subsection .

tmr20 11-002

xv

INTRODUCTION

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

A

WARNING

Torque wrench tightening specifications must be strictly adhered to.
Locking devices when removed (e.g,: locking tabs, elastic stop nuts, self-locking fasteners, cotter
pins, etc.) must be replaced.
In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following procedure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
3. Tighten fastener to the recommended torque value.

'!loil,.

Be sure to use the recommended tightening torque for the specified fastener used.

NOTE: When possible, always apply torque on the nut.
NOTE: Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are
used to secure a part (eg. a cylinder head). Some parts must be torqued according to a specific sequence
and torque pattern as detailed in the installation procedure.
4.8
Property
class and
head
markings

8.8

0 0 0

@

~ ~ ~
5

Property
class and
nut
markin gs

9.8

8

10.9

0
cgJ
10

12.9

0

@

~ ~
12

©~© ©~© ©~© ©~©

AOOAIIBS

FASTENER
SIZE

XVI

FASTENER GRADEITORQUE

5.8 Grade

8.8 Grade

10,9 Grade

12,9 Grade

M4

1.5 - 2 Nem
(13 - 18lbf ein )

2.5 -3N em
(22 - 27 lbf oin)

3.5-4N em
(31 - 35lbf oft)

4 - 5N em
(35 - 44 lbf oft)

M5

3 - 3.5N om
(27 - 31 Ibfoft)

4.5 - 5.5 Nom
(40 - 47lbf elt)

7 - 8.5 Nem
(52 - 75lbf eft)

8 - 10 Nom
(71 - 89lbf oft)

M5

5.5 - 8.5 Nom
(58 - 75lbfeft)

8-12N om
(71 - 105lbf oft)

10.5 - 15 Nem
(93 - 133lbf oin)

15N om (142Ibf oin )

M8

15 Nom (133Ibf ein)

25 Nem (18Ibf oft)

32 Nem (24Ibf eft)

40 Nom (30 Ibf eft)

Ml0

29 Nom (21 Ibfoft)

48 Nem (35Ibf oft)

51 Nom (45 Ibf eft)

73 Nom (54Ibf oft)

M12

52 Nom (38Ibf eft)

85 Nem (53 Ibfoft)

105 Nem (77 Ibfolt)

128 Nom (94Ibf eft)

M14

85 Nem 153lbf eft)

135 Nem 1100 Ibfeft)

170 Nom 1125lbf oft)

200 Nom 1148lbf oft)

tmr201 1-OO2

INTRODUCTION

FASTENER INFORMATION

,.yulllij

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

Threadlocker Application for
Uncovered Holes (Bolts and Nuts)

SELF-LOCKING FASTENERS
PROCEDURE
AOOA3LA

7. Apply here
2. Do not apply

1. Clean threads (bolt and nut) with solvent.
2. Apply LOCTITE PRIMER N (PIN 293 800 041) on
threads and allow to dry.

AOOA6LA

TYPICAL -

SELF-LOCKING FASTENER

The following describes common procedures
used when working with self-locking fasteners.
Use a metal brush or a tap to properly clean a
threaded hole. then use a solvent. Allow the solvent time to act, approximately 30 minutes, then
wipe off. Solvent utilization is to ensure proper
adhesion of the product used for locking the fastener.

3. Choose proper strength Loctite threadlocker.
4. Fit bolt in the hole.
5. Apply a few drops of thread locker at proposed
tightened nut engagement area.
6. Position nut and tighten as required.

Threadlocker Application for Blind
Holes

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

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

1. Clean threads (bolt and hole) with solvent.
2. Apply LOCTITE PRIMER N !PIN 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.

tmr2011·Q02

XVII

INTRODUCTION

4. Apply several drops along the th readed hole
and at the bottom of the hole.

Threadlocker Application for
Pre-Assembled Parts

5. Apply several drops on bolt th reads.
6. Tighten as requi red.

Threadlocker Application for Stud
Installation in Blind Holes

2
AOOAJOA

1. Apply here
2 . Do not apply

1. On stud threads

2 , On threads and in the hole
3. On re taining nut threads

1. Clean threads (stud and hole) w ith so lvent.
2. Apply LOCTITE PRIMER N (P/N 293 800 041) on
threads and al low to dry.
3. Put 2 or 3 drops of proper strength Loctite
thread locker on female threads and in hole.
NOTE : To avoid a hydro lock sit uation, do not apply too much Loctite.
4. Apply severa l drops of proper strength Loctite
on stud threads.
5. Install stud.
6. Install cover, part, etc.

1. Clean bo lts and nuts with solvent.
2. Assemble components.
3. Tighten nuts.
4. Apply a few drops of proper strength Loctite on
bolt/nut contact surfaces.
5. Avoid touching metal with tip of fla sk.
NOTE : For preventive maintenance on existing equipment, retighten nuts and apply proper
strength Loctite on bolt/nut contact surfaces.

Threadlocker Application for an
Adjustment Screw

7. Apply a few drops of proper strength Loctite on
un cove red stud threads.

2

8. Instal l and tighten retai nin g nutls) as requi red.

1. Apply here
2 . Plunger

1. Adjust sc rew to proper setting.
2. Apply a few drops of proper strength Loctite
threadl ocke r on screw/body contact su rfaces .
3. Avoid touchi ng metal w ith tip of flask.
XVIII

lmr2011-002

INTRODUCTION

NOTE: If it is difficult to readjust, heat screw with
a soldering iron (232°C (450°F)).

Gasket Compound Application

Application for Stripped Thread Repair

1

1

1.
2.
3.
4.
5.
6.
7.
8.

Release agent
Stripped threads
Form-A-Thread
Tapes
Cleaned bolt
Plate
New threads
Thread/ocker

Standard Thread Repair
Follow instructions on Loctite FORM-A-THREAD
81668 package.
If a plate is used to align bolt:
1. Apply release agent on mating surfaces.
2. Put waxed paper or similar film on the surfaces.
3. Twist bolt when inserting it to improve thread
conformation.
NOTE: NOT intended for engine stud repairs.
Repair of Small Holes/Fine Threads
Option 1: Enlarge damaged hole, then follow
STANDARD THREAD REPAIR procedure.

1

3

1. Proper strength Loctite
2. Loctite Primer N (PIN 293 800 041) and Gasket Eliminator 518
(PIN 293 800 038) on both sides of gasket
3. Loctite Primer N only

1. Remove old gasket and other contaminants using LOCTITE CHISEL (GASKET REMOVER) (PIN 413
708 500). Use a mechanical means only if necessary.
NOTE: Avoid grinding.
2. Clean both mating surfaces with solvent.
3. Spray Loctite Primer N on both mating surfaces
and on both sides of gasket and allow to dry 1
or 2 minutes.
4. Apply LOCTITE 518 (PIN 293 800 038) on both
sides of gasket, using a clean applicator.
5. Place gasket on mating surfaces and assemble
parts immediately.

Option 2: Apply FORM-A-THREAD on the screw
and insert in damaged hole.
Permanent Stud Installation (Light Duty)

NOTE: If the cover is bolted to blind holes, apply
proper strength Loctite in the hole and on threads.
Tighten fastener.

1. Use a stud of the desired thread length.

If holes are sunken, apply proper strength Loctite
on bolt threads.
6. Tighten as usual.

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.

tmr2011-OO2

Threadlocker Application for Mounting
on a Shaft
Mounting with a Press

XIX

INTRODUCTION

3. Apply a strip of proper strength Loctite on leading edge of outer metallic gasket diameter.

NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
strength and gap are required.

c.!.+-2
3
AGOA3UA

4. Install according to standard procedure.

5. Wipe off excess product.
6. Allow 30 minutes for product to cure.
NOTE: Normally used on worn-out housings to
prevent leaking or sliding.

1. Bearing
2 . Proper strengrh Loctite

It is generally not necessary to remove gasket
compound applied on outer gasket diameter.

3. Shaft

1. Clean shaft external contact surface.

2. Clean internal contact surface of part to be installed on shaft.
3. Apply a strip of proper strength Loctite on circumference of shaft contact surface at insertion or engagement point.

NOTE: Retaining compound is always forced out
when applied on shaft.
4. DO NOT use antiseize Loctite or any sim ilar
product.

5. No curing period is required.
Mounting in Tandem
1. Apply retaining compound on internal contact
surface (bore) of parts to be insta lled.

2. Continue parts assembly as per previous illustration.

Threadlocker Application for Case-In
Components (Meta llic Gaskets)

;;;:;
AOOA3VA

1

-I§

1. Proper s trength Loctite

1. Clean inner housing diameter and outer gasket
diameter.

2. Spray housing and gasket with LOCTITE PRIMER
N (PIN 293 800 0411

xx

tmr2011·002

SERVICE TOOLS INDEX

CAMSHAFT TIMING TOOL
(PIN 529 036 201)

ADAPTER HOSE
(PIN 529 035 652)

CRANKSHAFT TDC POSITION TOOL
(PIN 529 036 200)

Page: 126-128
Page: 52
Page: 123-124
BACKLASH MEASUREMENT TOOL
(PIN 529 035 665)

CLUTCH PULLER
(PIN 529 035 746)

CRIMPING TOOL (HEAVY GAUGE
WIRE)
(PIN 529 035 730)

Page: 399
Page: 159
Page: 301,313
BLIND HOLE BEARING PULLER SET
(PIN 529 036 117)

CRANKCASE SUPPORT MAG/PTO
(PIN 529 036 031)

CV JOINT EXTRACTOR
!PIN 529 036 005)

Page: 299, 309
DIGITAL INDUCTION TACHOMETER
!PIN 529 014 500)
~

~ ~

oecCl
coco

§min]

Page: 189
Page: 144
BLIND HOLE PULLER KIT
CRANKSHAFT LOCKING BOLT
(PIN 529035617)

!PIN 529 036 056)

Page: 226
DISCONNECT TOOL
(PIN 529 035 714)

.--

---..

--,
Page: 85, 112, 146
CRANKSHAFT PROTECTOR
(PIN 529 036 034)

Page: 52
DRIVE PULLEY HOLDER (CVT)
(PIN 529 006 400)

Page: 76

Page: 158
Page: 86

SERVICE TOOLS INDEX

DRIVE SHAFT OIL SEAL INSTALLER
!PIN 529 036 028)

ECM TERM INAL REMOVER 3.36
(PIN 529 036 174)

HANDLE
!PIN 420 877 650)

Page : 78, 182
LARGE HOSE PINCHER
(PIN 529 032 500)

Page: 135, 182
Page: 397
DRIVE SHAFT OIL SEAL PROTECTOR
(PIN 529 036 029)

ENGINE LIFTING TOOL
!PIN 529 036 022)

Page: 64-66
Page: 39
Page: 137
DRIVEN CLUTCH HOLDER
(PIN 529 035 771)

MAGNETO DIAGNOSTIC HARNESS
!PIN 529 036 199)

FLUKE 115 MULTIMETER
(PIN 529 035 868)

Page: 166
ECM ADAPTER TOOL
!PIN 529 036 166)

Page: 84-85

Page: 68, 176, 180, 229, 235, 241,
244-245,258,271,279

MAGNETO PULLER
!PIN 529 035 748)

FU EL HOSE ADAPTER
!PIN 529 036 023)
Page: 86
MPI-2 DIAGNOSTIC CABLE
!PIN 710 000 851)

Page: 178, 229, 241, 243-246, 259,
271,278,344,396
ECM TERMINAL REMOVER 2.25
!PIN 529 036 175)
Page: 253
GEAR LOCK PIN
(PIN 529035 747)

Page: 211

Page: 397

=
Page: 157

2

at;

SERVICE TOOLS INDEX

MPI-2 INTERFACE CARD
(PIN 529 036 018)

OIL SEAL PUSHER
(PIN 529 035 757)

PLAIN BEARING
REMOVERIINSTALLER
(PIN 529 035 917)

Page: 78
PISTON CIRCLIP INSTALLER
(PIN 529 035 921)

Page: 211-212
OETIKER PLIERS
(PIN 295 000 069)

Page: 143-144
Page: 115

PRESSURE GAUGE
(PIN 529 035 709)

PISTON CIRCLIP INSTALLER
!PIN 529 036 153)

Page: 299, 309
OETIKER PLIERS
(PIN 295 000 070)

Page: 115
PISTON RING COMPRESSOR
!PIN 529 035 919)

Page: 52, 253
PTO COVER OIL SEAL INSTALLER
!PIN 529 036 033)

Page: 238, 256, 299, 309, 359
Page: 112
OIL SEAL INSTALLER (GEARBOX)
!PIN 529 035 758)

PLAIN BEARING
REMOVERIINSTALLER
!PIN 529 036 032)

Page: 137
Page: 182

ROTARY SEAL PUSHER PLATE
(PIN 529 036 130)

OIL SEAL INSTALLER
!PIN 529 036 204)
Page: 139

Page: 74
Page: 183

3

SERVICE TOOLS INDEX

SEAL PUSHER
(PIN 529 035 766)

TEST CAP
(PIN 529 035 99 1)

Page: 74, 78

Page: 18

SPANNER SOCKET
IPIN 529 035 649)

VACUUMIPRESSURE PUMP
(PIN 529 021 800)

VALVE SPRING COMP RESSOR
(PIN 529 035 724)

Page: 106

Page: 301, 312
SPRING COMPRESSOR
IPIN 529 036 184)

Page: 18, 28, 252, 263
VALVE GUIDE INSTALLER
(PIN 529 036 140)

~

Page: 337

I

STEERING ALIGNMENT TOOL
IPIN 529 036 059)

I
I
•

Page: 110

•

VALVE GUIDE REMOVER 5 MM
(PIN 529 035 924)

Page: 321

TDC DIAL INDICATOR
(PIN 414 104 700)

Page: 110
VALVE SPRING COMPRESSOf) CUP
(PIN 529 035 764)

Page: 97
Page: 106

4

Section 01
Subsection 01

MAINTENANCE

(BREAK-IN INSPECTION)

BREAK-IN INSPECTION
This vehicle should be serviced after the first 10 hours or 300 km (200 mil of operation, whichever comes
first, by an authorized Can-Am dealer. The break-in inspection is very important and must not be neglected.
The following message will appear in the cluster as a reminder of when the break-in inspection is due:
MAINTENANCE SOON. The message can be cancelled by alternately pressing the override button and
the brake pedal 3 times, or by using B.U.D.S. software.
Replace
Adjust
Tighten

BREAK-IN INSPECTION CHART

Lubricate
Clean
Inspect
ENGINE
Engine oil and filter
Valve clearance

X
X

X

Cylinder head screws

X

Air filter

X

Engine seals

X

Engine mounting fasteners

X

Exhaust system

X

COOLING SYSTEM
Radiator/cooling system leak (leak test)

X

FUEL SYSTEM
Throttle body
Fuel lines, fuel rails, connections, check valves and fuel tank leak test

X
X

ELECTRICAL SYSTEM
Spark plugs

X

Battery connections

X

CVT TRANSMISSION
CVT air inlet/outlet

X

CVT air filter

X

GEARBOX
Gearbox oil

X

Vehicle speed sensor

X

DRIVE SYSTEM
Front differential/rear final drive oil

X

Front differential/rear final drive (seals and ventsl

X

Front and rear propeller shaft joints

X

X

WHEEL
Wheel nuts/studs
Wheel bead lock (X model)

tmr2011-Q46

X

X
X

5

Section 01 MAINTENANCE
Subsection 01 (BREAK-IN INSPECTION)

Replace
Adjust
Tighten

BREAK-IN INSPECTION CHART

Lubricate
Clean
Inspect
STEERING SYSTEM
Steering system (column, bearing, etc.)

X

Front wheel alignment

X

BRAKES
Brake fluid

I

X

I

I

I

OCCUPANT RESTRAINT SYSTEM
Seat belts
Side nets

X
X

BODY/CHASSIS
Cage fasteners
Upper and lower tailgates latches

X

Seats latch

X

6

X

tmr2011-Q46

Section 01 MAINTENANCE
Subsection 02 (PERIODIC MAINTENANCE SCHEDULE)

PERIODIC MAINTENANCE SCHEDULE
Maintenance is very important for keeping the vehicle in a safe operating condition. Proper maintenance is the owner's responsibility. The vehicle
should be serviced as per the maintenance schedule.
The following message will appear in the cluster
after the first 10 hours of operation and then at every 50 hours that follow as a reminder of when an
inspection is due: MAINTENANCE SOON. The
message can be cancelled by alternately pressing
the override button and the brake pedal 3 times,
or by using B.U.D.S. software.

A

EVERY 3 000 KM (2,000 MI) OR
100 HOURS OF OPERATION
OR 1 YEAR (whichever comes first)
Inspect seat belts (check for any damages and
proper operation)
Inspect side nets (check for any damages and
ensure they buckle properly)
Replace the engine oil and filter
Inspect and adjust the valve clearance
Inspect and clean the muffler spark arrester
Check engine coolant strength

WARNING

Failure to properly maintain the vehicle according to the maintenance schedule and
procedures can make it unsafe to operate,
EVERY 750 KM (500 MI) OR 25 HOURS OF
OPERATION (whichever comes first)

Inspect throttle body
Clean the fuel pump pre-filter
Inspect the fuel pump pressure
Replace fuel vent breather filter
Inspect the drive belt

Clean the CVT air inlet/outlet

Inspect, clean and lubricate the drive and driven
pulleys (including the one-way bearing)

Inspect and clean the CVT air filter

Inspect the gearbox oil level and condition

Inspect the brake pads

Inspect wheel bearings

Tighten the wheel lug nuts

Inspect the steering system (column, bearing, etc.)

Inspect the drive shaft boots and protectors

Inspect and clean the brake system

Inspect passenger grab handles condition

Inspect frame for any damage

Inspect hitch condition

Replace rear final drive oil

Inspect driver and passenger seat latch operation
Inspect tailgates latch operation
EVERY 1 500 KM (1,000 MI) OR 50 HOURS OF
OPERATION (whichever comes first)
Replace the air filter
Verify battery condition

EVERY 6 000 KM (4,000 MI) OR
200 HOURS OF OPERATION
OR 2 YEARS (whichever comes first)
Replace the engine coolant
Verify the cooling system and perform a pressure
test on pressure cap and cooling system

Inspect the front differential/rear final drive oil level

Verify the fuel system and perform a fuel system
leak test

Inspect the drive shaft joints condition

Replace spark plugs

Inspect the front/rear propeller shaft joint condition

Replace the front differential oil

Grease the front/rear propeller shaft joints

Replace gearbox oil

Inspect the tie rod ends

Clean the vehicle speed sensor

Inspect shock absorbers for any leaks

Replace the brake fluid

Lubricate shock absorber spherical bearings
(X model)
Inspect and lubricate front suspension arms

tm r2Q l l.oo3

7

8

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

PERIODIC MAINTENANCE
PROCEDURES
SERVICE TOOLS
Description

Part Numbar

Page

TEST CAP ,""""'''''''''''''''''" .. ,'''''''' "'"''''''''''''''''''''''''''''''''
VACUUMIPRESSURE PUMP """"

529035991 .. ,...... ,....... ,........ " .. "" , .... ,18
529021 800 .................................. ,18, 28

SERVICE PRODUCTS
Description

Part Number

BRAKE FLUID""" '" ,.. ,,"'" """ ,,"" ,,'" ,,"'" '" ,,', "'" "'" "'"'' "'" ""'"
BRP PREMIXED COOLANT """""""""""""""""" .,,""""""""'"
COSMO RUBBER GREASE " .. "" ...... "" .. ,"", .. " .. ," .... " " " .. "''''''''
SUSPENSION GREASE """"""""""'"'''''''''''''''''''''''' """"""',,'
XPS PARTS AND BRAKES CLEANER """"""""""""""""""""'"
XPS SYNTHETIC BLEND OIL (SUMMER GRADE) """"""""'"''''
XPS SYNTHETIC GEAR OIL (75W 140) """"" " """""""""""'"
XPS SYNTHETIC GEAR OIL (75W 90) """""""""""""""""""",
XPS SYNTHETIC GREASE", '" ""'" ,,' ''','''''''' "'" " .. ""'" " .. "'" """
XPS SYNTHETIC OIL (WINTER GRADE)""""""""""""""""""",

293600131", .. ",,,,,,,,, .. ,,,,,,,,, .. 28
219700362 ,,, .. ,,.,,,,,,,, ..... ,,,, .... ,,13
293550055 " .... ", .. " .. " .. " .. " ", .. ,," 27
293550033 " .. "" .. " .. " ."""""" .. , , , ' 26
219701705 " .. "" .. " .. "." .. " .. """ .. ",,22,27
293600 121 ".",.,., .... . "",,, .. ,,. 12
293 600 140 " ....... """ .. " .. ",." .. ,.,, .... 21, 24
293600043 ".".".""" .. ..... ".""""",, .... ,, 24
293550010 .. "" ... "." .... " ".,,""" ..... ,,'" 27
293600 112 ".,,, .. ,, .. .. ,,,, ... ,,.,,,,.,,,,,, ... 12

GENERAL
This subsection provides:
- Fluid leve) verifications
- Maintenance procedures,
The following systems should be serviced according to the PERIODIC MAINTENANCE SCHEDULE

Page

NOTE: Riding in a group in these conditions
would increase even more the air filter replacement requirement.

Air Filter Removal
Remove service cover,

PROCEDURES
AIR FILTER REPLACEMENT
'Nu,@j

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

Air Filter Replacement Guideline
Air filter replacement should be adjusted according to riding conditions as it is critical to ensure
proper engine performance and life span.
Air filter replacement frequency must be increased for the following dusty conditions:
- Riding on dry sand
- Riding on dry dirt covered surfaces
- Riding on dry gravel roads or similar conditions.
tmr2 0 11·Q44

1. Service cover

Release clamps and remove air filter housing
cover.

9

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

MUFFLER SPARK ARRESTER
CLEANING AND INSPECTION

A

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

1, Release clamps

Remove air filter.

1. Muffler cover

2. Exhaust tail pipe

Remove and discard the tail pipe retaining screws.

tmo2011-001.Q87 _a

1. Air filter

Replace air filter if clogged. Always use the recommended air filter or an equivalent.

Air Filter Installation
Inspect air filter housing for cleanliness .

'i!l.'illili If

any sands or other particles are
found in air filter housing, clean it using a
vacuum cleaner.

Install air filter.

tmo201 1-001·045_"

7_ Retaining screws

Remove exhaust tail pipe, gasket (discard) and
spark arrester.

Install air filter housing cover and latch all clamps.
Install service cover.

10

tmr2011-044

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

ENGINE OIL LEVEL
VERIFICATION

,,,t')'III'

Operating the engine with an improper level may severely damage engine.

With vehicle on a level surface and engine cold,
check the oil level as follows:
1. Remove passenger seat.
2. Unscrew dipstick then remove it and wipe

clean.

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

Remove carbon deposits from the spark arrester
using a brush.

W,Jiliiil Use a soft brush and be careful to
avoid damaging spark arrester mesh.

7. Dipstick

3. Reinstall dipstick, screw in it completely.
4. Remove dipstick and check oil level. It should

be near or equal to the upper mark.

1 2

3
1. Clean spark arrester

Inspect mesh of spark arrester for any damage.
Replace as required.

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

For installation, reverse the removal procedure.
However pay attention to the following.
Install new gasket and retaining screws.

To add oil, remove the dipstick. Place a funnel into
the dipstick tube.

PART

TORQUE

Add a small amount of recommended oil and
recheck oil level.

Tail pipe retaining screws

11 Nom ± 1 Nom
(97Ibf o ;n ± 9Ibf o ;n)

Repeat the above procedures until oil level
reaches the dipstick's upper mark.
NOTE: Do not overfill. Wipe off any spillage.
Properly tighten dipstick.
Install passenger seat.

tm r2011-044

11

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

ENGINE OIL CHANGE
Pla ce vehicle on a level surface.
Oil change and oil filter replacement should be
done with a warm engine.

IN"'lRj

Never use the gasket ring a second
time. Always replace by a new one.
Install and tighten drain plug to the recommended
torque.
DRAIN PLUG TIGHTENING TORQUE

A

CAUTION The engine oil can be very hot.
Wait until engine oil is warm.

30 Nom ± 2 Nom (22lbf oft ± 1 Ibfott)

Ensu re vehicle is on a level surface.
Remove dipstick.

Replace oil filter. Refer to ENGINE OIL FILTER REPLACEMENT in this subsection.

Place a drain pan under the engine drain plug area.
Clean the drain plug area.

Refill engine with recommended engine oil.
ENGINE OIL CAPACITY

Unscrew drain plug and discard the gasket ring.

2.2 L (23.25 qt IU.S. liq.))
RECOMMENDED ENGINE OIL
SEASON

TYPE

Summer

XPS SYNTHETIC BLEND
OIL (SUMMER GRADE)
(PIN 293 600 121)

Winter

XPS SYNTHETIC OIL (WINTER
GRADE)IP/N 293 600 112)

If recommended XPS oil is not available. use a
4-stroke SAE 5W 40 engine oil that meets or exceeds the requirements for API service classification SM. SL or SJ. Always check the API service
label certification on the oil container, it must contain at least one of the above standards.
After filling, check the oil level, refer to ENGINE
OIL LEVEL VERIFICATION in this subsection.

1. ai/ drain plug
2. Skid plate

Start engine and let it idle for a few minutes.
Ensure oil filter and drain plug areas are not leaking.
Stop engine.
Wait a while to allow oil to flow down to
crankcase. then check oil level again.
Dispose oil and filter as per your local environmental regulations.

j ·. . . . ._ - 2
1.

2. Drain plug

Allow oil to drain completely from the crankcase.
Clean the magnetic drain plug from metal shavings and residue. Presence of debris gives an indication of internal engine damage.
Install a NEW gasket ring on the drain plug.
12

ENGINE OIL FILTER
REPLACEMENT
Oil Filter Removal
Clean oil filter area .
Remove oil filter cover screws.
Remove oil filter cover.
Remove oil filter.

Imr2Ql1·()44

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

1

~
1.
2.
3.
4.

Oil filter screw
Oil filter cover
O-ring
Oil filter

1. Slightly oil
2. Slightly oil

Oil Filter Installation

Install the cover on the engine.

Check and clean the oil filter in let and outlet area
for dirt and other contaminations.

1ighten oil filter cover screws to recommended
torque.
OIL FILTER COVER SCREWS TIGHTENING
TORQUE
10 Nom ± 1 Nom (89 lbf oin ± 9lbf oin)

RECOMMENDED ENGINE
COOLANT
COOLANT

1. Outlet bore to the engine oil providing system
2. Inlet bore from the oil pump to the oil filter

Install a NEW O-ring on oil filter cover.
Install the filter into the cover.
Apply eng ine oil on O-ring and grease on the end
of filter.

BRP
RECOMMENDED
PRODUCT

BRP PREMIXED COOLANT
(PIN 219 700 362)

ALTERNATIVE,
OR IF NOT
AVAILABLE

Distilled water and
antifreeze solution
(50% demineralized water,
50% antifreeze)

'W.,'&j

Always use ethylene-glycol ant ifreeze containing corrosion inhibitors specifically formulated for internal combustion
aluminum engines.

ENGINE COOLANT LEVEL
VERIFICATION

1. Place vehicle on a level surface.
2. Open service cover.
3. Remove the pressure cap.

tmr2011-044

13

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

COOLANT EXPANSION TANK
7. MAX. level
2. MIN level

3. Operating range
tmo201 1-00 1-3 13_b

1. Air filter housing cover
2, Coolant expansion tank cap
3. Pressure cap

4. Ensure cooling system is full up to the pressure
cap seat.

8. Add coolant if level is below MIN. mark. Use a
funnel to avoid spillage. Do not overfill.
9. Properly reinstall coolant expansion tank cap.
10. Reinstall service cover.
NOTE: A cooling system that frequently requires
addition of coolant is an indication of leaks or engine problems.

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

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

5. Add coolant in system as necessary.
6. Properly reinstall pressure cap on refill adapter.
7. Check coolant level in expansion tank.
NOTE: Coolant level can be checked by looking at
the side of the coolant expansion tank under the
RH front fender.

ENGINE COOLANT
REPLACEMENT
Cooling System Draining

A

WARNING

In order to avoid potential burns, do not remove the pressure cap or loosen the coolant
drain plug if the engine is hot.
1. Remove service cover.
2. Remove the cooling system pressure cap.

14

tmr2011-044

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

1. Pressure cap

3. Unscrew coolant drain plug and drain the
coolant into a suitable container.
NOTE: The drain plug is accessible from underneath the vehicle.

1. Oil filter cover
2. Water pump cover
3. Coolant drain plug

4. Disconnect the lower radiator hose and drain
the remaining coolant into a suitable container.
NOTE: Take note of the position of the hose
clamp on the lower radiator hose at the radiator.

1. Cooling system drain plug access

NOTE: Do not unscrew the coolant drain plug
completely.

1. Hose clamp position to note
2. Lower radiator hose to remove

5. Drain cooling system completely.
6. Reinstall cooling system drain plug.
COOLING SYSTEM DRAIN PLUG TORQUE

9 Nom to 11 Nom (80 Ibloin to 97lbl oin)
7. Reinstall radiator hose as noted prior to removal.
RADIATOR HOSE CLAMP

2.5 Nom to 3.5 Nom (22lbloin to 31 Ibloin)
8. Siphon the cooling system expansion tank.
tmr2011-044

15

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

9. Fill cooling system with coolant, refer to COOLING SYSTEM BLEEDING procedure.

Cooling System Bleeding
BOOR Models
1. Unscrew bleed screw on thermostat housing
cover of front cyl inder.

1. Rear cylinder bleed screw

All Models
3. Remove the pressure cap.
4. Fill the cooling system until coolant comes out
of the bleed screw(s)
5. Install the bleed screw(s) using NEW gasket
ring(s) and torque as per following chart.
TYPICAL
7. Bleed screw

BLEED SCREW INSTALLATION
GASKET RING

TORQUE

New

4.4 Nom to 5.6 Nom
(39lbf oin to 50lbf oinl

1000 Models
2. Unscrew bleed screws on thermostat housing
covers of both front and rear cylinders.

6. Continue adding coolant until system is full up
to the pressure cap seat in the refill adapter.

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

7. Install pressure cap.

Il!lui$J

The following steps must be carried
out as specified to ensure proper cooling system bleeding in addition to the previous steps.

16

tmr2011-044

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

8. Lift the entire front end of the vehicle so the
front tires are 60 em (2 ft) above the ground for
at least 1 minute.

--- 1
ENTIRE FRONT END LIFTED
1. Ground {evel
A. 60cm (24 in)

9. Lower veh icle to the ground.
10. Remove pressure cap and add coolant as required.
11. Install pressure cap.
12. Lift driver's side of vehicle 60 em (2 ft) above
it's horizontal position for at least 1 minute.

1. Coofing system reM adapter
2. ExpanSion tank hose
3, Coolant system fufJ level (pressure cap seat)

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

In order to avoid potential burns, do not reif the en
e is hot.
move t he
19. When the engine is cool, remove pressure cap
and add coolant if required.
20. Install pressure cap.
21. Check coolant level in the expansion tank.
Add coolant as required. Refer to ENGINE
COOLANT LEVEL VERIFICATION in this subsection.

COOLING SYSTEM INSPECTION
1. Check general condition of hoses and clamps
for tightness.
tmr2011~11.()26 ••

DRIVER'S SIDE LIFTED
,. Ground level
A. 60cm (24 in)

13. Lower vehicle to the ground.
14. Remove pressure cap and add coolant as required up to the pressure cap seat in the refill
adapter.

!mr2011·044

2. Check the leak indicator hose for oil or coolant.
NOTE: Leaking coolant indicates a defective rotary seal. Leaking oil indicates a defective oil seal.
If either seal is leaking, both seals must be replaced at the same time. Refer to WATER PUMP
SHAFT ANO SEALS in this subsection.

17

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

1

1. Water pump

2. Leak indicator hose

NOTE: Another leak indicator hole is visible on the
PTa side. It provides an indication of the PTa gasket condition . If a liquid leaks from this hole, PTa
gasket replacement is necessary.

2

COOLANT EXPANSION TANK VENTS
1. Slots atop neck
2. Flat threadless portion on tank neck

4. Carry out an ENGINE COOLANT SPECIFIC
GRAVITY CHECKas detailed in this subsection.
5. Carry out a PRESSURE CAP TESTas detailed in
this subsection.
6. Replace engine coolant if contaminated.
NOTE: Engine coolant should be replaced every 2
years or if contaminated.

COOLING SYSTEM LEAK TEST

A

WARNING

To avoid potential burns, do not remove the
pressure cap or loosen the cooling system
drain plug if the engine is hot.
1. Open service cover.
2. Remove cooling system pressure cap.
3. Install TEST CAP (pIN 5290359911 on filler neck.
1. Leak indicator hole
2. Oil cooler

3. Ensure vents on coolant expansion tank neck
are not obstructed (see following illustration).

529035991

4. Using the VACUUMIPRESSURE PUMP (PIN 529
021 8001, pressurize cooling system.

18

tmr2011-Q44

Section 01
Subsection 03

MAINTENANCE

(PERIODIC MAINTENANCE PROCEDURES)

NOTE: Use mean value of exhaust/intake to ensure a proper valve adjustment.
Hold the adjustment screw at the proper position
and torque the locking nut.

529021800

COOLING SYSTEM LEAK TEST
103 kPa (15 PSII
If there is no pressure drop after 10 minutes, there
is no leak in the cooling system.
If the pressure drops, check all hoses, radiator,
cylinders and engine base for coolant leaks or air
bubbles.

PRESSURE CAP TEST
Test the pressure cap using a cooling system
tester.
Replace the cap if it does not hold the pressure,
or if it opens at a relief pressure that is too low or
too high.

1. Adjustment screw
2. Locking nut
3. Feeler gauge

Repeat the procedure for each valve.
Before installing valve covers, recheck valve clearance.

PRESSURE CAP RELIEF PRESSURE
Approximately 110 kPa (16 PSII

CVT AIR FILTER CLEANING
CVT Air Filter

ENGINE VALVE CLEARANCE
ADJUSTMENT
NOTE: Check and adjust valve clearance only
when engine is cold.

CVT Air Filter Removal
1. Remove the CVT air filter plastic cover located
on LH side of hood near driver.

Remove valve covers, refer to TOP END subsection.
Before checking or adjusting the valve clearance,
turn crankshaft to TDC ignition of the respective
cylinder, refer to CAMSHAFT TIMING GEARin the
TIMING CHAIN subsection.
Using feeler gauge, check the valve clearance.
VALVE CLEARANCE
EXHAUST

0.11 mm to 0.19 mm
(.0043 in to .0075 inl

INTAKE

0.06mmtoO.14mm
(.0024 in to .0055 inl

If the valve clearance is out of specification, adjust
valves as follows.
lmr2011-Q44

1. CVT air filter plastic cover

2. Slide the cover rearward.
19

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

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

DRIVE BELT INSPECTION
Inspect belt for cracks, fraying or abnormal wear.
Replace if necessary.
Step 1: Slide cover rearward

Check drive belt width at cord level. Replace if it
is out of specification (see table below).

3. Pull CVT air filter out.

DRIVE BELT WIDTH
SERVICE LIMIT

1. CVT air filter

CVT Air Filter Cleaning
1. Remove CVT air filter.

I

30 mm (1.181 inl

1. Drive belt
2. Cord in drive belt

DRIVE PULLEY, DRIVEN PULLEY
AND ONE-WAY BEARING
MAINTENANCE
Refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT/ subsection.

CVT AIR INLET/OUTLET
CLEANING
1. Remove CVT cover, refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT/ subsection .
2. Inspect and clean the air inlet and outlet openings from inside the inner CVT cover.
!mo201 1,{)Ol·0n _8

1. CVT air filter

2. Inspect filter and replace if damaged.
3. Gently clean using a solution of soft soap and
water, then rinse filter.
20

3. Inspect and clean the aft end of air outlet duct
at rear of the vehicle.
NOTE : If a lot of debris or grime are found in the
CVT system, it may be necessary to remove the
ducts and thoroughly clean them.
4. Reinstall CVT cover.

tm r201'-044

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

GEARBOX OIL LEVEL
VERIFICATION
Remove the RH lateral console panel and the fuel
tank cover.
Check the gearbox oil level by removing the gearbox oil level plug.

1. Magnetic drain plug
2. Sealing ring
3, Oil fifler screw
4. O-ring

Dispose gearbox oil as per your local environmenta l regulations.

Inspection
lmo2011-nO l -117 _~

1. Engine oil dipstick
2. Gearbox oi/level plug

The oil should be level with the bottom of the oil
level hole.

pt,Utlli Operating the

gearbox with an improper oil level may severely damage gearbox.

GEARBOX OIL REPLACEMENT

Oil condition gives information about the teeth
condition inside the gearbox. See TROUBLESHOOTING in this subsection.
Clean the magnetic drain plug from metal shavings and dirt. Presence of debris gives an indication of failure inside the gearbox. Check gearbox
to correct the problem.
Replace O-ring of oil filler screw if brittle, hard or
otherwise damaged.

Draining Procedure

Filling Procedure

Prior to change the oil, ensure vehicle is on a level
surface.
Oil change should be done with a warm engine.

Make sure that magnetic drain plug is reinsta lled
and tight.
Always install a NEW sealing ring.
PART
Magnetic drain plug

Place a drain pan under the gearbox drain plug
area.
Clean drain plug area and remove magnetic drain
plug with its sealing ring to drain gearbox oil.
Discard sealing ring. Always install a NEW one.
Remove oil filler screw including its O-ring.

','l.)illil

Pay attention not to loose O-ring on
oil filler screw.

Wait a wh ile to allow oil flow out of gearbox.

tmr2011-044

TORQUE
20N-m
(15Ibf-ft

±
±

2N-m
1 Ibf-ft)

With the vehicle on a level surface, fill the gearbox through the oil filler hole with XPS SYNTHETIC GEAR OIL (75W 140) !PIN 293 600140) until the
oil reaches the lower threads of the oil filler hole
(around 450 ml (15.22 U.S. oz)).
However, if the XPS synthetic gear oil is not
available use a gearbox oil that meets the requirements of 75W 140 API GL-5 synthetic gear oil.
Install the oil filler screw with its O-ring. Tighten
oil filler screw to recommended torque.

21

Section 01 MAINTENANCE
Subsection 03 (pERIODIC MAINTENANCE PROCEDURES)

PART

Oil filler screw

TORQUE
5 Nom ± 0.6 Nom

(44lbfoin

±

5lbfoin)

THROTTLE BODY INSPECTION
1. Refer to AIR INTAKE SYSTEM subsection and

remove the following:
- Air filter housing
- Adapter hose between air filter housing and
throttle body.
2. Visually inspect throttle plate and throttle body

venturi for cleanliness .
3. Clean inside throttle body using a common

throttle body cleaner if necessary.

FUEL TANK VENT BREATHER
FILTER REPLACEMENT
Ensure breather filter is installed with the flow arrow pointing towards the vent hose.
Secure the vent hose using a locking tie as illustrated.

A

WARNING

All fuel system leaks must be repaired. Damaged, worn or leaking fuel system components should be replaced to ensure fuel
system tightness.

FUEL PUMP PRESSURE TEST
Refer to FUEL TANK AND FUEL PUMP subsection for procedure.

FUEL PUMP PREFILTER
CLEANING
1. Remove fuel pump from fuel tank, refer to
FUEL PUMP REMOVAL in FUEL TANK AND
FUEL PUMP subsection.

2. Clean the fuel pump prefilter (strainer) using
XPS PARTS AND BRAKES CLEANER (pIN 219 701

705) and low pressure air.
3. If the fuel pump prefilter is heavily soiled,

clogged or damaged:
- Replace it with a new one. Refer to FUEL
PUMP STRAINER REPLACEMENT in the
FUEL TANK AND FUEL PUMP subsection.
- Inspect inside of fuel tank for contaminants.
- Clean fuel tank as required.
- In spect fuel tank vent breather filter. Replace as necessary. Refer to FUEL TANK
VENT BREATHER FILTER in FUEL TANK
AND FUEL PUMP subsection .

BATTERY INSPECTION
Visua lly inspect battery casing for cracks or other
damage. If casing is damaged, replace battery
and thoroughly clean battery rack with water and
baking soda.
FUEL TANK VENT BREATHER FILTER
1. Direction arrow on breather filter pointing towards vent hose

2. Vent hose secured with a locking tie

FUEL SYSTEM INSPECTION
1. Visually inspect fuel tank for cracks, wear
marks, signs of leakage or any other damages.
2. Visually inspect fuel system hoses for proper
rooting, cracking, wear marks, signs of leakage
or any other damages.

Inspect battery posts condition, battery rack
mounting, straps and strap attachment points.
For battery testing, refer to CHARGING SYSTEM
subsection.

SPARK PLUG REPLACEMENT
Spark Plug Removal
Unplug the spark plug cable.
Clean the spark plug area with pressurized air.
Unscrew spark plug.

3. Carry out a FUEL TANK LEAK TEST. refer to
FUEL TANK AND FUEL PUMP subsection.

22

tmr2011·044

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

Spark Plug Installation
Prior to installation make sure that contact surfaces of the cylinder head and spark plug are free
of grime.
1. Using a wire feeler gauge, set electrode gap as
specified in TECHNICAL SPECIFICATIONS.
2. Apply antiseize lubricant over the spark plug
threads to prevent possible seizure.
3. Hand screw spark plug into cylinder head, then
tighten with a torque wrench and an appropriate socket.

TORQUE
FILLER PLUG

22.5 Nom ± 2 .5 Nom
(17lbl olt ± 21bl oltl

FRONT DIFFERENTIAL OIL
REPLACEMENT
Place vehicle on a level surface. Set transmission
in park position.
From underneath of vehicle, clean drain plug area.

SPARK PLUG TORQUE
20 Nom ± 2 Nom (15lbl oft ± 1 Ibloltl

VEHICLE SPEED SENSOR (VSS)
CLEANING
Remove the VSS. Refer to VSS REMOVAL in
GEARBOX AND 4X4 COUPLING UNIT subsection.
Remove all metal particles and oil from the VSS
magnet.
NOTE: A dirty VSS will cause erratic speedometer
readings.

1. Drain plug access hole

Place a drain pan under the front differential.
Remove drain plug.

FRONT DIFFERENTIAL OIL LEVEL
VERIFICATION

Unscrew filler plug .

Clean filler plug prior to checking oil level.

FRONT RIGHT SlOE OF VEHICLE
1. Filler plug
FRONT RIGHT SlOE OF VEHICLE
7_ Filler plug

With vehicle on a level surface, check oil level
by removing filler plug. Oil level must reach the
lower edge.
Reinstall filler plug with a NEW sealing ring.

tm r2 0 1'-044

Install drain plug.
TORQUE

DRAIN PLUG

7.5N o m ± 0.5N o m
(66lbl o in ± 41bl oinl

Refill front differential with recommended oil.

23

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

CAPACITY

RECOMMENDED OIL

500ml
(17U.S.ozl

XPS SYNTHETIC GEAR OIL
(75W 901 (PIN 293 600 0431 or
a 75W 90 (API GL-51 gear oil

Place a drain pan under rear final drive.
Unscrew filler plug.
Remove drain plug.

Reinstall filler plug with a NEW sealing ring.
TORQUE
FILLER PLUG

I

22.5 Nom ± 2.5 Nom
(17lbf oft ± 21bf oftl

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

Remove filler plug.

Install drain plug.
TORQUE
7.5 Nom ± 0.5 Nom
(66lbf oin ± 41bf oinl

DRAIN PLUG

Refill the rear final drive.

LH REAR SIDE OF VEHICLE
1. Filler plug

It is possible to verify the oil level by inserting a
wire with a 90° bend through the oil filler hole.
Oil level is within the following distance from the
bottom of oil filler plug threads when the vehicle
is level on ground.
OIL LEVEL
20 mm ± 5 mm (9/16 in ± 3116 inl

Reinstall filler plug with a NEW sealing ring.
TORQUE
FILLER PLUG

22.5 Nom ± 2.5 Nom
(17lbf oft ± 2lbf°ftl

REAR FINAL DRIVE OIL
REPLACEMENT

RECOMMENDED OIL

QUANTITY

XPS SYNTHETIC
GEAR OIL (75W 1401
(pIN 293 600 1401
or a 75W 140
(API GL-51 gear oil

350ml
(12 U.S. ozl

Reinstall filler plug with a NEW seali ng ring.
TORQUE
FILLER PLUG

I

22.5 Nom ± 2.5 Nom
(17 Ibf0ft ± 21bf oftl

DRIVE SHAFT BOOT AND
PROTECTOR (VISUAL
INSPECTION)
Visual ly inspect each drive shaft boot for grease
leak, cracks or opening.
Check if the drive shaft boot protector are fixed
firmly, not torn or otherwise damaged.
Replace if necessary.

Ensure vehicle is on a level surface.
Remove the rear skid plate.
Clean filler and drain plug areas.
24

tmr2011-044

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

DRIVE SHAFT JOINT
INSPECTION
Turn and move drive shaft to detect excessive
play.

PROPELLER SHAFT U-JOINT
CONDITION
Check yoke U-joints for wear, backlash or axial
play, replace if necessary.

PROPELLER SHAFT U-JOINT
LUBRICATION
PROPELLER SHAFT U-JOINT LUBRICATION
Use Hi-temp bearing grease NLGI-2 or an equivalent

2. Hold wheel by the top and the bottom and
move it. Check for any play.
3. If there is any loose, replace wheel bearing, refer to STEERING SYSTEM subsection.
NOTE: To properly locate play during this inspection, be sure to check other components for wear
or loose (ball joints, suspension pivots, etcl. If
necessary repair or replace all defective parts
before checking the wheel bearing condition. Be
careful not to misjudge loose in the ball joint and
loose in the wheel bearing.

STEERING SYSTEM INSPECTION
Steering Column
Turn and move steering column to detect any play.

Rack and Pinion

WHEEL LUG NUT TORQUE
CHECK
Tighten wheel lug nuts to the specified torque using the illustrated sequence.
WHEEL LUG NUTS

TORQUE

I

100N o m±10N o m
(74lbf o ft ± 71bf o ftl

Check rack and pinion boots for:
- Damage
- Cracks.
Replace if necessary.

Tie-Rod End
Check tie-rod end ball joint for:
- Damage
- Pitting
- Play.
Replace if necessary.

SHOCK ABSORBER INSPECTION
Check shock absorber for any leaks, replace if necessary.

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

TIGHTENING SEQUENCE

WHEEL BEARING INSPECTION
1. Safely lift and support the front of vehicle. Refer to INTRODUCTION subsection.
mr2011-044

25

Section 01

MAINTENANCE

Subsection 03

(PERIODIC MAINTENANCE PROCEDURES)

1

2
LOWER SUSPENSION ARM
1. Grease fittings

1. Sleeve
2. O-ring

3. Clean spherical bearing using a shop rag to remove any dirt and debris.
4. Lubricate spherical bearing as illustrated.
SPHERICAL BEARING LUBRICATION
SUSPENSION GREASE (PIN 293 550033)

UPPER SUSPENSION ARM
1. Grease fitting

FRONT SUSPENSION ARM
INSPECTION

5. Install O-rings then shock sleeves.
6. Install shock absorber

Check suspension arm for:
- Cracks
- Pitting
- Bending
- Distortion.

FRONT SUSPENSION ARM
LUBRICATION

Check suspension arm for abnorma l play:
- Side to side
- Up and down.

vmr20 10-004·70 L b

1. Apply grease here

Lubricate suspension arm at grease fittings.
SUSPENSION ARM LUBRICATION
SUSPENS ION GREASE (PIN 293 550 033)

If
-

any play is detected, inspect:
Bushings
Cushions
Wear plates.

Check ball joint for:
- Damage
- Pitting
- Play.

26

tm r2011·044

Section 01 MAINTENANCE
Subsection 03 (PERIODIC MAINTENANCE PROCEDURES)

Check ball joint bellows for:
- Damage
- Cracks.

BRAKE SYSTEM INSPECTION
AND CLEANING

'W,j'lIlj Do

3. Lubricate caliper sliders and pins using an
appropriate BRAKE CALIPER SYNTHETIC

GREASE

Brake Disc
1. Check brake disc as follows:
- Check disc thickness
- Check disc surfaces
- Check disc warpage.

not clean brake components in
petroleum based solvent. Use brake system
cleaner only. Soiled brake pads must be replaced with new ones.

NOTE: Refer to BRAKE DISC INSPECTION in
BRAKES subsection for details.

Brake Pads

2. Clean brake disc using XPS PARTS AND BRAKES
CLEANER (PIN 219 701 705).

1. Measure brake pad lining thickness.
BRAKE PAD MINIMUM THICKNESS
1 mm (1/32 in)

NOTE: The brake pad grooves are wear indicators.

Master Cylinder
1. Check master cylinder as follows:
- Check cleanliness of master cylinder rod and
boot.
- Check master cylinder boot for cracks or
damage.

2. If required, clean then lubricate master cylinder
rod and boot using COSMO RUBBER GREASE
(pIN 293 550 055).

Brake Pedal

BRAKE PAD GROOVE

1. Check brake pedal as follows:
- Brake pedal pivot movement
- Brake pedal pivot cleanliness.
2. If required, clean then lubricate brake pedal
pivot using XPS SYNTHETIC GREASE (PIN 293
550010) .

Brake Caliper

Brake Hoses

1. Remove calipers then check the following components:
- Check brake pad pins
- Check caliper boot for cracks
- Check caliper movement on its support
- Check pistons movement
- Check pistons for scratches, rust or other
damages.

1. Check hoses for leaks, crushed, deformations,
cracking or scrapes.

2. Clean the following components using XPS
PARTS AND BRAKES CLEANER (PIN 219 701 705):
- Brake pads
- Caliper support and slider
- Ca liper pistons, spring and pins.

NOTE: Any deformation can restrict the proper
flow of fluid and cause braking problems.

BRAKE FLUID REPLACEMENT
Brake Fluid Draining
1. Clean and remove reservoir cover with its diaphragm.
2. Connect a clear hose into caliper bleeder.

NOTE: Do not remove pistons from caliper for
cleaning them.

tmr2011-Q44

27

30

Section 01 MAINTENANCE
Subsection 04 (PRESEASON PREPARATION)

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

1 ~E"'UY3000 KM 12,OOOM I) OR 100 HOUR8 OF Of'ERATION Oft 1
YEAR {WH ICHEVER COMES FIR.ST)

Inspv¢l ' (1.;11 ~IS IchtI'I;~ 101 any  ..f· ........
:",'
':~-~r-c' •• 'Ii:.
~~ !I ... .
" •.

1. Fill engine w ith the recommended oil and quantity. Refer to LUBRICATION SYSTEM subsection.

" .

:.--~

6. Raise the front of engine to separate front propeller shaft from engine.
NOTE: If the propeller shaft cannot be removed
easily. remove bolts retaining the front differential to create more space. Refer to FRONT DRIVE
subsection.
7. Lower the front of engine to remove the rear
engine support bolt and the spacer.
8. Remove engine from vehicle.

Engine Mount Installation
The installation is the reverse of the removal procedure.

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

40

mmr2Ql1-()()7

Section 02 ENGINE, CVT AND GEARBOX
Subsection 02 (AIR INTAKE SYSTEM)

AIR INTAKE SYSTEM
SERVICE PRODUCTS
Description

Part Number

Page

LOCTITE 5910 ............................................................................... 293 800 081 ........... ... ............. ........ .... ... 44

tmr201 1-008

41

Section 02 ENGINE, CVT AND GEARBOX
Subsection 02 (AIR INTAKE SYSTEM)

AIR FILTER HOUSING

6

j:

1 Nom

(53 ± 9 Ibfoinl

--/

2.5

~ -.

±

0.5 Nom

(22" 4lbfoin)
To
Th rottle

Body

r

To PTO
cover

42

tmr2011-008

Section 02 ENGINE, CVT AND GEARBOX
Subsection 02

(AIR INTAKE SYSTEM)

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

A

WARNING

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

- PASSENGER SIDE
1. RH inner panel

2. Remove retaining bolts of air filter housing.

Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory standards.

,.,.,,&1

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

PROCEDURES
AIR FILTER

1. Air filter housing retaining bolts

For air filter servicing, refer to PERIODIC MAINTENANCE PROCEDURES subsection.

3. Disconnect air inlet hose from the LH side of air
filter housing.

AIR FILTER HOUSING
Air Filter Housing Removal
1. Remove the following parts:
1.1

Service cover

1. Air inlet hose

4. Disconnect intake adapter from throttle body.

1. Service cover

1.2 RH inner panel.

tmr2Ql1 ·008

43

Section 02 ENGINE, CVT AND GEARBOX
Subsection 02 (AIR INTAKE SYSTEM)

l mr2011-006-009_a

1. Intake adapter recess into air filter housing notch

FROM INSIDE OF COCKPIT - PASSENGER SIDE

1. Intake adapter
2. Throttle body

TORQUE

5. Di sconnect vent hose from the rear of air filter
hous ing.

Gear clamps

2.5 Nom ± 0.5 Nom
(22 Ibfoin ± 4lbf oin)

Air f ilter housing nuts

6Nom ± 1 Nom
(53 lbf oin + 9 lbf oin)

1. Vent hose

Air Filter Housing Installation
For installation, reverse t he removal proced ure
but pay attention to the following.
If the inta ke adapter is removed, reseal it with
LOCTITE 5910 (PIN 293800081) and align its recess
with the notch on air filter housing.

1. Apply Loc rite 59 10 between ' taka ad8p ter /ips

44

ana

wall

lmr201H)OS

Section 02 ENGINE. CVT AND GEARBOX
Subsection 03 (EXHAUST SYSTEM)

EXHAUST SYSTEM
"'---"--13 ± 1 Nom
(155 , 9 Ibfoinl

mm

= Component must be replaced when removed

lmr20'1~1..a

tmr2011-009

45

Section 02 ENGINE, CVT AND GEARBOX
Subsection 03

(EXHAUST SYSTEM)

GENERAL

A

WARNING

To avo id potential burns, never touch ex haust
system components immediately after the
engine has been run because these components are very hot. Let engine and ex haust
system cool down before performing any
servicing.
Imr201 HIo90002. 8

During assem bly/installation, use the torque values and service products as in the exploded
views.
Clean threads before app lyin g a t hread locker. Refe r to SEL F-LOCKING FAS TENERS and LOCTITE
APPLICA TION at the beg inning of this manua l for
com plete proced ure.

A

1. Muffler cover bolts

2. Open ca rgo box and detach spri ngs from the ' Y"
exhaust pipe .

WARNING

Torque wrench tightening specifications
must st rictly be adhered t o.
Lockin g dev ices w hen rem oved (e.g.: locking
tabs, elastic stop nuts, self-lockin g faste ners,
cotter pin, etc. ) must be replaced.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory standards.

3. Remove muffler retaining bolts.

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

MUFFLER

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

Muffler Inspection
1. Muffler

Muffler Removal
1. Remove the muffler cover.

Check muffler for cracks or other damages. Replace if necessary.

Muffler Installation
For the installation, reverse the removal procedure.

46

Imr2011.1)09

Section 02 ENGINE, CVT AND GEARBOX
Subsection 03 (EXHAUST SYSTEM)

"Y" EXHAUST PIPE

- Rubber support
- Head pipe nuts.
3. Remove front head pipe from vehicle according
to following sUb-steps:
NOTE: The space to remove the front head
pipe is limited. When the head pipe is positioned correctly as shown, it can be removed
easily without force.
3.1

Position the rubber support rod near the
front of the seat bracket.

7. "Y" exhaus t pipe

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

"Y" Exhaust Pipe Inspection
Check "Y" exhaust pipe for cracks, bending or
other damages. Replace if need.
Check if the rubber support is brittle, hard or otherwise damage. Replace if need .

1. Rubber support rod
2. Sea r bracket

3.2 Turn and lift t he rear end of the head pipe.

"Y" Exhaust Pipe Installation
The installation is the reverse of the removal procedure.

HEAD PIPE (FRONT CYLINDER)

Srep 1.' Turn outward

Step 2: Lift

3.3 Remove head pipe from vehicle.
1. Front head pipe

Front Head Pipe Inspection

Front Head Pipe Removal

Check head pipe for cracks, bending or other damages. Replace if need.

1. Refer to BODY subsection and remove the following plastic parts:
- LH lateral console panel
- Under seat storage compartment.
2. Remove the following parts:
- Springs from "Y" exhaust pipe

tmr201 1-Q09

Check if the rubber support is brittle, hard or otherwise damage. Replace if need.

Front Head Pipe Installation
The installation is the reverse of the removal procedure. However, pay attention to the following.
Install NEW exhaust gaskets.
47

Section 02 ENGINE, CVT AND GEARBOX
Subsection 03 (EXHAUST SYSTEM)

TORQUE
Head pipe nuts

13 Nom ± 1 Nom
(115lbl o in ± 9lbl o in)

HEAD PIPE (REAR CYLINDER)

1

1. Rear heap pipe

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

Rear Head Pipe Inspection
Check head pipe for cracks, bending or other damages. Replace if need.
Check if the rubber support is brittle, hard or otherwise damage. Replace if need.

Rear Head Pipe Installation
The installation is the reverse of the removal procedure. However, pay attention to the following.
Install NEW exhaust gaskets.

TORQUE
Head pipe nuts

48

13 Nom ± 1 Nom
(115lbl o in ± 9lbl o in)

ImI2011-()09

Section 02 ENGINE, CVT AND GEARBOX
Subsection 04

(LUBRICATION SYSTEM)

LUBRICATION SYSTEM
SERVICE TOOLS
Description

Part Number

Page

ADAPTER HOSE ......... .. .
DISCONNECT TOOL ..
PRESSURE GAUGE ............ .. .. .

529 035 652 . .................
................... 52
529035714 ........
...................... 52
529 035 709 .................. ..... .. .. ...... ........ 52

SERVICE PRODUCTS
Part Number
Page
LOCTITE 243 (BLUEI........................ ......................... .. 293 800 060 ....... .. ................ ............. 54

Description

Imr2011'()10

49

Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

COMPONENTS

50 ± 6 N-m
(37 ± 4 Ibfoft)

20 ± 2 Nom
(15 ± 1 Ibfoft)

-a

Engine
oil

6±O.7 Nom
(53 ± 6 Ibloin)

--.f'------..tJ Loctlte
.

8 ± 1 Nom
(71 ± 9 Ibfoin)

243

mm

50

= Component must be replaced when removed

~o,
Loctiter!
243

7 ± 0.5 Nom
(62 ± 4 Ibf·in)

tmr2011-010

Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

ENGINE LUBRICATION CIRCUIT

vmr2007-0J3.001.a

1. Camshaft bearings
2. Oil pressure switch
3. Oil filter
4. Oil pressure regulator valve

5.
6.
7.
8.
9.

Oil strainer
Oil pump
Crankshaft main bearings
Crankshaft support bearing
Connecting rod bearings

tmr2011-010

51

Section 02 ENGINE. CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

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

A

WARNING

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

INSPECTION

ENGINE OIL PRESSURE
NOTE: The engine oil pressure test should be
done with a warm engine 100°C (212°F) and the
recommended oil.
Remove the oil pressure switch. Refer to OIL
PRESSURE SWITCH in this subsection.

OIL
PRESSURE

1250 RPM

6000 RPM

MINIMAL

70 kPa (10 PSII

300 kPa
(44PSII

NOMINAL

150 kPa
(22 PSII

350 kPa
(51 PSII

MAXIMAL

250 kPa
(36PSII

450 kPa
(65PSII

If the engine oil pressure is out of specifications,
check the points described in TROUBLESHOOTING section.
Remove oil pressure gauge and adapter hose.
NOTE: To remove adapter hose from oil pressure
gauge, use the DISCONNECT TOOL (PIN 529 035
7141.
Reinstall the oil pressure switch.

TROUBLESHOOTING
LOW OR NO OIL PRESSURE
1.

Oil level is too low.
- Refill engine with recommended engine oil. Refer to OIL LEVEL VERIFICATION in the PERIODIC
MAINTENANCE PROCEDURES sl.Jbsection.
- Check for high oil consl.Jmption, refer to HIGH
OIL CONSUMPTION in the TROUBLESHOOTING sl.Jbsection.
- Check for engine oil leaks. For leak indicator
holes, refer to COOLING SYSTEM sl.Jbsection.
Repair if necessary.

2.

Use of unsuitable engine oil type.
- Replace engine oil bV the recommended engine
oil.

3.

Clogged oil filter.
- Replace oil and oil filter at the same time.

4.

Defective oil pressure switch.
- Test oil pressl.Jre switch, see procedl.Jre in this
sl.Jbsection.

Install PRESSURE GAUGE (PIN 529 035 709) and
ADAPTER HOSE (PIN 5290356521.

5, Defective or worn oil pump.
- Check oil pl.Jmp, see procedl.Jre in this subsection.
6.

Defective engine oil pressure regulator.
- Check Iml1ine oil pressure regl.Jlator, see procedl.Jre in thiS sl.Jbsection.

7, Worn plain bearings in crankcase.
- Check plain bearings clearance, refer to BOTTOM
END sl.Jbsecrion.
The engine oil pressure should be within the following values.

52

8.

Clogged engine oil strainer.
- Clean engine oil strainer, see procedl.Jre in this
sl.Jbsection.
Imf2011~Ol 0

Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

OIL CONTAMINATION
1.

Defective water pump seal ring or rotary seal.
- Check for oil or coolant leak from indicator hole
near water pump, refer to COOLING SYSTEM
subsection. Replace seal if necessary.

2.

Cylinder head or cylinder base gasket leak.
- Retighten cylinder head to specified torque, refer
to TOP END subsection. Replace gasket if tightening does not solve the problem.

3.

Engine internal damage .
- Repair engine.

4.

Oil cooler gasket leak.
- Replace oil cooler gasket and change engine oil.

Place rags or towels under oil cooler to catch remaining oil and coolant.
Remove oil cooler and discard gasket.

HIGH OIL CONSUMPTION
1.

Leaking breather oil seal.
- Check if the oil seal of the breather is brittle, hard
or damaged. Re fer to BOTTOM END subsection.

2.

Valve stem seals worn or damaged.
- Replace valve stem seals.

3.

Worn piston rings (blue exhaust smoke).
- Replace piston rings.

PROCEDURES
OIL COOLER
Oil Cooler Removal
Drain engine oil. Refer to ENGINE OIL CHANGE
in the PERIOOIC MAINTENANCE PROCEDURES
subsection.
Drain coolant. Refer to COOLING SYSTEM subsection.
Remove oil cooler retaining screws.

1. Oil cooler
2. Gasket

Oil Cooler Inspection
Check oil cooler for cracks or other damage.
Replace if necessary.

Oil Cooler Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Wipe off any oil and coolant spillage.
Install a NEW gasket.
Refill engine oil with recommended oil and at the
proper oil lever. Refer to ENGINE OIL CHANGE
in the PERIODIC MAINTENANCE PROCEDURES
subsection.
Refill and bleed cooling system. Refer to COOL1NG SYSTEM subsection.

1. Retaining screws
2. Oil cooler

tmr2011.()10

53

Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

OIL PRESSURE SWITCH (OPS)

If resistance values are incorrect, replace the oil
pressure switch.

1. Oil pressure switch

Oil Pressure Switch Activation

If th e values are correct, chec k w iring.

Oil pressure switch w orks when engine oil pressure is 20 kPa to 40 kPa (2 .9 PSI to 5.8 PS I)

Oil Pressure Switch Removal

To check the function of the oil pressu re switch ,
an oil pressure test has to be performed. Refer to
ENGINE OIL PRESSURE in this subsection.

Unscrew and remove oil pressure switch.

If t he engine oil pressu re is good, check the res istance of the oi l pressure switch wh ile eng ine is off
and while eng ine is run ning .

Oil Pressure Switch Resistance Test
Disconnect the connector from the oil pressure
switch.
Use a mu ltimeter to check the resista nce bet w een as shown .

ops
CONNECTOR
PIN

4

Engine
ground

ENGINE NOT
RUNNING

ENGINE
RUNNING

RESISTANCE In)
Close to 0 0
(normally
closed switch)

Unplug the oil pressu re switch con nector.

Oil Pressure Switch Installation
Apply LOCTITE 243 (BLU E) !PIN 293 800 060) on
threads of oil pressure switch.
Tighten oil pressure switch to specified t orque .
OIL PRESSURE SWITCH TIGHTENING TORQUE
12 Nom ± 1 Nom (106 1bfoin ± 9 lbf oin)

ENGINE OIL PRESSURE
REGULATOR
The oil pressure regulator is located on the engine
magneto side (inside magneto cover).

Infinite (open)
when pressu re
reach es
20 kPa to 40 kPa
(2.9 PSI to 5.8 PS I)

1. Engine oil pressure regulator

54

tm r2011-010

Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

NOTE: The oil pressure regulator system works
whe n the oil pressure exceeds 400 kPa (58 PSI).

Oil Pressure Regulator Removal
Remove plug screw and pull oil pressure reg ulator
out.

7. Oil pump

Oil Pump Removal
Remove the PTa cover. Refer to PTO COVER in
the BOTTOM END subsection.
1.
2.
3.
4.
5.

Plug screw
Gasket ring
Pressure regulator housing
Spring
Pressure regulator valve

Oil Pressure Regulator Inspection

1. Remove :
- Retaining ring
- Oil pump gear
- Needle pin
- Thrust washe r.

Inspect pressure regulator housing and valve for
scoring or other damages.
Check spring for free length.
SPRING FREE LENGTH
NEW NOMINAL

39 mm (1.535 inl

SERVICE LIMIT

37 mm (1457 in)

NOTE: Repla ce worn or damaged components.
Clean bore and thread in the magneto housing
from metal shavings and other contaminations.

Oil Pressure Regulator Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTE: At installation always replace the gasket
ring of the plug screw by a new one.

OIL PUMP

1. Thrust washer
2. Needle pin
3. Oil pump gear

4. Retaining ring

2. Remove oil pump cover screws and pull oil
pump cover out.

The oil pump is located on the engine PTa side
(behind PTa cover).

tmr2011-Ql0

55

Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

vmr2006-042-011 ..11

1. Retaining screws
2. Oil pump cover
1. Oil pump bore

3. Remove oil pump shaft with needle pin and inner rotor.
4. Remove outer rotor.

2. Outer rotor
3. Oil pump shaft
4. Need!e pin
5. Inner rotor

Check inner rotor for corrosion pin holes or other
damages. If so, replace oil pump shaft assembly.

7. Pittings on the teeth

1. Outer rotor
2. Needle pin
3. Oil pump shaft
4. Inner rotor

Using a feeler gauge, measure the clearance of
inner and outer rotors as shown.

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

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

56

lmr2011-010

Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

If clearance of inner and outer rotors exceeds the
tolerance, replace oil pump shaft assembly. Ensure to also check oil pump cover. If damaged, replace the complete oil pump assembly.
If clearance between outer rotor and its bore
in crankcase exceeds the tolerance, replace
the complete oil pump assembly and/or the
crankcase.
Using a depth gauge, measure the axial clearance
of the oil pump as shown .

Oil Pump Installation
For installation, reverse the removal procedure.
Pay attention to the followi ng details.
NOTE: The outer rotor and inner rotor are marked.
When installing, make sure both markings are on
the outer side.

Rl 0()4motr5 1A

TYPICAL
1. Markings

After reinstallation of the remain ing parts, check
for smooth operation of the oil pump assembly.

Oil Pump Final Test
After engine is completely reassembled, start engine and make sure oil pressure is within specifications (refer to ENGINE OIL PRESSUREin this
section).

ENGINE OIL STRAINER

'-

The engine oil strainer is located between both
crankcase halves.

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

YfTlJ2001I-042 0 16

OIL PUMP COVER - MEASUREMENT "8"

Difference between measurements A and B
should not exceed specification. If so, replace
the complete oil pump assembly.

OIL PUMP AXIAL CLEARANCE
SERVICE LIMIT

I

0.2 mm (,008 inl

NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure decreases.
tm r;;'0 1' ·0 10

lmr 20 11,(jIQ 0 13_&

1,

En~ in o oil srr8inor
2. Retaining plMO
3. Scro ws

57

Section 02 ENGINE, CVT AND GEARBOX
Subsection 04 (LUBRICATION SYSTEM)

Oil Strainer Cleaning and Inspection

Reed Valve Installation

Clean engine oil stra iner with a part cleaner then
use an air gun to dry it.

The installation is the reverse of the removal procedure.

Always wear eye protector.
cause a rash break out and
Check engine oil strainer for cracks or other damage. Replace if damaged.

Oil Strainer Installation
The installation is the reverse of the removal procedure.

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

2

3
1. Reed vafve
2. Stopper
3. Screws

Reed Valve Removal
Remove:
- PTO cover (refer to PTO COVER in the BOTTOM END subsection)
- Reed valve retaining screws
- Stopper plate
- Reed valve.

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

58

tmr2011-OlO

Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

COOLING SYSTEM
SERVICE TOOLS
Description

Part Number

................... .. ............... .. . .
BLIND HOLE PULLER KIT
FLUKE 115 MULTIMETER
.................................... ..
HANDLE
.................... ..
LARGE HOSE PINCHER ................ .
OIL SEAL PUSHER...........
.. ...... ... ..
ROTARY SEAL PUSHER PLATE.......... ..... .
SEAL PUSHER ......
.................
.. ...................... .

529 036 056 ......................................... 76
529 035 868................. ............ 68
420 877 650 ........ ........... ....
.. ..... 78
529 032 500 ........ .................. .......... 64-66
529 035 757... .. ...... ....
.. ...... 78
529036130 ........... ...........
.. ....... 74
529035 766 ..................................... 74, 78

Page

SERVICE PRODUCTS
Description

Part Number

DOW CORNING 111 .......... ... .
LOCTITE 243 (BLUE) ........... ..

413 707 000 ................
. 78
293 800 060 ...............
.......... .... 66

tmr2011-Q'1

Page

59

Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

RADIATOR
BOOR Engine

10:t 2 N-m

.181bloi n l

./
./

3.0.5 Nom
127.41bfolnl

l'

L

_

3.0.5 Nom
127.41bfoln l

Engine

3.0.5 Nom
127.41bfol nl

DIm

80

;II

Component must be replaced when removod,

!mr2011.()11

Section 02 ENGINE. CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

RADIATOR
1000 Engine
-----------------,

1
1

Early Models

1

1

1

fJ~
n

I
I

1

"'"

Radiator

1

JlJ ~ -

1

~

1

I
1

1
1
1

1
1
1

1

1

1

1

1
I

I
1
I

I

,~I

1
3 ± 0.5 N'm
(27 ± 4 Ibloin)

1
1

I

Engine

1

"V

10 ± 2 N·m
(88 ± 18 Ibl·in)

./

/' 1

./-

/' /'

./ ./

/' /'

<'_ "'/""'_(q

3 ± 0.5 N' m
(27 ± 4 Ibloi n )

/'

/ ' / ' . /

1

/ ' / ' . /

c __ _ ___ _

~

./

./

-""

----'

3!: 0.5 Nom
(27 ± 41bfoinl
Engine

~ = Component must be replaced when removed.

Imr201'·011

61

Section 02 ENGINE. CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

WATER PUMP
BOOR Engine

5:t:O.6N o m _
144 ± 5 Ibloini

6±O.7N·~
± 6Ib!","i

!~

--- J Loctite
243

•

..

5 ± 0.6 N'm
(44 ± 5 Ibf'in)

I

6

"

0.7 Nom

± 6lbloin)

/

CTS See (EF/)

~ 16±2 N"m
,.

62

±

1142 ± 18 Ibloin)

Imr2011·Ql1

Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

WATER PUMP
1000 Engine

5 ± 0.6 Nom
(44 ± 5 Ibf.in)

tfto
o

6 ± 0.7 Nom

J

~ .../ 1 5 3 ± 6 IbHn)
~ ~

O~

Loctite

~



5 ± 0.6 N'm
144 ± 5 IbHn)

I
= to

20:t 2 Nom
115 + 1 Ibfoft)-----~

-

243

0 ./'" CTS

6 ± 0.7 N'm
/'53±6IbHn )

See IEF/}

,&:::....- 16 ± 2 N'm

_

(142

±

181bHnl

..

""lo~tite
243

~

o

10
(89

±

±

1 Nom
9 Ibf·in)

/'

~o

Molycote

111

Imr2011.Ql1

63

Section 02 ENGINE, CVT AND GEARBOX
Subsection 05 (COOLING SYSTEM)

GENERAL

A

WARNING

There are two possible locations (see illustrations).

Never start eng ine without coolant. Some
engine parts such as the rotary seal on the
water pump shaft can be damaged.

During assembly/installation, use the torque values and service products as specified in the exploded views.
Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

A

WARNING

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

THERMOSTAT LOCATION - LH FRONT WHEEL WELL ACCESS
7. In-line thermostat
2. Radiator

PROCEDURES
THERMOSTAT
The thermostat is a single action type.

Thermostat Location
BOOR Models
The thermostat is located in the thermostat housing at the top of the front cylinder (RH side)

tmr2011-tbI.,

1

i lilOlY

.f-

1. Click 'Disabled"

2. Release fuel pressure by running engine until it
runs out of gas.
3. Disconnect the fuel hoses at the fuel injectors,
refer to ELECTRONIC FUEL INJECTION (EFI).

A

CAUTION The fuel hose may still be under pressure.

4. Disconnect fuel injectors electrical connectors.
5. Remove intake plenum adapter.

Imr2011-Q13

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

1. Plenum adapter elbow
2. Plenum elbow to plenum retaining screws
3. Plenum elbow to intake manifold clamps

6. Remove intake manifold to cylinder head retaining screws, then remove intake manifold.

1. Valve cover screws
2. Valve cover

Remove valve cover and gasket.

Intake Manifold Inspection
Check intake manifold for cracks, warping at
flanges or any other damage. Replace if necessary.

1

Intake Manifold Installation
The installation is the reverse of the removal procedure. However, pay attention to the following.
1ighten intake manifold retaining screws to specified torque one cylinder at a time .
INTAKE MANIFOLD RETAINING SCREWS
TIGHTENING TOROUE

20 Nom ± 2.5 Nom (15Ibf°ft ± 2lbfoft)

R400motr53A

7. Valve cover
2. Gasket

Enable fuel pump using B.U.D.S.

Repeat the procedure for the other valve cover if
required.

VALVE COVER

Valve Cover Inspection

Valve Cover Removal

Check the gasket on the valve cover if it is brittle,
cracked or hard. If so, replace the gasket.

To remove cylinder 1 valve cover, remove plenum.
Remove valve cover screws of valve cover.

Valve Cover Installation
For installation, reverse the removal procedure.
1ighten valve cover retaining screws to specified
torque in a criss-cross sequence.
VALVE COVER RETAINING SCREWS
TIGHTENING TOROUE
7 Nom ± 0.8 Nom (62 Ibfoin ± 7lbf oin)

On cylinder 1, install the plenum bracket using the
appropriate mounting holes.

tm r2011-013

99

Section 02 ENGINE, CVT AND GEARBOX
Subsection 07

(TOP END)

1
2
Imr2011.Q13-018_,

1. Mounting holes for the 1000 engine
2. Mounting holes for the BOOR engine

ROCKER ARM
Rocker Arm Removal
Remove valve cover.
Place the cylinder at TDe ignition, refer to TIMING
CHAIN subsection.
Remove timing chain tensioner and camshaft timing gear, refer to TIMING CHAIN subsection.
Remove pan head screw and camshaft retaining
plate.

1. Camshaft reta ining plate
2. Pan head screw
3. Cylinder head

Remove rocker arm shafts.

100

1.
2.
3.
4.
5.

Rocker arm
Rocker arm
Rocker arm
Adjustment
Lock nut

shaft
(exhaust side)
(intake side)
screw

Remove rocker arm assembly (exhaust side and
intake side) with adjustment screws and lock
nuts.
Remove thrust washers.

1. Rocker arm (exhaust side)
2. Rocker arm (intake side)
3. Thrust washers

'Nu,l""

Pay attention not to lose thrust
washers or drop them into the timing chain
compartment.

tmr2011-013

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

1

2

l

1

I
4

R40{)mOf57A

1.
2.
3.
4.

•

1

R400mot.69A

1. Free movement of adjustment screw top

2 thrust washers
Rocker arm (exhaust side)
Cylinder head (spark plug side)
Big taper to spark plug side

Rocker Arm Shaft

Rocker Arm Inspection
Inspect each rocker arm for cracks and scored friction surfaces. If so, replace rocker arm assembly.

Check for scored friction surfaces; if so, replace
parts.
Measure rocker arm shaft diameter.

Check the rocker arm rollers for free movement,
wear and excessive radial play. Replace rocker
arm assembly if necessary.
2

~

1

~

A

R400motr70A

A. Measure rocker arm shaft diameter here

ROCKER ARM SHAFT DIAMETER
NEW

12.00 mm to 12.018 mm
(.4724 in to .4731 inl

SERVICE LIMIT

11.990 mm (.472 inl

Any area worn excessively will require parts replacement.

A4ll0motr68A

1. Rocker arm (exhaust side)
2. Roller

A. Bore for rocker arm shaft

Rocker Arm Installation

Measure rocker arm bore diameter. If diameter
is out of specification, change the rocker arm assembly.

NOTE: Use the same procedure for exhaust and
intake rocker arm.

ROCKER ARM BORE DIAMETER
NEW

12.036 mm to 12.050 mm
(.4739 in to .4744 inl

SERVICE LIMIT

12.060 mm (.4748 inl

Check adjustment screws for free movement,
cracks and/or excessive play.

Apply engine oil on rocker arm shaft.
Install the rocker arm shafts with the chamfered
edge first and use following procedure.
Insert a rocker arm pin through rocker arm pin
bore.
Install a thrust washer at timing chain side, then
the proper rocker arm (exhaust side or intake
sidel.
Push in rocker arm shaft until its chamfer reaches
the end of rocker arm bore.

tmr2Ql1·013

101

Section 02 ENGINE, CVT AND GEARBOX
Subsection 07

(TOP END)

NOTE: Before removing cylinder head, blowout
remaining coolant by air pressure. During cylinder head removal, the remaining coolant in cylinder head could overflow into the engine and a little
quantity of coolant could drop into the engine. In
this case, the engine oil will be contaminated.
Disconnect spark plug wire.
Disconnect temperature sensor connector, located at rear cylinder head.
Remove the intake manifold (see INTAKE MANIFOLD in this subsection).
On cylinder 1, remove plenum.
On cylinder 2, remove the shift cable bracket.
Remove the chain tensioner (see CHAIN TENSIONER in the TIMING CHAIN subsection).
1. Rocker arm shaft
2. Thrust washer (timing chain side)
3. Thrust washer (spark plug side)

Place the other thrust washer and push rocker
arm shaft to end position.
Install the camshaft retaining plate.

Remove the valve cover and its gasket (see VALVE
COVER above).
Remove the camshaft timing gear (see TIMING
CHAIN GEAR in the TIMING CHAIN subsection).
Unscrew cyl inder head M6 and M10 screws retaining cylinder head and cylinder to cylinder base.

Adjust valve clearance, refer to PERIODIC MAINTENANCE PROCEDURE

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

1. Cylinder head screws M1D
2. Cylinder head screws M6

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

LH PASSENGER HANDHOLD BAR

Cylinder Head Removal
The removal procedure is the same for both cylinder heads.
Drain coolant (refer to COOLING SYSTEM!.
102

tmr2011-Q13

Section 02 ENGINE, CVT AND GEARBOX
Subsection 07

(TOP END)

IWuWj Timing chain guide (fixed) has to be
fixed between cylinder and cylinder head.

2

R400motr72A

1.
2.
3.
4.

3

Cylinder head
Timing chain
Chain guide (fixed)
Cylinder head gasket

TYPICAL
1. Timing chain guide ftensioner side) mounted in crankcase
2. Timing chain guide (fixed) between cylinder and cylinder head

Cylinder Head Inspection
Inspect timing chain guide (fixed) for wear, cracks
or other damages. Replace if necessary.
Check for cracks between valve seats, if so, replace cylinder head.
Check mating surface between cylinder and cylinder head for contamination. If so, clean both surfaces.
Clean oil support through the cylinder head from
contamination.

Install a NEW cylinder head gasket.

II![,)Wj Cylinder head screws of 800R engine and 1000 engine have different lengths.
BOOR

1000

1 -----;ii~~

3

800R
1. MI0x 140
R400mOI.73A

1. Oif port to lubricate camshaft fobes intake/exhaust
2. Oif supply to camshaft bearing journal (timing chain side)
3. Oil supply to camshaft bearing journal (spark plug side)

Cylinder Head Installation
NOTE: Never invert front and rear cylinder heads .
On the 800R, cylinder heads are not identical.
For installation, reverse the removal procedure.
Pay attention to the following details.

2. M6x85
1000
1. MI0x 159
2. M6 x 705

First, torque Ml0 cylinder head screws in
criss-cross
sequence
to
20 Nom ± 1 Nom
(15lbfolt ± 1 Ibf-It) then finish by tightening to
180° +/- 5°.

Ensure dowel pins are in place.

tmr201H)13

103

Section 02 ENGINE. CVT AND GEARBOX
Subsection 07

(TOP END)

CYLINDER HEAD TIGHTENING TORQUE
Preliminary
torque

20Nom ± 1 Nom
(15lblolt ± 1 Iblolt)

Final torque

180 0 +1_ 50

Install cylinder head M6 screws.

3 -• • ~-_ 1
5-~
tmr2011 .Q 13-013_a

1.
2.
3.
4
5.

Intake cam
Exhaust cam
Camshaft of cylinder 7
Camshaft of cylinder 2
Frat spot

Camshaft Removal
The removal procedure is the same for both
camshafts.
7. Cylinder head screws M 10
2. Cylinder head screws M6

Check timing chain guide (tensioner side) for
movement.
Remove crankshaft locking bolt and reinstall plug
screw with sealing ring
On cylinder 1, install the plenum bracket using the
appropriate mounting holes.

Each camshaft is different in design. Thus, it is important not to mix up any parts of the camshaft assembly with that of the other cylinder. Keep parts
as a group.
Remove valve cover (see VALVE COVER in this
subsection) .
Remove the chain tensioner (see CHAIN TENSIONER in the TIMING CHAIN subsectionl
Remove the camshaft timing gear (see
CAMSHAFT TIMING GEAR in the TIMING CHAIN
subsection).
Remove the camshaft retaining plate.

1
2

1. Mounting holes for the 1000 engine
2. Mounting holes for the BOOR engine

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

Remove rocker arms (see ROCKER ARM above).
Remove the camshaft.
104

tmr2011 -013

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

NOTE: For removal rotate camshaft so that
intake/exhaust lobe shows to upper side of cylinder head.

1000
CAMSHAFT LOBE (EXHAUST)
NEW

32.860 mm to 33.060 mm
(1.294 in to 1.302 in)

SERVICE LIMIT

32.840 mm (1.293 in)

CAMSHAFT LOBE (INTAKE)
NEW

32.960 mm to 33.160 mm
(1.298 in to 1.306 in)

SERVICE LIMIT

32.940 mm (1.297 in)

CAMSHAFT JOURNAL
(TIMING CHAIN SIDE)

l m.20 1 l -1J 1 3-{l 14_~

NEW

34.959 mm to 34.975 mm
(1.3763 in to 1.377 in)

SERVICE LIMIT

34.950 mm (1.376 in)

7. Camshaft retaining plate
2. Area for camshaft lobes
3. Camshaft

CAMSHAFT JOURNAL
(SPARK PLUG SIDE)
NEW

21.959 mm to 21.980 mm
(8645 in to .8654 in)

SERVICE LIMIT

21.950 mm (.8642 in)

Camshaft Inspection
Check each lobe and bearing journal of camshaft
for scoring, scuffing, cracks or other signs of wear.
Measure camshaft journal diameter and lobe
height using a micrometer

Measure clearance between
camshaft and cylinder head.

both

ends

of

A. Camshaft lobe (exhaust valves)
B. Camshaft lobe (intake valves)

C. Camshaft journal (timing chain side)
D. Camshaft journal (spark plug side)
A400mOlr77A

SOOR
CAMSHAFT LOBE (EXHAUST)
NEW

32.950 mm to 33.150 mm
(1.2972 in to 1.3051 in)

SERVICE LIMIT

32.930 mm (1.2965 in)

A. Camshaft bearing (timing chain side)
B. Camshaft bearing (spark plug side)

CAMSHAFT LOBE (INTAKE)
NEW

32.890 mm to 33.090 mm
(1.2949 in to 1.3028 in)

SERVICE LIMIT

32.870 mm (1.2941 in)

tmr2011-013

105

Section 02 ENGINE, CVT AND GEARBOX
Subsection 07

(TOP END)

CAMSHAFT BEARING
(TIMING CHAIN SIDE)
NEW

35.000 mm to 35.025 mm
(1.378 in to 1.3789 in)

SERVICE LIMIT

35.040 mm (1.3795 in)

Compress valve spring using VALVE SPRING COMPRESSOR !PIN 529 035 7241 and VALVE SPRING
COMPRESSOR CUP (PIN 5290357641.

CAMSHAFT BEARING
(SPARK PLUG SIDE)
NEW

22.000 mm to 22.021 mm
(.8661 in to .867 in)

SERVICE LIMIT

22.040 mm (.8677 inl
529035724

Replace parts that are not within specifications.

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

IMI')'@I

The camshafts are not identical in
design. Do not invert the camshafts during
assembly. Any mix-up of the components will
lead to engine damage.
Place the camshaft retaining plate in the slot of the
camshaft.

529035764

A

WARNING

Always wear safety glasses when disassembling valve springs. Be careful when unlocking valves. Components could flyaway because of the strong spring preload.

R4llOmor79A

1. Direction of movement
2. Camshaft retaining plate
3. Slot retaining camshaft

For other parts, refer to proper installation procedure.

LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF
THE VALVE

Remove valve cotters.

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

106

tmr2011-Q13

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

1

~

•
,

I

'l"

"t

R400motrBOA

A. Valve spring length

R400mOr16A

1. Valve spring compressor clamp
2. Valve spring compressor cup
3. Valve cotter

Remove valve spring compressor and withdraw
valve spring retainer and valve spring.

VALVE SPRING FREE LENGTH
NOMINAL NEW

40.81 mm 11.607 in)

SERVICE LIMIT

39.00 mm 11.535 in)

Replace valves springs if not within specifications.

Valve Spring Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Colored area of the valve spring must be placed
on top.
To ease installation of cotters, apply oil or grease
on them so that they remain in place while releasing the spring.
NOTE: Valve cotter must be properly engaged in
valve stem grooves.

1. Valve spring retainer
2. Valve spring

Valve Spring Inspection
Check valve spring for visible damage. If so, replace va lve spring.
Check va lve spring for free length and straightness.
1. Position of the valve spring

2. Valve cotter

After spring is installed, ensure it is properly
locked by tapping on valve stem end w ith a soft
hammer so that valve opens and closes a few
times.

,nul/11M An

improperly locked valve spring
will cause engine damage.

Imr2Ql1..()13

107

Section 02 ENGINE, CVT AND GEARBOX
Subsection 07

(TOP END)

VALVES

Valve Inspection

Valve Removal

Valve Stem Seal
Always install new sea ls whenever valves are removed.

Remove valve spring, see VALVE SPRING in this
subsection .
Push valve stem, then pull valves (intake and exhaustl out of valve guide.

,

-

Valve
Inspect valve surface, check for abnormal stem
wear and bending. If out of specification, replace
by a new one.

--

•'LJ.
...
VALVE OUT OF ROUND
(INTAKE AND EXHAUST VALVES)

vmr2000.{l~3 , 021 Q

1. In take valves 31 mm
2. Exhaust valves 27 mm

Remove valve stem seal with SNAP-ON PLIERS
(PIN YA 8230) and discard it.

NEW

0.005 mm (.0002 inl

SERVICE LIMIT

0.06 mm (.0024 in)

Valve Stem and Valve Guide Clearance
Measure valve stem and valve guide in three
places using a micrometer and a small bore
gauge.

NOTE: Clean valve guide to remove carbon deposits before measuring.
vmr200G-043.on

Change valve if valve stem is out of specification
or has other damages such as wear or friction surface.

R4QOmo!r83A

A. Valve stem diameter
108

tmr20 11-01 3

Section 02 ENGINE, CVT AND GEARBOX
Subsection 07

(TOP END)

VALVE STEM DIAMETER

VALVE SEAT CONTACT WIDTH

EXHAUST VALVE

EXHAUST VALVE

NEW

4.956 mm to 4.970 mm
(.1951 in to .1957in)

NEW

1.25 mm to 1.55mm
(.049 in to .061 in)

SERVICE LIMIT

4.930 mm (.1941 in)

SERVICE LIMIT

2.00 mm (.079 in)

INTAKE VALVE

INTAKE VALVE

NEW

4.966 mm to 4.980 mm
(.1955 in to .1961 in)

NEW

1.05 mm to 1.35 mm
(.041 in to .053 in)

SERVICE LIMIT

4.930 mm (.1941 in)

SERVICE LIMIT

1.80 mm (.071 in)

Replace valve guide out of cylinder head if valve
guide is out of specification or has other damages such as wear or friction surface (see VALVE
GUIDE PROCEDURE in this subsection).

If valve seat contact width is too wide or has dark
spots, replace the cylinder head.

VALVE GUIDE DIAMETER (INTAKE AND
EXHAUST VALVES)
NEW

4.998mm to 5.018mm
(.1968 in to .1976 in)

SERVICE LIMIT

5.050 mm (.1988 in)

Valve Face and Seat

V01C1HA

2

3

A. Valve face contact width
B, Valve seat contact width

Valve Installation
1
fl400mot.84A

1. Valve seat

2. Exhaust valve contaminated area
3. Valve face (contact surface to valve seatJ

Check va lve face and seat for burning or pittings
and replace valve or cylinder head if there are
signs of damage.

For installation, reverse the removal procedure.
Pay attention to the following details.
Install a NEW valve stem seal. Make sure thrust
washer is installed before installing seal.
Apply engine oil on valve stem and install it.

Ii'l')'@i

Be careful when valve stem is
passed through sealing lips of valve stem
seal.

Ensure to seat valves properly. Apply some lapping compound to valve face and work valve on its
seat with a lapping tool (see VALVE GUIDE PROCEDUREin this subsection).
Measure valve face contact width.
NOTE: The location of contact area shou ld be in
center of valve seat.
Measure valve seat width using a caliper.

Imr2011-G13

109

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

2

1

R400motr85A

......

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

To ease installation of cotters, apply oil or grease
on them so that they remain in place while releasing the spring.
After spring is installed, ensure it is properly
locked by tapping on valve stem end with a soft
hammer so that valve opens and closes a few
times.

W.,llij

An improperly locked valve spring
will cause engine damage.

VALVE GUIDES
Valve Guide Removal
Remove cylinder head (see CYLINDER HEAD in
this subsection).
Remove valves (see VALVES in this subsection).

1. Valve guide remove r

2. Valve guide

Valve Guide Inspection
Always replace valve stem seals whenever valve
guides are removed.
Clean the valve guide bore before reinstalling the
valve guide into cylinder head.

Valve Guide Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Use the VALVE GUIDE INSTALLER (PIN 529036 1401
to install valve guide.

NOTE: Clean valve guide area from contamination
before removal.
Using the VALVE GUIDE REMOVER 5 MM (PIN 529
035924) and a hammer, drive the valve guide out
of cylinder head .
52 9036140

~--1

520035924

R400motr87A

1. Valve guide installer
2. Valve guide

110

tmr2011·Q13

Section 02 ENGINE, CVT AND GEARBOX
Subsection 07

NOTE: Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
!PIN 293 800 070) on valve guide prior to install it
into the cylinder head.

lMol/lil Push valve guide in the cold cylinder
head as per following illustration.

(TOP END)

CYLINDER
Cylinder Removal
Remove chain tensioner (see CHAIN TENSIONER
in the TIMING CHAIN subsection).
Remove the camshaft timing gear (see
CAMSHAFT TIMING GEAR in the TIMING CHAIN
SUbsection).
Remove the cylinder head (see CYLINDER HEAD
in this subsection).
Pull cylinder.
Discard cylinder base gaskets.

2
1
R400motr878

1. Th rust surface of cylinder head
2. Valve guide
A. Measurement from thrust surface to valve guide top

VALVE GUIDE (MEASUREMENT "An)

NEW

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

Apply some lapping compound to valve face and
work valve on its seat with a lapping tool.

R400motr9OA

1.
2.
3.
4.

Cylinder
Piston assembly
Cylinder base gasket
Camshaft timing chain

Cylinder Inspection
Check cylinder for cracks, scoring and w ear ridges
on the top and bottom of the cylinder. If 50, replace cylinder.

R400mott89A

Cylinder Taper
Measure cylinder bore and if it is out of specifications, replace cylinder and piston rings.
Measure cylinder bore at 3 recommended positions. See the following illustration.

1. Valve seat
2. Valve face (contac t surface to valve seat)
3. Turn valve while pushing against cylinder head
A. Valve seat angle 45°

NOTE: Ensure to seat valves properly. Apply
marking paste to ease checking contact pattern.
Repeat procedure until valve seat/valve face fits
together.

tmr2011.Q13

111

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

Cylinder Installation

3

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

1N"'lI1.. Always replace cylinder base gasket
before installing the cylinder.

2~--------- -------~
R400motr91A

1. First measuring of diameter
2. Second measuring of diameter
3. Third measuring of diameter

800R
A. 5 mm (.197 in) from cylinder bottom
B. 63mm (2.48in)
C. 32 mm (1.26 in)
1000
A. 5mm (.197in) from cylinder bottom
B. 58mm (2283;n)
C. 52 mm (2.047 in)

First mount cylinder 2. Then remove the CRANKSHAFT LOCKING BOLT (PIN 529 035 617). Crank
the engine further and position piston 1 at TOe.
Mount cylinder 1. The cylinder can not be pushed
fully over the piston unless the piston is located
at TDC.
Apply engine oil in the bottom area of the cylinder bore and also on the band of the PISTON RING
COMPRESSOR (PIN 529035919).

CYLINDER TAPER IN DIAMETER
NEW (maximum)

0.038 mm (.0015 in)

SERVICE LIMIT

0.090 mm (.0035 in)

Distance between measurements should not exceed the service limit mentioned above.

529035919

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

R400motrS2A

A. Perpendicular to crankshaft axis
8. Parallel to crankshaft axis

1. Piston ring compressor tool

2. Piston

CYLINDER OUT OF ROUND
NEW (maximum)

0.015 mm (.0006 in)

SERVICE LIMIT

0.020 mm (.0008 in)

3. Cylinder

NOTE: Put timing chain through the chain pit then
put the cylinder in place.

Rt.J'lI1..

Chain guide has to be fixed between
cylinder and cylinder head.
112

tmr2011·Q13

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

NOTE: After both cylinders are installed, turn
crankshaft until piston of cylinder 2 is at TDC and
lock crankshaft. Refer to CRANKSHAFT in the
BOTTOM END subsection.
Install cylinder head and the other parts in accordance with the proper installation procedures.

1

2

PISTON
Piston Removal
Remove cylinder head (see CYLINDER HEAD in
this subsection).
Remove the cylinder (see CYLINDER in this subsection).
Place a rag under piston and in the area of timing
chain compartment.

Remove one piston circiip and discard it.

~400mo1r95A

1. Piston
2. Piston pin

Detach piston from connecting rod .

Piston Inspection
Inspect piston for scoring , cracking or other damages. Replace piston and piston rings if necessary.
Using a micrometer, measure piston at 8 mm
(.315 in) perpendicularly (90°) to piston pin.

1. Measuring perpendicularly (90°) to piston pin
A. 8mm (.315in)

1. Piston circlip

NOTE : The removal of both piston circlips is not
necessary to remove piston pin.
Push piston pin out of piston.

The measured dimension should be as described
in the following tables. If not, replace piston.
PISTON MEASUREMENT
NEW
SERVICE LIMIT

90.950 mm
(3.5807 in

to 90.966 mm
to 3.5813 inl
90.850 mm (3.577 inl

Piston/Cylinder Clearance
Adjust and lock a micrometer to the piston dimension.

tmr2011.Q13

113

Section 02 ENGINE. CVT AND GEARBOX
Subsection 07

(TOP END)

Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance.
PISTON/CYLINDER CLEARANCE
NEW

0.027 mm to 0.057 mm
(.0011 in to .0022 in!

SERVICE LIMIT

0.100 mm (0039 in!

NOTE: Make sure used piston is not worn .
FOO80BA

1, Micrometer set to the piston dimension

With the micrometer set to the dimension, adjust
a cylinder bore gauge to the micrometer dimension and set the indicator to 0 (zero).

If clearance exceeds specified tolerance, replace
piston by a new one and measure piston/cylinder
clearance again .
NOTE: Make sure the cylinder bore gauge indicator is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Connecting Rod/Piston Pin Clearance
Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracking or other
damages.

2

Measure piston pin. See the following illustration
for the proper measurement positions.

FI)OB09A

1. Use the micrometer to set the cylinder bore gauge
2. Dial bore gauge

A

R400motr30A

A. Piston pin diameter

PISTON PIN DIAMETER
800R
NEW

19.996 mm to 20.000 mm
(7872 in to .7874 in!

SERVICE LIMIT

19.980 mm (.7866 in!
1000

FOOBOAA

TYPICAL
1. Indicator set to 0 (zero)

Position the dial bore gauge 20 mm (.787 in) above
cyl inder base, measuring perpendicularly (90°) to
piston pin axis.
114

NEW

21.996 mm to 22.000 mm
(.866 in to .8661 in!

SERVICE LIMIT

21.980 mm (8654 in!

Replace piston pin if diameter is out of specifications.
Measure inside diameter of connecting rod small
end bushing.

tmr2011-013

Section 02 ENGINE. CVT AND GEARBOX
Subsection 07

2

R10ll4motrl1A

1. Bore gauge
2. Connecting rod

(TOP END)

_1

-

CONNECTING ROD SMALL END DIAMETER

BOOR
NEW

20010 mm to 20.020 mm
(7878 in to .7882 in)

SERVICE LIMIT

20.060 mm (7898 in)
1000

NEW

20.010 mm to 20.020 mm
(7878 in to .7882 in)

SERVICE LIMIT

20.050 mm (7894 in)

Replace connecting rod if diameter of connecting
rod sma ll end is out of specifications. Refer to
BOTTOM END subsection for removal procedure.

,. Piston of cylinder 1

2. Mark on piston must show to intake side of cylinder 1
3. Piston of cylinder 2
4. Mark on piston must show to exhaust side of cylinder 2

Use the piston appropriate circlip installer to assemble the NEW piston circiip as per following
procedure:
ENGINE TYPE

TOOL

BOOR

PISTON CIRCLIP
INSTALLER
(PIN 529 035 921)

1000

PISTON CIRCLIP
INSTALLER
(PIN 529 036 153)

Compare measurements to obtain the connecting
rod/piston pin clearance.
CONNECTING ROOf
PISTON PIN CLEARANCE
SERV ICE LIMIT

I

0.080 mm (.0031 in)

Piston Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Apply engine oil on the piston pin.
Insert piston pin into piston and connecting rod.
For each cylinder, install piston with the punched
arrow on piston dome is pointing toward the rear
side of the engine.
Front cylinder:

Mark on top of piston must show
to intake side .

Rear cylinder:

Mark on top of piston must show
to exhaust side.

tmr20'1-013

vm12006-043-030

TYPICAL

RMIlHj Always replace disassembled piston
circlip(s) by new ones. Place a rag on cylinder
base to avoid dropping the circlip inside the engine.
Place circlip in sleeve as per following illustration.

115

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

1
2

R400mo!rl00A

CORRECT POSITION OF THE PISTON CIRCLIP

1. Circfip
2. Sleeve
3. Assembly jig from piston clip installer

PISTON RINGS

Push taper side of assembly jig until circlip
reaches middle of sleeve.
Align sleeve with piston pin axis and push assembly jig until circlip engages in piston.

Ring Removal
Remove the piston (see PISTON in this subsection).

Ring Inspection

2

3

Ring/Piston Groove Clearance
Using a feeler gauge measure each ring/piston
groove clearance. If the clearance is too large, the
piston and the piston rings should be replaced.
RING/PISTON GROOVE CLEARANCE
UPPER COMPRESSION RING
NEW

0.03 mm to 0.07 mm
(.0012 in to .0028 in)

SERVICE LIMIT

0.150 mm (.0059 in)

LOWER COMPRESSION RING
1.
2.
3.
4.

Hold piston while pushing circ/ip in place
Sleeve
Assembly jig
Direction to push circ/ip

NEW

0.02 mm to 0.06 mm
1.0008 in to .0024 in)

SERVICE LIMIT

0.150 mm (.0059 in)

NOTE: Take care that the hook of the piston circlip
is positioned properly.

116

OIL SCRAPER RING
NEW

0.01 mm to 0.18mm
(.0004 in to .007 1 in)

SERVICE LIMIT

0.250 mm (.0098 in)

tmr2011·013

Section 02 ENGINE, CVT AND GEARBOX
Subsection 07

(TOP END)

1

/

( I~0(--1

2

~

'---,--_ -_ -_ -L)T-]";0(--2

_-_-_-~ 0(
1. Piston
2. Feeler gauge

3

vmr2007-{l36..001La

1. Upper compression ring
2. Lower compression ring
3. Oil scraper ring

Ring End Gap
RING END GAP
UPPER COMPRESSION RING
NEW

0.20 mm to 0040 mm
(.008 in to .016 in)

SERVICE LIMIT

0.60 mm (.024 in)

LOWER COMPRESSION RING
NEW

0.20mm to OAOmm
(.008 in to .016 in)

SERVICE LIMIT

0.70 mm (.028 in)

Riel,,,,.. Ensure that top and second rings are
not interchanged.
NOTE : Use a ring expander to prevent breakage
during installation. The oil ring must be installed
by hand .
Check that rings rotate smoothly after installation.
Space the piston ring end gaps 120 0 apart and do
not align the gaps with the piston pin bore or the
thrust side axis.

OIL SCRAPER RING
NEW

0.20 mm to 0.70 mm
(.008 in to .028 in)

SERVICE LIMIT

1.00 mm (.039 in)

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

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

A31C20A

1. DO NOT align ring gap with piston thrust side axis
2. DO NOT align ring gap with piston pin bore axis
A. 120 0

NOTE: First install spring and then rings of oil
scraper nng.
Install the oil scraper ring first, then the lower
compression ring with the word "N and TO P "
facing up, then the upper compression ring with
the word" N and TOP" facing up.

tmr2011-013

117

118

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

TIMING CHAIN
SERVICE TOOLS
Description

Part Number

Page

CAMSHAFT TIMING TOOL ............ .. ........... .. .......... ... .
..... . 529036201
.......... .. .............. 123-124
CRANKSHAFT TDC POSITION T O O L . . . .. .... . .
529036 200 .............. ..... .. .. ..... ... 126-128

SERVICE PRODUCTS
Description

Part Number

LOCTITE 243 (BLUE) .. ... ... ....

293 800 060 ..... ... ......... ... .......... .......... 124

tm r2 0 11·045

Page

" 9

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

TIMING CHAIN

4.5.0.5 N'm
(40. 4 Ibl'i"!
0.1N·m
(0.89 Ibloi"!

10± 1 Nom

(89.9Ibloi"!

Engine oil

Loctite 243

~
. "

~

~I

6.0.7N·m
± 6 lbf·in)
Loctite 243 ~

(53

f

~

6±0.7 Nom
(53.6Ibloi"!
Loctite 243

=

10 1 Nom
(89 • 9 Ibloi"!

Loctite 243
10 ± 1 Nom

(89.9Ibloi")

120

tmr2011-04S

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

GENERAL

PROCEDURES

During assembly/installation, use the torque
values and service products as shown in the exploded view(s).

TIMING CHAIN TENSIONERS

Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE
APPLICA TlON in INTRODUCTION section.

A

liming Chain Tensioner Location
BOOR Engine

WARNING

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

TROUBLESHOOTING
UNUSUAL ENGINE NOISE OR VIBRATION
1.

IMPROPER VALVE CLEARANCE ADJUSTMENT
ANDIOR WORN OUT ROCKER ARM(S)
- Readjust valve clearance and/or replace defective
part(s), refer to TOP END subsection.

2.

DEFECTIVE CHAIN TENSIONER
. Replace chain tensioner.

3.

WORN OUT TIMING CHAIN GUIDE(S)
- Replace timing chain guiders).

4.

STRETCHED TIMING CHAIN OR WORN OUT
TIMING GEARS
- Replace timing chain and timing gears.

5.

LOOSE TIMING GEAR RETAINING SCREWS
- Retighten screws to recommended torque.

6.

INCORRECT CAMSHAFT TIMING
- Replace damaged components and readjust
camshaft timing.

BOOR ENGINE - CYLINDER HEAD (FRONT CYLINDER)
1. Timing chain tensioner

1000 Engine

ENGINE LACKS ACCELERATION OR
POWER
1.

INCORRECT CAMSHAFT TIMING
- Replace damaged components and readjust
camshaft timing.

1000 ENGINE - FRONT CYLINDER
1. Timing chain tensioner

Timing Chain Tensioner Removal
Make sure the respective cylinder is set to TDC
ignition. Refer to CAMSHAFT TIMING GEARS in
this subsection.
Carefully unscrew chain tensioner plug and release spring tension.

A
tmr20 11 -045

CAUTION Tensioner is spring loaded.

121

Section 02 ENGINE. CVT AND GEARBOX
Subsection 08

Remove a-ring,
plunger.

(TIMING CHAIN)

spring and chain tensioner

Check spring condition.
worn.

Replace if broken or

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

1.
2.
3.
4.

Chain tensioner plug
O-ring
Spring
Chain tensioner plunger

Remove chain tensioner housing retaining
screws.
Remove chain tensioner housing and a-ring.
MOVE GEAR BACK ANO FORTH

Apply eng ine oil on the plunger before installation .
Slightly turn the camshaft timing gear in order to
get the timing chain play on the tensioner side.
Slightly screw the plunger in until the timing chain
allows no more back and forth movement of the
camshaft timing gear.
Screw the plunger in an add itional 1/B turn to
reach the required specified torque.
TIMING CHA IN TENS ION ER ADJUSTM ENT
(TORQUE)
0.1 Nom (.9Ibf oin)
1. Screws
2. Chain tensioner housing
3. O-ring

Timing Chain Tensioner Inspection
Check the chain tensioner housing and plug for
cracks or other damages. Replace if necessary.
Check chain tensioner plunger for free movement
andlor scoring.
Check if a-rings are brittle, cracked or hard. Replace if necessary.

,&,),&j

Improper adjustment of the timing
chain will lead to severe engine damage.

Fit the spring on one side into the slot of the plug
and on the other side into the plunger.
NOTE: Turn spring only clockwise in order to fit
the spring end into the notch of the plunger and to
avoid loosening the plunger during spring installation. Do not preload the spring.
NOTE: Do not forget to place the a-ring on chain
tensioner plug.
Then compress the spring and screw the plug in.

122

tmr2011 -045

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

NOTE: To avoid overstressed timing chain, the
plug must engage into threads within the first full
turn.
Remove locking tool and install all other removed
parts.

Clean mating surface and threads of camshaft
prior installing camshaft timing gear.

"

Finally, tighten the plug.

CAMSHAFT TIMING GEARS
Camshaft Timing Gear Removal
Remove the valve cover, refer to TOP END subsection.
Turn crankshaft to TDC ignition of the respective cylinder and lock magneto flywheel, see
CAMSHAFT TIMING in this subsection.
Unscrew timing chain tensioner. Refer to TIMING
CHAIN TENSIONERSin this subsection.
Remove camshaft timing gear retaining screws.

1. Mating surface on camshaft
2. Threads for camshaft screws

Crankshaft must be set to TDC ignition position before installing the timing chain, refer to
CAMSHAFT TIMING in this subsection.
Install the CAMSHAFT TIMING TOOL (PIN 529 036
201).

o

,,.,,.,.,
1.

gear

screws

2. Camshaft timing gear

NOTE: Align tube of camshaft adjustment tool
properly with machined radius on cylinder head.

Remove the camshaft tim ing gear.
NOTE: Secure timing chain w ith a piece of w ire.

Camshaft Timing Gear Inspection
Check cams haft timing gear for wear or deterioration .
If gear is worn or damaged, replace it as a set
(camshaft timing gear and timing chain).
For crankshaft gear, refer to BOTTOM END section, see CRANKSHAFT

Camshaft Timing Gear Installation
For installation, reverse the removal procedure.
Pay attention to the fo llowing detai ls.
tmr2011-045

123

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

1

CAMSHAFT TIMIN G TOOL INSTALLED
1. Tube (camshaft adjustment toof)
2. Machined radius (camshaft adjustment too/)
3. Cylinder head

Set camshaft to TD C ignition position by al ignin g
the camshaft flange flat spot w ith the tool lever.
NOTE: In addition, to ensure proper camshaft timing, press camshaft adj ustment tool lever downwa rds.

PRESS TOOL LEVER DOWN
1. Lever
2. Flat spot
3. Camshaft

'ill,),tIli

Crankshaft and camshaft must
be locked at TDC ignition position to place
camshaft timing gear and timing chain in the
proper position.
Place cams haft t im ing gear along with the timin g
chai n on the camshaft.
NOTE : The pri nted marks on the ca mshaft ti ming
gear m ust be parallel to the cyl inder head ba se.

124

1. Timing chain
2. Camshaft timing gear
3. Printed marks on camshaft timing gear

Install and adjust timing cha in tensioner, refer to
TIMING CHAIN TENSIONER in this subsection.
Apply LOCTITE 243 (BLUE) !PIN 293 800 060) on the
camshaft timing gear retaining screw threads.
Install and tighten camshaft timing gear retaining
screws to specified torque.

1. Camshaft timing gear

2. Timing gear retaining screws

CAMSHAFT TIMING GEAR RETAINING
SCREWS TIGHTENING TORQUE
10 Nom ± 1 Nom (89Ibl o;n ± 9Iblo;n)
Re move t he CAMSHAFT TIMING TOOL (PIN 529 036
201 ).

Camshaft Timing
NOTE: If a piston (of cylinder 1 or 2) is set to TD C
ignition, th e camshaft timing gear of the opposite
cyl inder m ust be in the following position.

tmr2Ql1 ·045

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

1. CPS
TYPICAL
1. Cylinder head base
2. Marks on timing gear of the opposite cylinder

Camshaft Timing Cylinder 2 (rear)
Turn crankshaft until piston is at TOC ignition as
follows.
Remove spark plug of both cylinders.
Remove valve covers of both cylinders.

2. Screw

Use a 14 mm Allen key to turn crankshaft until
piston 2, rear is at TOC ignition

Remove the plug and O-ring of magneto cover.

1. Allen key 14mm

When rear piston is at TOC ignition, marks on
magneto flywheel "2" and on the magneto cover
are aligned.
1. Plug
2. O-ring

Remove the crankshaft position sensor (CPS).

tmr201Hl45

125

Section 02 ENGINE. CVT AND GEARBOX
Subsection 08

(TIMING CHAIN)

2

1
3

529036200

Make sure to match the crankshaft TOC position
tool teeth w ith the magneto rotor shape.

CYLINDER 2 AT TOC IGNITION
1. Mark "2" on magneto flywheel
2. Notch on magneto cover
3. Crankshaft position sensor location

At TOC ignition, the printed marks on the
camshaft timing gear have to be paral lel to cylinder head base.
1. Crankshaft TOC position tool teeth

'l!teJiMJ Do not use the CRANKSHAFT TDC POSITION TOOL (PI N 529 036 200) to remove or install drive pulley or magneto retaining screws.

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

To lock crankshaft at TOC ignition, proceed as follows.
Insert CRANKSHAFT TO C POS ITIO N TOOL (PI N 529
036 200) in CPS orifice to lock cra nkshaft in position.

126

MAGNETO COVER
1. Crankshaft position sensor bore

'l!leJiMJ Tool must be inserted fully.

Imr2011..{)45

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

3

, . Magneto cover
2. Tool

Camshaft Timing Cylinder 1 (front)
Turn cylinder 2 (rear) to TDC ignition, see
CAMSHAFT TIMING CYLINDER 2 (REAR) in
this subsection.
NOTE: Do not lock crankshaft yet.
Using a 14 mm Allen key, turn crankshaft 280 0
counterclockwise, until marks on magneto flywheel" 1 " and magneto cover are aligned .

CYLINDER 1 AT TOC IGNITION
1. Mark" 1 " on magneto flywheel
2. Notch on magneto cover

3. Location of crankshaft position sensor

NOTE: At TDC ignit ion, the printed marks on t he
camshaft timing gear have to be parallel to cylinder head base as per following ill ustration.

TURN CRANKSHAFT 280 0 COUNTERCLOCKWISE
1. Allen key 14 mm
TYPICAL
1. Printed marks on camshaft timing gear
2. Cylinder head base

Insert the CRANKS HAFT TOC POSITI ON TOOL
(PIN 529036200) in CPS orifice to lock crankshaft
in position.

529036200

lmr2011-045

127

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

Make sure to match the crankshaft TDC position
tool teeth w ith the magneto rotor shape.

TIMING CHAIN
The engine is equipped with two timing chains.
One of the timing chain is located on engine MAG
side behind the magneto cover. The second timing chain is located on engine PTO side behind the
PTO cover.

Timing Chain Removal (Magneto Side)

1. Crankshaft TDC position tool teeth

IIlt,)itR.,

Do not use the CRANKSHAFT TDC POSITION TOOL (PIN 529 036 200)to remove or install drive pulley or magneto retaining screws.

Refer to MAGNETO SYSTEM subsection and remove following parts:
- Magneto cover
- Rotor
- Sprag cl utch gear.
Refer to TOP END subsection and remove following parts:
- Valve cover.
Refer to following procedures in this subsection
and remove following parts:
- Chain tensioner
- Camshaft timing gear.
Remove timing chain guide (tensioner side) and
low er timing chain guide .

1. Crankshaft TOC position tool

lilt,)Il,., Tool must be fully inserted.
1. Timing chain

2. Lower timing chain guide
3. Tim ing chain guide (tensioner side)

NOTE: Mark the operating direction of the timing
chain before removal.
Carefully pull the timing chain downwards and
sidew ays, then out of the crankcase.

Timing Chain Removal (PTa Side)
1. Magneto cover
2. Tool

128

Refer to BOTTOM END subsection and remove
follow ing parts:
- PTO cover
- Breather gear
- Intermediate gear.
tmr2011 -045

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

Refer to TOP END subsection and remove following parts:
- Va Ive cover.
Refer to following procedures in this subsection
and remove following parts:
- Chain tensioner
- Camshaft timing gear.
Remove timing chain guide (tensioner side) and
lower timing chain guide.

CHECKING TIMING CHAIN RADIAL PLAY

Check chain condition for wear and teeth condition.

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

Carefully pull the timing chain sideward and down
from the crankcase.
NOTE: Mark the operating direction of the timing
chain before removal.

Timing Chain Inspection
Inspection is the same for both timing chains.
Check timing chain on camshaft timing gear for
excessive radial play.

1
1. Timing chain

If chain is excessively worn or damaged, replace
it as a set (camshaft timing gear and timing chain)
Check timing chain guides for wear, cracks or deforming. Replace as required.
NOTE: Check also the timing chain guide (tensioner side).

Timing Chain Installation
The installation is essentially the reverse of the removal procedure, but pay attention to the following details.
NOTE: Installation is the same for both timing
chains.
TIMING CHAIN GUIDE BEARING SCREW
TIGHTENING TORQUE
10 Nom ± 1 Nom (89 lbf oin ± 9lbf oin)

Install timing chain with camshaft timing gear.
NOTE: Ensure to carry out proper valve timing, refer to CAMSHAFT TIMING GEARSin this subsection.
'Nu'liiilimproper valve timing will damage
eng ine components.
tmt20t 1-045

129

Section 02 ENGINE, CVT AND GEARBOX

Subsection 08 (TIMING CHAIN)

TIMING CHAIN GUIDE
(TENSIONER SIDE)

Timing Chain Guide Removal
(Tensioner Side)
Refer to TIMING CHAIN in this subsection.

Timing Chain Guide Inspection
(Tensioner Side)
Check timing chain guide for wear, cracks or deforming. Replace if necessary.

Timing Chain Guide Installation
(Tensioner Side)
The installation is the reverse of the removal procedure.
TIMING CHAIN GUIDE BEARING SCREW
TIGHTENING TORQUE
10 Nom ± 1 Nom (89Ibl o;n ± 9Ibl o;n)

130

tmr2011.Q4S

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

BOTTOM END
SERVICE TOOLS
Description

Part Number

CRANKCASE SUPPORT MAG/PTO ............
.... .......
CRANKSHAFT LOCKING BOLT........................ ..... .. ..... .....
DRIVE SHAFT OIL SEAL INSTALLER .......................... ................
DRIVE SHAFT 01 L SEAL PROTECTOR......
..... ..................
PLAIN BEARING REMOVER/INSTALLER ..........
..........
PLAIN BEARING REMOVER/INSTALLER
...................
PTO COVER OI L SEAL INSTALLER ......... ............ ...... .. ...............

529036 031
529035 617
529036028
529 036 029
529036 032
529035 917
529036 033

Page

....... ................................. 144
....... ...................... ........... 146
.................. .. ........... .. ........ 135
......... ................................ 137
........ .. ............................... 139
................................. 143-144
...................................... 137

SERVICE PRODUCTS
Description
LOCTITE 5910 .. ............................... ...... ....................... ..
LOCTITE CHISEL (GASKET REMOVER)

tmr2011-014

Part Number

Page

293 800 081 ........ .. ........ .. ........... ......... 136
413708500 ........ .. ........ ... .................... 136

131

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

ENGINE DRIVE SHAFT

Engine oil

Loctite 767
(antiseize lubricant)

Super Lube

grease

~
Loctlte
5910
Engine oil

Loctite

59 10
~
Engine oil

~

Super Lube
grease

tmr2011.Q1 4-'----7

2.5
(22

Imr201 1-Q15

±
±

±

0.5 Nom

(22 ± 4 Ibfoin)

0.5 Nom
4 Ibf·in)

155

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

GENERAL

PROCEDURES

NOTE: For a better understanding, the following
illustrations are taken with engine out of vehicle.
To perform the following instructions, it is not necessary to remove engine.
This CVT is lubrication free. Never lubricate any
components except drive pulley one-way clutch.
During assembly/installation, use the torque values and service products as in the exploded
views.
Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

CVT COVER

A

CVT Cover Access
1. Refer to BODY and remove :
- LH seat
- LH lateral console panel.
2. Remove under seat storage compartment.
NOTE: The CVT cover lower screws are accessible through the square holes in the central skid
plate.

WARNING

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

A

WARNING

Never touch CVT while engine is running.
Never drive vehicle when CVT cover is removed.

A

WARNING

Any drive pulley repairs must be performed
by an authorized Can-Am dealer. Subcomponent installation and assembly tolerances require strict adherence to procedures detailed.

1. Central skid plate

2. Access holes

CVT Cover Draining
If water is present in CVT cover, it can be drained
as follows:
1. Remove drain screw.

INu,t"J

Never use any type of impact
wrench at drive pulley removal and installation.

A

WARNING

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

INu'tIlJ These

pulleys have metric threads.
Do not use SAE threads puller. Always tighten
puller by hand to ensure that the drive pulley
has the same type of threads (metric vs SAE)
prior to fully tightening.

1. Drain screw

2. Let water drain from CVT cover.
3. Reinstall drain screw.

INmtRJ

If any debris entered the CVT cover,
CVT must be cleaned and inspected.

CVT Cover Removal
Remove CVT cover screws.
156

tmr 2011-Q1S

Section 02 ENGINE, CVT AND GEARBOX
Subsection 10

(CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

NOTE: Remove the center top screw last. This
screw allows to support the cover during removal.
Remove the CVT cover and its gasket.

Open driven pulley with the GEAR LOCK PIN
(PIN 529035 747).

5290:15747

Screw tool in the threaded hole of driven pulley
and tighten to open the pulley.

vmr2006-021-OO2..,.a

,. CVT cover screw
2. CVT cover

3. Gasket

CVT Cover Installation
Install the center top screw of first.
1ighten the CVT cover screws as per following sequence.

,

y

•

vnv200&ml-ooJ_a

TYPICAL
,. Driven pulley expander
2. Fixed sheave of driven pulley

To remove belt, slip the belt over the top edge of
fixed sheave, as shown.

CVT COVER TIGHTENING SEQUENCE

CVT COVER SCREWS TIGHTENING TORQUE
7 Nom ± 0.8 Nom (62Ibf o;n ± 7Ibf o;n)

DRIVE BELT

Drive Belt Installation

Drive Belt Removal

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

lj!iu,IIlJ In

case of a drive belt failure, the
CVT, cover and air outlet must be cleaned.
Remove CVT COVER.

tmr2011-Q15

The maximum drive belt life span is obtained
when the drive belt has the proper rotation direction. Install it so that the arrow printed on belt
is pointing towards front of the vehicle, viewed
from top.
157

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

1.
2.
3.
4.

Arrow printed on belt
Drive pulley (front)
Driven pulley (rear)
Rotation direction

1. Crankshaft locking bolt
2. Engine drive shaft (front side)
3. Oil cooler

DRIVE PULLEY

Second Locking Method :

Drive Pulley Removal

(CVT) (PIN 529006 400).

Block drive pul ley w ith the DR IVE PUL LEY HOLDER

Remove DRIVE BEL T
Prior to removing t he drive pulley, mark sl iding
sheave and governor cup to ens ure correct indexation at reinstallation.

~---~
e)
"""'00

vm r2000-021 -0 11_J

7. Mark on drive pulley sliding sheave
2. Mark on governor cup

Block the drive pulley using on e of the follow ing
methods:
First Locking Method:
Remove spa rk plugs.

1. Pulley holding tool
2. Drive pulley sliding sheave
3. Area to place holding tool hook

Ii![uilllil Do

not lean the tool hook on the
slider shoe guides.

Lock crankshaft at TDC position. Refer to BO TTOM END section .

158

tmr2011-015

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

529035746

'lq,Jltlij

Make sure to use the specified tool.
Using another tool will damage the crankshaft
threads.

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

Drive Pulley Removal Continuation
Loosen the drive pulley screw.
NOTE: Do not unscrew the drive pulley scre w
completely. If governor cup is stuck, hit it using
a soft hammer.
Apply axial pressure with your hand on the sliding
sheave and governor cup.
Remove drive pulley screw w ith its co nica l sp ring
washer and thru st w asher.

A

CAUTION Sliding sheave of drive pulley is
spring loaded.

1. Drive pul/ey puller
2. Fixed sheave

Drive Pulley Disassembly
Governor Cup
Carefully lift governor cu p unti l sl ider shoes come
at their highest position into guides.

2

1. Thrust washer
2. Conical spring washer
3. Orive pulley screw
4. Sliding sheave with governor cup
Step 1: Push

Slowly relea se and remove sliding sheave.
Screw CLUTCH PULLER (PI N 529 035 746) in fixed
sheave to remove fixed pulley.

tmr2011-015

1.
2.
3.
4.

Governor cup
Slider shoes
Sliding shave
Guides

NOTE: The follow ing procedure is not necessary
except if roller must be removed. Refer to INSPECTION before proceeding.

159

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

--

Remove slider shoes out of each bearing sleeve.
Use a flat scre w driver if necessary.

,. Remo va l direc tion
2. Assembly direction

NOTE: Whenever removing a governor cup with
already two marked boxes replace it by a new one.
R40<1rnoul71A

1

1. Sfider shoe

Put governor cup on a vice to push out bearing
sleeve of ro ll er in the foreseen direction (again st
arrow). Use an appropriate punch (diameter of
punch m ust be sma ller than the bearing sleeve
diameter).

'&oi&j

Do not clamp the governor cup in
the vice to push out bearing sleeve. Governor
cup will be damaged.
NOTE: Use protection plates to avoid marks
and/or damages to the governor cup.

'NoilBj

Always replace all rollers at the
same time. Partly worn rollers may cause
damage to the CVT system.

vm r2006-02Hl l e

Sliding Sheave
Unscrew lock nut and remove centrifugal lever
pivot bolt. This drive pulley is equipped with 6
levers.
Remove centrifugal lever and both thrust washers.

1

2

vrrv2000-021-0 19.1

,. Punch
2. Vice

160

1.
2.
3.
4.

Lock nut
Centrifugal/ever pivot bolt
Centrifugal/ever
Thrust washers

tmf2Ql1.()15

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

Fixed Sheave

Always wear safety glasses to remove spring
Pull and rotate one-way clutch slowly until the
sheave of spring sleeves are visible.

Drive Pulley Cleaning
Clean pulley faces and shaft with fine steel wool
and dry cloth.
Using a paper towel with PULLEY FLANGE
CLEANER (PIN 413 711 809) cleaning solvent,
clean crankshaft tapered end and the taper inside
the fixed sheave of the drive pulley, crankshaft
threads and threads of drive pulley screw.

'N".tij Avoid

contact between cleaner and
crankshaft seal because damage may occur.

Remove all hardened oil deposits that have baked
on crankshaft and pulley tapered surfaces with
coarse or medium steel wool and/or sand paper
no. 600.

'N".tij Do not use any other type

of abra-

sive.

Reclean mounting surfaces with paper towel and
PULLEY FLANGE CLEANER (PIN 413 711 809).

Wipe off t he mounting surfaces with a clean, dry
paper towel.

'N""Rj Mounting

surfaces must be free of
any oil, cleaner or towel residue.

1. One-way clutch

2. Fixed sheave
3. Spring sleeve area

Hold both spring sleeves with fingers and release
when one-way clutch is disengaged.

1. Taper of fixed sheave

Only use petro l base cleaner w hen cleaning bushings of sliding sheave.

'N".tij Do
1. Springs
2. Spring sleeves

tmr2011.{)15

not use acetone to clean bush-

ing.

161

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

2

1

1

1. Sliding sheave
2. Bushings

1. Roller
2. Slider shoe
A Roller outer diameter

ROLLER OUTER DIAMETER

Drive Pulley Inspection
Bushings
For bushing inspection, refer to SLIDING SHEAVE
in this subsection.

NEW

13.70mm to 13.80mm
(.539 in to 543 in)

SERVICE LIMIT

13.20 mm (.519 in)

ROLLER INNER DIAMETER

Governor Cup
Check governor cup for cracks or other visible
damage . Replace if necessary.
Roller and Slider Shoe
Check each roller for rou ndness of external diameter.
Check if rollers move freely.

NEW

8.05 to 8.15 mm
(.317 to .321 in)

SERVICE LIMIT

9 mm (. 354 in)

Centrifugal Lever Pivot Bolt
Measure diameter of centrifugal lever pivot bolt.
replace if it is out of specification.

W"ltIij

Whenever replacing rollers and
slider shoes, always replace all rollers and
slider shoes at the same time.

Check slider shoes for visible wear and replace if
damaged.
NOTE: If necessary, use a screwdriver to remove
slider shoes.

R610tran12A

A

1. Centrifugal/ever pivot bolt
A. Measure diameter here

CENTRIFUGAL LEVER PIVOT BOLT DIAMETER
NOMINAL

6.078 mm to 6.100 mm
(.239 in to .24 in)

SERVICE LIMIT

6.00 mm (.236 in)

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

162

Imr2011 -015

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

1

1
tmr20 11---...
10 ± 1 N·m
(89 ± 9 IbNo)

/

Loetite 648

0:;

Super Lube

0ff-::-~--;~ Iii
mz!J "" Component must be replaced when removed.

10 ± 1 N-m _ .......
(89 ± 9 Ibf·in) ~

Engine oil

tmr2011-016-001_8

174

(mr2011-Q16

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

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

A

2

3-......

WARNING

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

'kl,).IRj

Hoses, cables and locking ties removed during a procedure must be reinstalled
as per factory standards.

GEARBOX OVERVIEW

1.
2.
3.
4.
5.

Center housing
Left cover
Countershaft
Output shaft
Shift shaft

TROUBLESHOOTING
UNUSUAL GEARBOX NOISE AND/OR
VIBRATIONS
1.

Low oil level in gearbox.
- Oil leakage from gearbox. Replace damaged gasket(s) and/or oil seal(s).

2.

Defective bearings.
- Bearing(s) do(es) not turn smoothly.
bearing(s).

Replace

3. Damaged or worn gears.
- Inspect gears for damages or missing teeth. Replace respective gears.

GEAR INDICATION FAILS
1.
1. Gearbox position sensor (GBPS)

2. Right cover
3. Vehicle speed sensor (vSS)
4. Actuator

5. 4WD indicator switch

Defective gearbox position sensor (GBPS).
- Perform a gearbox position sensor test.
- Damaged wires. Repair as required.

GEAR(S) IS (ARE) HARD TO SHIFT
1.

Incorrect shifter cable adjustment.
- Adjust shifter cable (refer to SHIFTER CABLE in
SHIFTER subsection.

4 WHEEL DRIVE INDICATION FAILS
1.

4WD indicator switch failure.
- Test 4WD indicator switch. Replace as required.
- Bad contact. Check for corrosion or loose con-

nector.
- Damaged wires. Repair as required.

tmr2011-Q16

175

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

4 WHEEL DRIVE DOES NOT ENGAGE OR
DISENGAGE
1. Defective 4WD switch.
- Check 4 WO switch operation.
2. Defecti ve actuator.
- Test actuator
3.

VSS Circuit Protection
CONDITION

CIRCUIT PROTE CTION

Supplied w ith main
relay activated

Fuse 5 of fuse block 1
(from main relay R2)

VSS Input Voltage Test

Damaged or w orn sh ifting fork or sleeve.
- Remove actuator and inspect shifting fork and
sleeve.

1. Use t he FLU KE 115 MULTIMETER (PIN 529 035
868) and select Vdc.
2. Turn ig nition switch ON.
3. Back-probe the VSS connector using FLUKE
RIGID BACK-PROBE (PIN TP88) or equiva lent.

PROCEDURES
VSS (VEHICLE SPEED SENSOR)
VSS Location
The vehicle speed sensor is located on the ri ght
housing of the gearbox behi nd t he act uator.

4 . Measu re voltage as per following table.
VEHICLE SPEED SENSOR INPUT VOLTAGE TEST
TEST PROBES
PIN A
(RED wire)

PIN C
(BLACK/GREEN
wirel

RESULT
(KEY ON)
Battery voltage

If voltage is not as specified, test positive and
ground separately.

VSS Signal Test
1. Lift rea r of veh icle so that rear wheels are off
the ground.
2. Set t ransmission to 2WD and to Neutral.
3. Back-probe t he VSS connector using FLUKE
RIGID BACK-PROBE (PIN TP88) or equivalent.
4 . Turn ignition switch ON.
5. Set m ultimeter to Vdc.
6. Measure voltage while slowly rotating re ar
w heels by ha nd.

1. Right housing of gearbox

2. Actuator
3. VSS (Vehicle Speed Sensor)

VEHICLE SPEED SENSOR SIGNAL TEST

VSS Access
To reach the VSS, remove th e follow ing parts:
- Passenger seat
- RH lateral console panel
- Fuel tank cowl.

VSS Wire Identification
FUNCTION

PIN

CO LOR

12-volt input from fuse F5

A

RED

Speed signal
(to ECM-A E1)

B

WHITE

Ground (to ECM-A 04)

C

BLACK/G REEN

176

TEST PROBES
PI N B
(WHITE
wire)

PIN C
(BLACK/GREEN
wire)

RESULT
(WHILE ROTATING
WHEELS)
Alternate reading
between battery
voltage and 0 Vdc

NOTE: Since w e m easure pul sating voltage, the
nu me ric display will continuously change. The
analog display may be easier to follow.

!mr2011-o16

Section 02 ENGINE, CVT AND GEARBOX
Subsection 11

(GEARBOX AND 4X4 COUPLING UNIT)

Apply SUPER LUBE GREASE (PIN 293 550 030) on
VSS O-ring.

GBPS (GEARBOX POSITION
SENSOR)
GBPS

Reset

When replacing the gearbox position sensor
(GBPSI. it is required to reset (re-zero) its values
for proper operation.
smr2005-056-010_8

1. Analog display

VSS Removal
Remove screw retaining the VSS.

A reset must be carried out each time any of the
following parts has been replaced:
- Gearbox assembly
- Shift drum
- GBPS
- ECM.
1. Connect vehicle to the latest applicable version
of B.U.D.S. software, refer to COMMUNICATION TOOLS AND 8.U.D.S. subsection.
NOTE: Ignition key must stay ON during the reset
procedure. If the key is turned off, the procedure
must be carried out again.
2. In
-

B.U.D.S., select the following:
Read Data button
Setting page tab
ECM tab.

1. Screw

2. VSS

Turn sensor and weave it out of the gearbox right
cover.

. -,
tmr201J.<116-090_.

1. Read data burton
2. Setting page tab
3. ECM teb

3. Make sure that gearbox is set to NEUTRAL position.
4. In the Gear Position Sensor Initialization field,
click on the Reset button.

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

tmr2011·Q16

177

Section 02 ENGINE, CVT AND GEARBOX
Subsection 11

(GEARBOX AND 4X4 COUPLING UNIT)

0.0%

Set shift lever in NEUTRAL position,
Unplug the GBPS connector,
Test as follow:
MULTIMETER PROBE POSITIONS

VOLTAGE

PIN 1 and PIN 3 of the GBPS connector

_______._=______~~1

5 volts

GEAR POSITION SENSOR INITIALIZATION
1. Reser button

A message will be displayed if the operation is
successful.
If an error occurred or the GBPS is not within the
allowed range while resetting, the ECM will generate a fault code and will not accept the setting.
5. If a fault message is displayed, follow the instructions in the message(s).
6. Check for fault codes.
If a fault code is generated:
- Carry out the service action
- Reset the fault code
- Repeat the reset procedure.
7. Close and disconnect B,U.D.S.
NOTE: Do not turn ignition key OFF.
8, Verify gears engagement.
8,1 With the vehicle on ground and in NEUTRAL position, start engine,

If voltage is adequate, check GBPS communication link (CAN),
If there is no voltage, check each GBPS input as
follows,
MULTIMETER PROBE POSITIONS

VOLTAGE

GBPS connector (pin 1) and
battery ground

•

5 volts

GBPS connector (pin 3) and
battery + terminal
Battery
voltage

8,2 During 4-5 seconds, rev engine to 2500 ±
200 RPM,
8,3 Let engine returns to idle,
8.4 Select an other position (P, R, H or L), Repeat substeps 8,2 and 8,3 until all position
are verified,
NOTE: The vehicle must be in movement to
complete the procedure on R, Hand L position,

If there is no voltage, check wires and connector
pins, Replace or repair defective parts and reset
fau lt codes,

GBPS Communication Link Continuity
Test
Unplug connector" A" from ECM and connect it
to the ECM ADAPTER TOOL (PIN 529036 166),

GBPS Access
To reach the GBPS sensor, remove the following
parts:
- Passenger seat
- RH lateral console panel
- Fuel tank cowl.

GBPS Input Voltage Test
NOTE: Prior to conduct testing, check fault codes
in B,U'o,S ,
178

tmr201 H116

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

MULTIMETER PROBE
POSITIONS

RESISTANCE
@ 20°C
(68°F)

GBPS connector (pin 2) and ECM
adapter tool (pin F4)

Below 1

n

If resistance is out of specification, check wires
and connectors. Repair and reset fault codes.
If resistance is good and the other tests succeeded, replace the GBPS and reset fault codes.

Tmr 20 1 1.(l1 6.{l 1 1 _~

1. Flat on shift drum shaft

NOTE: The GBPS must be reset.

Reset the GBPS. Refer to GBPS RESET in this
subsection.

GBPS Removal

4WD INDICATOR SWITCH

Set shift lever in NEUTRAL position .
Unplug GBPS connector.
Remove screws and withdraw GBPS.

4WD Indicator Switch Access
To reach the 4WD indicator switch, remove the
following parts:
- Passenger seat
- RH lateral console panel
- Fuel tank cowl.

4WD Indicator Switch Removal
Disconnect 4WD indicator switch connector.

1. Screws
2. Gearbox Position Sensor (GBPS)

GBPS Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Shift lever must be in the NEUTRAL position.
Align GBPS with the flat on the shift drum shaft.

1. 4 WD indicator switch
2. Actuator

4WD Indicator Switch Test
Measure switch resistance as follows.
SWITCH
POSITION
2WD

tmf2Ql1-{)16

SWITCH WIRE
BLACK/
BEIGE

Engine
ground

RESISTANCE
Infinite (OU

179

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

If t he res istance is out of specification, replace the
4WD indicator switch.

4WD Indicator Switch Installation

If the selector is out of specifications, check
w ires, connectors and replace the selector if necessary.
If the selector is good, check the vehicle harn ess.

For insta ll ation, reverse the removal procedure.
Pay attention to th e follow ing details.

If the veh icle harness is good, replace the actuator.

Ta ke care do not damage indicator sw itch thread s
during installation.
Apply caref ully some LOCTITE 5910 (P/N 293 800
0811 on threads of indicato r switch.

IWu'liij Do not apply Loctite 5910 on switch
plunger, as it will lead to switch malfunction.

Actuato r Removal
NOTE: Before beginning any servicing on the actuator, make sure the vehicle is in 4WD position .
No need to remove engine from vehic le.
Place a drain pan under actuator.
Remove actuator screws.

ACTUATOR
Actuator Access
To access th e actuator, remove the following
part s:
- Pa ssenger seat
- RH latera l console panel
- Fuel tank cowl.
Remove screws securing fuel tank and move tank
on passenger's floor without disconnecting hoses
and connector from fuel pump.

Actuator Test
Using the FLUKE 115 MULTIMETER (P/N 529 035
8681, check if the 2WD/4WD selector works properly.

Actuator
2. Washer
3. Screw

When all actuator bolts are removed, pull the actuator out of housing.

Actuator Installat ion
Apply a small amount of SUPER LUBE GREASE
(P/N 293 5500301 on actuator O-ring.

~903680P

Unplug actuator connector.
Turn ignition key ON .
Measure voltage as follows.
SWITCH
POSITION

180

SWITCH WIR E

2WD

WHITE/BLUE

4WD

WHITE/BLACK

WH ITE

VOLTAG E
Battery
voltage

~mr2006.Q3!H102

A

1, ActUlHor D·ring

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

Verify if coupling fork is in 4WD position. The coupling fork should be positioned toward the front of
vehicle.

Turn front wheels. The front propeller shaft
should not turn (the PARK position must be selected).
If the front propeller shaft turns, the actuator is not
installed correctly. Remove actuator and reinstall
it.
Place ignition switch to ON position and select the
2WD position.
Turn front wheel again. The front propeller shaft
should turn easily.
If the front propeller shaft does not turn , the actuator is not installed correctly. Remove actuator
and reinstall it.

111l"'(ljj

Refill missing gearbox oil, refer to

GEARBOX OIL REPLACEMENT in PERIODIC
MAINTENANCE PROCEDURES subsection.
Install all other removed parts.

1. Coupling fork in 4WD position

Align the actuator fork with the pin on coupling
fork then push the actuator in the housing. See
the following illu stration to position the actuator
correctly.

GEARBOX OIL SEALS
Gearbox Oil Seal Replacement
Replace oil seals if they are brittle, hard or damaged.
A small flat screwdriver can be used to remove
most of these oil seals.

l.y"'(ljj

Avoid scoring parts during oil seal

removal.
When replacing an oil seal, take thi s opportunity
to inspect the following:
- Check bearings behind each oil seal for contamination and/or metal shavings.
- Check oil seal running surfaces for scratches.
Countershaft Oil Seal
1. Actuator
2. Actuator fork
3. Coupling fork

Rotate the actuator counterclockwise until it orients itself to mounting position.

IN"Wj Do

not cut or break the actuator

To replace the countershaft oil seal, remove:
- Drive and driven pulleys
- CVT air guide.
NOTE: When oil seal is removed also inspect
a-ring behind distance sleeve .

a-ring.
Install all actuator screws and tighten them.
PART

TORQUE

Actuator scre ws

25N o m ± 3N o m
(18 lbf o ft ± 2lbf o ft)

Connect actuator.
Lift the front of vehicle.

!mr201H116

181

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

2
Tm r2011 ..() 1S-0 13_1

1. Countershaft oil seal
2. Distance sleeve

=0-

Tmr201 1.o16-017_1

1. Countershaft oil seal
2. Oil seal installer

Shift Shaft Oil Seal
1

2

To replace the shift shaft oil seal, remove:
- RH lateral console panel and fuel tank cowl, refer to BODYsubsection.
- Shift plate from shift shaft.
The shift shaft oil seal can be removed w ithout
removing the gearbox from the vehicle.
Use a suitable tube w ith the proper diameter to
install the oil seal.
If gearbox housing is apart, use the OIL SEAL INSTALLER (GEARBOXI (PIN 529 035 7581 and the HANDLE (PIN 420 877 6501 for shift shaft oil seal installation.

1. Distance sleeve
2. O-ring

Install countershaft oil seal w ith the DRIVE SHAFT
OIL SEAL INSTALLER !PIN 529 036 0281.

529035758

529036028

OIL SEAL INSTALLER

420677650

11!l.)ilIij Oil seal must be installed with sealing lip toward gearbox.
Shift Drum Shaft Oil Seal
To replace the shift drum shaft oil seal, remove
the GBPS (GEARBOX POSIT/ON SENSOR). See
procedure in this subsection.
Use a suitable tube with the proper diameter to
install the oil seal.

182

!mr2011.{)l S

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

Subsection 11

li!ltlitlli Oil seal

must be installed with sealing lip toward gearbox.

Output Shaft Oil Seal
To replace the output shaft oil seal. proceed as follows:
Remove propeller shaft screw from gearbox output shaft.
Remove rear final drive bolts .
Move the rear final drive rearward to dislodge the
propeller shaft from the gearbox output shaft.

Apply SUPER LUBE GREASE (PIN 293 550 030) on
sealing lips.
Apply engine oil on outer diameter of oi l seal to
avoid damaging it during installation.
Place oil seal on output shaft using the OIL SEAL
INSTALLER !PIN 529 036 204) with a flat was her
(PIN 250 200 102) and a M12 x 1.25 x 35 hexagonal screw (PIN 207 683 544).

529006204

1. Shift shaft oil seal
2. Shift drum shaft oil seal
3. Output shaft oil seal

Punch a sharp screwdriver through oil seal for removal.
NOTE: Position screwdriver only in marked areas
to avoid damaging the ball bearing underneath oil
seal during removal.

1.
2.
3.
4.
5.

Output shaft oil sea!
Oil seal installer
Flat washer (PIN 250 200 102)
M12 x 1.25 x 35 hexagonal screw (PIN 207683544)
ApplV engine oil on outer diameter of oil seal

GEARBOX
Gearbox Removal

1. Marked areas for removal
2. Output shaft oil seal

Before beginning the installation ensure gearbox
is set to PARK position.
Imr2011-D16

Remove eng ine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION for the procedure.
Refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT) subsection to remove following parts:
- CVT cover
- Drive and driven pulleys
- CVT air guide.
Drain gearbox. Refer to GEARBOX OIL REPLACEMENTin PERIODIC MAINTENANCE PROCEDURES subsection.
183

Section 02 ENGINE. CVT AND GEARBOX
Subsection 11

(GEARBOX AND 4X4 COUPLING UNIT)

Remove ACTUATOR, see procedure in this subsection.
Unscrew the four (4) nuts that attach the gearbox
to the engine.

1. 3 screws M6 x 35
2. 13 screws M6 x 55

Place the center housing on a wood stand, left
cover pointing upwards.
LH SIDE OF ENGINE
1. Nut M8

Using a big flat screwdriver and a soft hammer to
lift the left cover.

Tmr2011./l16-044

RH SIDE OF ENGINE

POSITION FOR SOFT HAMMER

1. Nut MB

Pull gearbox to separate it from engine.

Gearbox Disassembly
NOTE: During gearbox disassembly, inspect the
condition of each part closely.
Gearbox Left Cover
Set gearbox to NEUTRAL position.
Unscrew all bolts retaining the gearbox left cover.

Tmr2011-016-045

POSITION FOR BIG FLAT SCREWDRIVER

184

!mr2011-016

Section 02 ENGINE, CVT AND GEARBOX
Subsection 11

(GEARBOX AND 4X4 COUPLING UNIT)

Index Lever and Index Washer
Set gearbox to NEUTRAL position.
Remove screw retain ing the index washer to the
shift drum.

j

1.
2.
3.
4.

1. Screw
2. Index washer

Insert a flat screwdriver in the slot of index lever.
Turn screwdriver clockwise and remove index
washer.

Washer
Index lever
Step ring
Index spring

Main Shaft and Shift Forks
Remove bearing pin, reverse intermediate gear
and thrust washers.
NOTE: Take care not to lose lower thrust washer
during removal.

~)
1. Index lever
2. Index washer

3. Shifr drum

vO('ie.irlte!,neo1ime gear
I

Remove the index lever with washer, step ring
and spring.

tmr;Z01 1·Q16

Thrust washers

Remove shift fork shaft.
Disengage shift forks from shift drum.

185

Section 02 ENGINE, CVT AND GEARBOX
Subsection 11

(GEARBOX AND 4X4 COUPLING UNIT)

1. Shifting sleeve (HIGH range gear)
2. Shift fork

1. Shift fork shaft
2. Shift fork
3. Shift drum

Remove main shaft assembly with shift fork.

When required, remove from main shaft assembly:
- Snap ring (discard)
- HIGH range gear
- LOW range gear
- Needle bearings.

Tmr2011-016-048..a

1. Main shaft assembly
2. Shift fork

Remove shifting sleeve (HIGH range gear) and
shift fork.

7.
2.
3.
4.
5.

Snap ring
Free pinion (HIGH range gear)
Free pinion (LOW range gear)
Needle bearing
Main shaft assembly

Remove from main shaft assembly:
- Snap ring (discard)
- Shifting sleeve (LOW/REVERSE range gear)
- Snap ring (discard)
- REVERSE range gear
- Needle bearing.

186

Imr2011-Q16

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

POSITION FOR BIG FLA T SCREWDRIVER
,.
2.
3.
4.
5.
6.

Snap ring
Shifting sleeve (LOW/REVERSE range gear)
Snap ring
Free pinion (REVERSE range gear)
Need!e bearing
Main shaft assembly

Gearbox Right Cover
Remove ACTUATOR and GBPS (GEARBOX POSITION SENSOR), see procedures in this subsection.
Unscrew all bolts retaining the gearbox right
cover.
Tmr2011.()16-(133

POSITION FOR BIG FLAT SCREWDRIVER

Shift Shaft and Shift Drum
Withdraw shift shaft assembly.

4

2
2
Tmr2011 .()16-031_1

screws M8 x 55
2. 2 screws M6 x 85
3. 2 screws M6 x 55
4. 8 screws M6 x 35
1. 5

1. Shift shaft assembly

To remove cover, use 2 big screwdrivers.

tmr2011-()16

Remove screw retaining the shifting intermediate
gear.

187

Section 02 ENGINE, CVT AND GEARBOX
Subsection 11

(GEARBOX AND 4X4 COUPLING UNIT)

Tm,2011.o16-072_.

1.
2.
3.
4.

Screw
Washer
Intermeditlt9 gear
Dowel pin

Re move shift fork shaft.
Dise ngage shift forks from shift dru m.

7. Shift drum
2. Thrust washer

Output Shaft and 4x4 Coupling Mechanism
Remove output shaft from center housing and
w ithdraw 4x4 coupling sleeve.

'Nultij

Use a soft hammer to remove output

shaft.

1. Output shaft

1. Shift fork sheft
2. Shift fork
3. Shift drum

2. 4x4 coupling SI(J(JV8
3. Soft hammer

Remove shift drum and thrust w asher.

Remove set screw, coupling fork shaft and coupling fork from right cover.

18B

tmr2011·010

Section 02 ENGINE. CVT AND GEARBOX
Subsection 11

(GEARBOX AND 4X4 COUPLING UNIT)

To remove ball bearings of countershaft (right
cover) and main shaft (left cover) use the BLIND
HOLE BEARING PULLER SET (PIN 529036 117).

1

1. Set screw
2. Coupling fork sha ft
3. Coupling fork

Counters haft
Use a soft hammer to push out countershaft from
gearbox CVT side.
Remove distance sleeve and O-ring.

520036117

Remove screw securing the countershaft bearing
in the left cover.
For ball bearings of countershaft (left cover) and
main shaft (center housing) push with a suitable
puller from outside in.

2

1 ---1'-'


0-2
1. Countershaft
2. Distance sleeve
3. O-ring

Gearbox Bearings
If necessary heat housing up to 100'C (212'F) before removing ball bearings.

Tmr201 1-0 1e.052_"

1. Ball bearing countershaft
2. Right cover

Clean oil, outside and
before heati

INtlifliOJ

Always support gearbox housings
properly when ball bearings are removed.
Housing damages may occur if this procedure
is not performed correctly.

tmr2011-016

189

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

Check free pinions for wear.

. --

1

2

1.
2.
3.
4.

Screw
Ball bearing countershafr
Baff bearing main shaft
Left cover

TYPICAL
1. Micrometer
2. Free pinion

DIAMETER FREE PINION
NEW

29000 mm to 29.013 mm
(1.1417 in to 11422 in)

SERVICE LIMIT

29.015 mm (1.1423 in)

Shifting Sleeves
Check shifting sleeves for worn inner splines and
rounded or damaged engagement dogs.

1

1. Ball bearing main shaft
2. Center housing

Gearbox Inspection
Always verify for the following when inspecting
gearbox components:
- Gear teeth damage
- Worn or scoured bearing surfaces
- Rounded engagement dogs and slots
- Worn shift fork engagement groove
- Worn splines on shafts and shifting sleeves.
Bearings
Check if ball bearings turn freely and smoothly.
Check all bearings, bearing points, tooth flanks
and taper grooves.

2

Tmr1011f '*""'9_)"Nt!! '" '~l'''''' ~

..,-

"..

I

XlDI ~CMbr.uian~I.

2008AA: U

I

"".

2. After the write data operation, turn the ignition
key to the OFF position.
Disconnect MPI connections and store the vehicle
diagnostic connector in its protective cap.

,."
1-

;UJt","-",;u:o..k

--

I

mbg2008-0n· lOO.iI

I

TYPICAL
1. File description

Writing Changes (Saving) to a Module
1. When making a data or setting change in a module using B.U.D.S., save the new data (or setting) in the module by clicking the Write Data
button.

~

Read Data

'.q,)j(ljj

Failure to secure the diagnostic connector in its protective cap may result in corrosion or other damage to the terminals.

NOTE: There is a 120 n resistor in the protective
cap to minimize the possibility of communication
error.

11

J

TYPICAL
1. Diagnostic connector in irs storage cap

Write Data

vmr200&012·1 OCLben

NOTE: If the word Modified appears in the vehicle file identification number at the top of the
B.U.D.S. page, then a change has been made that
requires selecting the Write Data for the change
to be saved.

, ,
f""

'I:_

"E.lG~

· ~I

Read~
Vet";cl&

~

lodo:QoIp

~.

l.""",," 1

WnteData
581111")

I

MonitOfing

I

c: I

A.ctlvation

11

~

F"""

1

I

1. Indicate setting or data modified; Wnre Data to save

214

lm r2010-019

Section 03 ELECTRONIC MANAGEM ENT SYSTEM
Subsection 03

(D IA G NO STIC SY STEM AND FAULT CODES)

DIAGNOSTIC SYSTEM AND FAULT
CODES
GENERAL

If a more important fault occurs, eng ine RPM may
be limited. The engine/veh icle wil l continue to operate with reduced performance .

DIAGNOSTIC SYSTEM
The EMS features a diagnostic system that self-diagnoses va rious electrical and electronic components. Th is mode becomes active when the ignition key is turned ON.
NOTE: Some components require the engine to
be running for them to be monitored for normal
operation (fuel injectors for example).
The diagnostic system continuously validates that
the components (control modules, sensors and
actuators) are not faulty or defective . When a
malfunction is detected, the related electronic
module(s):
- Sets an active fault code.
- Adapts the proper protection strategy according to the failure.
- Sends out signals to the multifunction gauge to
inform the rider of a particular condition.

If a majo r component of the EMS fails, engine
RPM wi ll be limited as well as veh icle speed.
protect
These
strategies
are
used
to
engine/electrical system from damage and
to maintain safe operation of the ve hi cle. In extreme cases, the engine may also be comp letely
shut down.

Pil ot Lamps
When a problem is detected, a pilot la mp w il l turn
on or blink in the multifunction gauge. If the f au lt
that caused the pilot lamp to come on is momentary, the pi lot lamp may turn off automatical ly, or
may need to be reset by powering down the vehicle and then restarting it.
A message may also be displayed to provide additional information related to the fault that turned
on the pilot lamp. Refer to the following chart.

If a minor fault occurs, the engine and vehicle will
continue to operate without noticeable loss of performance.
PILOT LAM P

@

MULTIFU NCTI ON
GAU GE MESSAGE

ON

HI TEMP

ON

CHECK ENGINE

Blinks

LIMP HOME

to

CAUS E
Engine is overheating.

ADDITIONAL INFORMATION
Turns on when engine temperature
reaches 114 'C (237'F).

An engine management
component is not
functioning properly.

A fault code is active or has been activated
that requires attention. No engine
limitation.
An active fault code pertai ning to a critica l
An important engine
engine function has been activated that
management component is requires attention as soon as possible.
not working properly.
Engine behavior is modified or engine
RPM is limited to protect engine.

Turns ON when brake switch is activated
Brake pedal held pushed in continuously for 15 seconds. Brake
or faulty brake light switch. pressure felt at switch or switch failed in
closed position.
ON
BRAKE
Turns ON when brake switch is activated
ACTIVATION
Brake pedal held pushed in continuously for 15 seconds above 5 km/h
(Later production or faulty brake light switch. (3 MPH). Brake pressure felt at switch or
models)
switch failed in closed position.
HE H displayed instead of selected gear. GBPS fault or related part. GBPS signal fault or communication error.

ill

tmr2011'()20

PARK BRAKE
(Early production
models)

215

Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 03

(DIAGNOSTIC SYSTEM AND FAULT CODES)

Limp Home Mode
When a major component of the EMS is not operating properly, limp home mode will be set.
Engine RPM will be limited and/or engine behavior and control may be modified depending on the
cause of the failure.
This mode allows the rider to return home, which
would otherwise not be possible without this advanced system.
LIMP HOME will be displayed in the multifunction
gauge and the CHECK ENGINE light symbol will
be on in the gauge.

FAULT CODES
A fault code is an indication that a glitch or malfunction is detected by the monitoring system of
the vehicle.
A fault code consists of 5 digits that starts by a
letter followed by a 4 digit code that may be comprised of numbers and/or letters. The first letter
defines the type of fault code while the remaining
digits refer to a unique fault.
There are 2 types of fault codes used on the vehicle:
- "P" for power train and related system faults
(Pxxxx)
- "U" for communication faults (Uxxxx)
There are 2 modules that generate and store the
fault codes:
- ECM (Engine Control Module)
- Multifunction Gauge.
The ECM stores mainly "P" codes and some "U"
codes.
The multifunction gauge stores a few" P" and "U"
codes.
When many fault codes that mayor may not be
related to a specific system are set at the same
time, it is likely to be the result of low battery voltage, a burnt fuse(s) or a faulty relay.
NOTE: The faults detected are saved in the ECM
(Engine Control Module) or multifunction gauge
even if the battery is disconnected.

Fault Code States
Fault codes have 3 possible states:
- Active state
- Occurred state
- Inactive state.

216

All types of fault codes may be viewed in the
Faults page of B.U.D.S. Only fault codes in an
active state may be viewed in the multifunction
gauge.
Active Fault Codes
An active fault code is an indication of a fault
that is presently active. The active fault mayor
may not compromise normal operation of the
system(s) in question as indicated by the fault
code(s). Service action should be taken to correct
the problem that caused the fault code.
Once the cause of the active fault is corrected,
the fault code must be cleared using B.U.D.S. to
prevent it from being retained in memory.
Occurred Fault Codes
An occurred fault code indicates a fault that was
active, but no longer is. The occurred fault does
not presently affect system or component operation but is retained as a history of the faults that
were detected.
The fault may have been generated due to a
system or component that was momentarily operating outside normal parameters. Repeated
occurred faults of this type should be considered
when troubleshooting a problem, and may require
that maintenance action be taken.
An occurred fault may also be generated when
disconnecting and reconnecting a component, replacing a burnt fuse, when the software update of
an electronic module has been carried out, or may
be due to a momentary high or low voltage.
Inactive Fault Codes
An inactive fault code represents a fault code that
is neither active, nor occurred. It is simply part of
a list of all possible faults that can be monitored
by the ECM and multifunction gauge, which may
become active or occurred if the monitoring system detects an applicable fault. These codes can
be viewed in B.U.D.S.

How to Read Fault Codes Using
B.U.D.S. Software
1. Connect veh icle to the applicable version of
B.U.D.S . software, refer to COMMUNICATION
TOOLS AND B. UD.S. SOFTWARE subsection.
2. Click on the Read Data button.
3. Select the Faults tab.

tmr2011-020

Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 03 (DIAGNOSTIC SYSTEM AND FAULT CODES)

~ J_' J.

-rill

J ~J ~

I"'l~

I 1;11(_
1....'l1li
- I

3

4

-~-'-

5

'''-'-

J

tmr20 11-ll20-00' _B

1. Read Data button
2.
3.
4.
5.

Faults page tab
Recorded fault code
Fault code state
Fault code description

1. M (mode) button
2. 5 (set) button (pressed repeatedly to toggle secondary display)

For more information pertaining to the fault codes
and report, refer to B.U.D.S. online help.

How to Read Fault Codes Using the
Multifunction Gauge
A fault code must be active to be displayed in the
multifunction gauge. If a fault code is occurred, it
must be read using B.U.D.S.

Analog/Digital Gauge
Proceed as follows to view the active fault codes:
1. Turn ignition key to ON with lights position.

1. Toggle this digital display to Hr

4. Press and hold the M (mode) button while
quickly toggling the HI - LO beam switch to
enter the fault code display function.
NOTE: A minimum of 3 HI - LO toggles must be
completed within 2 seconds.

lmo2011.oot.o38 ••

IGNITION SWITCH POSITION
1. OFF
2. ON with lights (turn key to this selection)
3. ON

2. Wait for the multifunction gauge to complete its
self test function.
3. Press the S (set) button repeatedly until Hr
(hour) is displayed in the secondary digital display.
lmr2011-020

217

Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 03

(DIAGNOSTIC SYSTEM AND FAULT CODES)

2. Press the selector button on the gauge repeatedly until Engine Hour (EH) is displayed on the
gauge.

1

1. Low/High beam headlight switch

1. Selector button to toggle indication

If a fault code is active, it will be displayed in the
main digital display.
If no fault code is active, a scrolling NO ACTIVE
FAULT CODE message will be displayed.
If there are multiple fault codes, the display will
cycle through each fault code repeatedly. A maximum of 10 fault codes may be displayed.
If the fault code display function has been interrupted by another message, a fault code(s) may
not have been displayed. Repeat the fault code
display procedure to view all active fault codes.
To exit the fault code display function, press both
the M and S buttons simultaneously.

LCD Gauge
1. Turn ignition key to ON with lights position.

vdd2008-001.09S

TYPICAL· EH (ENGINE HOUR OISPLAY)

3. Press and HOLD the M button while QUICKLY
toggling HI - LO beam switch to enter the fault
code display function.
NOTE: A minimum of 3 HI - LO toggles must be
completed within 2 seconds.

,. Low/High beam headlight switch to toggle quickly
IGNITION SWITCH POSITION
1. OFF
2. ON (with lights)
3. ON

218

If no P-Code is active, a "No Active P Codes"
scrolling message w ill be displayed.
If there is an active P-Code, it will be displayed.

Imr2011{)20

Section 03 ELECTRONIC MANAGEMENT SYSTEM
Subsection 03 (DIAGNOSTIC SYSTEM AND FAULT CODES)

If there are multiple fa ult codes, the display w ill
cycle through each fault code.
Once the last fault code is displayed, the gauge
displays END then defaults back to normal operation.

How to Clear Fault Codes Using
B.U.D.S. Software
The fault(s) (occurred state only) can be cleared
by pressing the Clear Occurred Faults button in
B.U.D.S.

Clear Occured Faults
mv2008-039-009

FAULTS PAGE TAB, CLEAR OCCURREO FAULTS

This w ill reset the appropriate counter(s) and wi ll
also record that the problem has been fi xed in the
related ECU memory.
NOTE: An active fault code cannot be cleared.
In other word s, the problem relevant to the fault
code must be repaired before the fault can be
cleared.

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 actuator) which, is controlled by the ECM (see INTELUGENT THROTTLE CONTROL (ITC) subsection) .

TAS Fault
If one TAS (throttle accelerator sensor) signal is
missing, LIMP HOME MODE will be activated and
the check engine light w ill come ON. Pressing and
holding the OVERRIDE button w ill allow normal
control of the accelerator pedal.
If both sensors in the TAS are at fault, a TAS
FAULT message will appear in the gauge, the
check engine li ght will come ON and the engine
will run at idle. The accelerator pedal will not
have any affect on engine RPM. However, the
ve hicle may be driven in LIMP HOME MODE by
pressing the OVERRIDE button.
When limp home mode is engaged using the
override button, a MANUAL LIMP HOME message w ill appear in the gauge. The OVERRID E
button can then be used as the acce lerator,
vehicle speed is controlled by pressing and/or
releasing the button.

PARK BRAKE Fault Message in Gauge
Early Production Models (Only)
Although this vehicle is not equipped with a park
brake, a PARK BRAKE message wi ll be displayed
in the gauge if a brake signal is rece ived continuously for 15 seconds.

BRAKE ACTIVATION Fault Message in
Gauge
Late Production Models
If a brake signal is received continuously for 15
seconds above 5 km/h (3 MPH). a BRAKE ACTIVATION message will be displayed in the gauge.

A TPS fau lt is generally followed by LIMP HOME
mode and the engine is brought back to idle, or
may be completely shutdown.

Low Battery Voltage Fault
If the battery voltage is low when the engine is
runni ng at idle RPM, the ECM wi ll command an
increase in RPM to a set value, thereby increasing
the charging system output in order to prevent the
battery from being discharged, and to allow normal system operation.

tmr2011-020

219

220

Subsection 01

Section 04 FUEL SYSTEM
(INTELLIGENT THROTTLE CONTROL (iTC))

INTELLIGENT THROTTLE CONTROL
(iTC)
GENERAL
SYSTEM DESCRIPTION
The iTC is an electronic throttle control system
that includes:
- Throttle accelerator sensor (TAS)
- Electric throttle actuator (ETA)
- Throttle position sensor (TPS).
The TAS is part of the accelerator pedal module.
The ETA and TPS are comprised in the throttle
body.
The iTC is often referred to as a "throttle by wire'
system (no throttle cable is used).
According to the accelerator pedal position and
other EMS inputs, the ECM powers the ETA
motor using pulse width modulation (PWM), to
control the throttle plate. When the ECM detects through the TPS that the throttle plate has
reached the targeted position, the ECM stops the
throttle actuator.
Depending on various conditions and the type of
key used, the iTC can modify the ETA response,
limit the engine torque or vehicle speed.
For torque limitation, the ECM processes the TAS
input differently depending on the specific mode.
In other words, the driver's demand may not necessarily result in the corresponding throttle opening.
For vehicle speed limitation, the iTC controls the
throttle opening to maintain a maximum set speed
even if the accelerator is pedal fully depressed.

SYSTEM MAIN FEATURES
The use of the iTC allows the following features:
- Key modes
- Normal/Sport modes
- Override functions.

Key Modes
Normal Key
When a normal key is used, engine delivers approximately 70% of the accelerator pedal demand
(less if normal mode is selected). Vehicle speed is
limited to 70 km/h (43 MPH).

tm r2011.()21

Performance Key
When a performance key is used, engine delivers
100% of the accelerator pedal demand (less if normal mode is selected). The vehicle speed is limited to 120 km/h (75 MPH).
Work Key (Option)
When a work key is used, engine delivers approximately 50% of the accelerator pedal demand (less
if normal mode is selected) . Vehicle speed is limited to 40 km/h (25 MPH) .

Normal/Sport Modes
When sport mode is selected, the full potential of
the specific ignition key is deployed except when
gearbox is in reverse or low gear.
When normal mode selected, the full potential of
the specific ignition key is not reached and the accelerator pedal response is smoother than in sport
mode.

Reverse Override Function
In reverse gear, engine delivers less than the
accelerator pedal demand and vehicle speed is
limited to 20 km/h (12 MPH). Also, the accelerator pedal response is smoother than in high gear.
If the override button is depressed, vehicle speed
and engine acceleration are increased. Even with
the override is activated, the ECM will not allow
the engine to deliver 100% of the accelerator
pedal demand.

SYSTEM OTHER FEATURES
Driver's Seat Belt Monitoring
If driver's seat belt not fastened, speed is limited
to approximately 15 km/h (9 MPH)

Brake Monitoring
If the ECM receives a brake switch signal while
gearbox is in gear and the vehicle moving, the
ETA will decrease throttle plate opening and engine speed will drop to idle.
NOTE: A defective brake light switch that would
stay in a closed position would force the engine to
run at idle.

221

Section 04 FUEL SYSTEM
Subsection 01

(INTELLIGENT THROTTLE CONTROL (iTC))

Low Range Operation

SEAT BELT SWITCH

When gearbox is in low ra nge, engine delivers
less than the accel erator pedal demand and the
accelerator pedal response is smoother than in
high gear.

Seat Belt Switch Wire Information

Half Shaft Saver
In a case where the drive wheels would momentarily leave the ground while the driver holds the
throttle, this mode protects the drive system .
The system will enter the half shaft saver mode if
th e ECM detects an excessive wheel acceleration
rate. In such a case, the iTC wi ll reduce the engine
torque. When the wheels slow down, the system
returns to normal mode.

Engine Temperature Monitoring
If coolant gets too hot, engine wil l deliver less
than the accelerator pedal demand. The limitation
is proportional to the overheat degree.

Battery Voltage Monitoring
If the battery voltage gets low, the engine
idle RPM will be increased at approximately
1500 RPM.

Drowned Mode
In case of a fuel flood, the engine can be cranked
without fuel injection.
To enter the drowned mode, depress and hold accelerator pedal (at least 20% of the travell while
cranking engine.

FUNCTION

PIN

COLOR

Signal (to ECM B pin E3)

1

YELLOW/GREY

Ground through ECM
(to ECM B pin Al)

2

ORANGENIOLET

OVERRIDE SWITCH
Override Switch Wire Information
FUNCTION

PIN

COLOR

Normal position signal
(to ECM B pin D3)

1

VIOLET/YE LLOW

Ground through ECM
(to ECM B pin Bl)

2

VIOLET/GREY

Override position signal
(to ECM B pin F3)

3

VIOLET/ORANGE

THROTTLE ACCELERATOR
SENSOR (TAS)
TAS Description
The throttle accelerator sensor (TASI is a double
hall effect sensor that sends a signal to the ECM
wh ich is proportional to the accelerator pedal. The
redundancy is used for security purposes.
The voltage output of the hall effect sensors are
different

TAS Removal and Installation

Limp Home Mode
When certain faults are occurring, the ECM wi ll
enter the limp home mode. In this mode, the engine wi ll deliver less than the accelerator pedal demand.

PROCEDURES

The TAS is part of the accelera tor pedal.
1. Note the wire routing and tie-wrap position.
2. Disconnect electrical connector.
3. Remove both accelerator pedal retaining nuts
by outside the passenger compartment Reach
nuts by the RH side of the vehicle.

SPORT/NORMAL SWITCH
Sport/Normal Switch Wire Information
FUNCTION

PIN

COLOR

Signal Ito ECM B pin D4)

1

BROWN/GREEN

Ground through ECM
(to ECM B pin Al)

2

ORANGENIOLET

222

tmr2011-021

Section 04 FUEL SYSTEM
Subsection 01

(INTELLIGENT THROTTLE CONTROL (iTC))

Connect to the latest applicable S.U.D.S. software. Refer to COMMUNICATION TOOLS AND
B.U.D.S section.
Select the Monitoring and ECM tabs.
Look at the TAS (%) window as you depress the
accelerator pedal.

~/

3000

2000

.

1000

o

RPM

EnQine Speed.

1. Steering column
2. Accelerator pedal rstaining nuts

" I"

Intake (PSI)

To install, reverse the removal procedure, however pay attention to the following:

9000

:'0000
11000

12000

0 RPM

40
Intake Air

Mamto!(
•

10

L......L.

TPS(%)

TAS(%)

Route and attach wires correctly.

EC~

Tighten nuts to the specified torque.

1. TAS % Window

ACCELERATOR PEDAL RETAINING NUTS
TIGHTENING TORQUE

13 Nom ± 1 Nom 11151bf oin ± 9lbf oin)

The TAS signal should vary from near 0% to near
100% depending on the pedal position, which
confirms the TAS signal reaches the ECM.

Carry out the ECM F/RST /NITIALIZATlON, refer to
ELECTRONIC FUEL /NJECTION (EF/) subsection.

TAS Wire Information
FUNCTION

PIN

COLOR

Signal

A

BLUE/GREEN

Ground through ECM

B

BLUE/RED

Voltage input (5 volt)

C

BLUE/ORANGE

Voltage input (5 volt)

D

BLUE/BLACK

Signal

E

BLUE/PINK

Ground through ECM

F

BLUENIOLET

TAS Failure
If one TAS signal fails, the vehicle w ill enter the
limp home mode. In this case, depressing the
override button will temporarily restore accelerator pedal operation (while button is depressed).
If both TAS signals fail, the engine speed will drop
to idle. Depressing the override button will force
the ECM to open the ETA to an angle that allows
the vehicle to move.

TAS Test with B,U,D,S.
The TAS signal can be monitored in S.U.D.S.

(mr2011-021

223

224

Section 04 FUEL SYSTEM
Subsection 02

(ELECTRONIC FUEL INJECTION (EFI))

ELECTRONIC FUEL INJECTION (EFI)
SERVICE TOOLS
Description

DIGITAL INDUCTION TACHOMETER
ECM ADAPTER TOOL .....
FLUKE 115 MULTIMETER ........... ..
OETIKER PLIERS .......... "

Part
529
529
529
295

Number
Page
014 500 ............................ ",',' , .... 226
036 166 ............... , 229, 241, 243-246
035 868
"",.229, 235, 241, 244-245
000 070 ......... ...... ,........ ... 238

SERVICE PRODUCTS
Description

LOCTITE 243 (BLUE) .... ..... ,
XPS SYNTHETIC GREASE ." ...... " .....

GENERAL

Electrical System

A

WARNING

Fuel is flammable and explosive under certain conditions. Ensure work area is well ventilated. Do not smoke or allow open flames or
sparks in the vicinity.

A

WARNING

Fuel lines remain under pressure at all times.
Always proceed with care and use appropriate safety equipment when working on pressurized fuel system. Wear safety glasses.
Wipe off any fuel spillage. Do not allow fuel
to spill on hot engine parts and/or on electrical connectors.

A

WARNING

Replace any damaged, leaking or deteriorated fuel lines or connections. Always,
pressurize the fuel system if any fuel related
component was disconnected or removed.
Proceed with care when removing/installing
high pressure test equipment.

SYSTEM DESCRIPTION
The electronic fuel injection system (EFI) is comprised of various sensors used for detecting ongoing operating conditions of the engine and vehicle,
and includes all the components that perform the
required adjustments to the engine.

tmr201 1·022

Part Number
Page
293800 060 .. " .. ,.,.,' .. ,.,' .... ,' . ,......... ,... 246
293550 010
".,., .. ,.... "., .. ,.. ,." .. "." ... 243

ECM (Electronic Control Module)
From input signals, the ECM acknowledges
driver demands and converts them to an engine
torque requirement through calculation of several
variables. Then, the ECM controls the iTC, the
injection system and the ignition system to meet
the torque requirement.
The ECM manages the engine torque requirements and controls engine operation to ensure
it is delivering optimum performance and fuel
economy. The ECM also controls idle RPM and
limits maximum engine speed through the iTC
system,
EFI Sensors
The ECM reads the inputs from the sensors
which it compares to predetermined parameters
stored in the ECM, makes computations, and activates the outputs accordingly (injectors, ignition
coils etc,).
Signals from sensors are used by the ECM to determine the injection and ignition parameters (referenced to fuel maps) as required to maintain the
optimum air-fuel ratio,

Air Intake System
Air Filter
Air, drawn into the air filter housing, first passes
through an inlet duct.
After it passes through the air filter, an air duct
(intake adapter) is used to channel the air to the
th rottle body.

225

Section 04 FUEL SYSTEM
Subsection 02

(ELECTRONIC FUEL INJECTION (EFI))

Throttle Body

Fuel Injectors

The throttle body is mounted on the front end of
the plenum, aft of the air filter housing.

The fuel injectors are used to inject fuel into the
intake ports of the cylinder head. One injector is
used per cylinder.

Air for combustion, draw n in by the engine, flows
through the air intake system, then through the
throttle body where it is regulated by a throttle
plate.

Fuel Pump
An electri c fuel pu mp w ith an integrated pressu re
regulator and fuel system f ilte rs is used. For more
detail s on the fu el pump unit, refer to FUEL TANK
AND FUEL PUMP subsection.

ADJUSTMENT
IDLE SPEED
Idle speed is not adj ustab le. The ECM contro ls
th e idle speed of t he engine primarily through cont rol of t he throttle plate posit ion.

tmr2011-<122-OO'_8

1.
2.
3.
4.
5.

Throttle body
ETA and TPS
MA PTS (Manifold Air Pressure Tempera ture Sensor)
Plenum
Air intake manifold

The veh icle multifunction gauge can provide an accurate digital readout of the engine 's idle speed.
If desired, the engine RPM can be verified using

a DIGITAL INDUCTION TACHOMETER (PIN 529014
500).

Install the tachometer wire on a spark plug cable.

Fitted on the throttle body, an electric throttle actuator (ETA) allow s th e ECM to electronically control the throttle plate opening w hich regulates the
amount of air that enters the engine, and therefore engine torque .
There is no idle air control valve (IACV).
The TPS is also incorporated in the throttle body.
It provides a signal to the ECM of the actual throttle plate position.
Plenum
After the air flows through the throttle body, it
enters the plenum. The plenum provides a resonance effect which leads to an improved cylinder
charge.
Fuel System
Fuel Rail
Two fuel rails, one for each injector, are mounted
on the intake manifold. The fuel rails, which are
used to secure the injectors to the manifold, also
provide to the injectors the fuel pressure that they
receive from the fuel pump.
The fuel pressure applied to the fuel rails is regulated by the fuel pressure regulator located in the
fuel pump module.

226

VERIFYING ENGINE RPM USING A DIGITAL INDUCTION
TACHOMETER

The engine RPM may also be verified using the applicable B. U.D .S. software version, refer to COMMUNICATION TOOLS A ND B. Uo.5. subsection.
In B.U.D.S., select t he fol lowing:
- Read Data button
- Monitoring page tab
- ECM tab.

tmr2011-Q22

Section 04 FUEL SYSTEM
Subsection 02

-

...

,JOt

_(_I_~-

- /.; I-,-' /RPr" ' '~' """.. ~

u~,

Intak; AIr

i"7;-

~

Intake IPS1)

..

- Fuses
- Ground connections
- Wiring and connectors,
Ensure that all electronic components are genuine
OEM, Any modification to the wiring harness may
lead to poor system operation or generate fault
codes,
"I

•

"

Electrical Connections
Pay particular attention to ensure that terminals
and pins are not out of their connectors, corroded,
or out of shape ,

T~S(%)

TAS (___ )

(ELECTRONIC FUEL INJECTION (EFI))

2

VERIFYING ENGINE RPM USIN G R U,DS
1. Monitoring page tab
2. Engme RPM indication

NOTE: The multifunction gauge and B, U, D,S, use
t he same signa l to provide the eng ine RPM indication,

TROUBLESHOOTING
DIAGNOSTIC TIPS
Engine problems are not necessarily related to the
f uel injection system,
It is important to ensure that the engine and
propu lsion system, fuel delivery and electrical
systems are functioning normally,
For diagnostics purposes, use B,U D S softwa re,
See COMMUNICATION TOOLS AND HU DS
subsection,
After a problem has been solved, be su re to clear
the fault(s) in the ECM using t he B,U, DS software,

A

WARNING

Electrical actuators and electronic modules
may be powered up as soon as the ignition
switch is set to ON. Always disconnect the
battery prior to disconnecting any electrical
or electroni c parts.

W hen probing terminals, pay attention not to deform the terminals as this could cause a loose or
intermittent connection that would be difficult to
troubleshoot

PROCEDURES
ENGINE CONTROL MODULE
(ECM)
NOTE: As a first troubleshooting step, always
check for applicable fault codes using B,UD,S,
software,
Quick Test to Validate ECM Operation
Turn ignition key to ON,
NOTE: Setting the ignition sw itch to ON wakes
up the ECM, which then turns on the following ,
QUICK INDICATION THAT ECM IS FUNCTIONING
(assuming the observed component is
in good working order)
Multifunction gauge turns ON,
Fuel pump turns on for approx, 5 seconds,
Rear lights turn on,
Headlamps turn on (ignition key on with lights
positionL
ECM First Initialization

Never use a battery charger to tempora rily substitute the battery as it may cause the ECM to fu nction erratically, or not at ai L
Check related-circu it fuse solidity and condition
w ith an ohmmeter A visual inspection could lead
to a false diagnosis,
Electrical Related Problems

This procedure performs a reset of the following
values in the ECM:
- TAS (Throttle Accelerator Sensor)
- TPS (Throttle Position sensor)
- GBPS (Gearbox Position SensorL
This reset must be carried out whenever the ECM
has been replaced,

It is important to check the fo llowin g in the electrical system:
- Battery voltage
tmr2011-022

227

Section 04 FUEL SYSTEM
Subsection 02

(ELECTRONIC FUEL INJECTION (EFI))

This reset may be carried out whenever any of
the fol lowing components have been replaced instead of their respective reset procedures:
- Throttle body (for TPS)
- GBPS (Gearbox Position Sensor).
1. Connect vehicle to the applicable B.U.D.S. version, refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection.
2. In B.U.D.S., select the following:
- Read Data button
- Setting page tab
- ECM page tab

--_ -

5. Check for fault codes.
If a fault code is generated, carry out the service
actions, reset the fault and repeat the reset procedure.
6. Start engine and make sure it operates normally
throughout its full engine RPM range.

ECM Access
The ECM is located under the dashboard, driver's
side, above the control pedals.

.....

1

tmr2011 -018-"J
Ip2.3.22.12_2SPSBK8C6tMXXl168_2OO902O&_

Qpen

Oil

,m,""'"''''''
IMPORTANT: Be sure to use the file that specifically matches the vehicle you are servicing.
NOTE: The file name structure is as follows:

mmr2009'()23-080

3. Click once on the Folder Up button in the Open
box.

B.U.D.S. version_VIN_date read lyyyymmddLhour read
Ihhmmss).mpem
Example:

I?llxl

Op.n

P2.3.22.12_2BPSBK8C68VOOO168_20090206_111640.mpem
Therefore:
B.U.D.S. version: P2.3.22.12
VIN: 2BPSBK8C68VOOO168
Date: 2009 02 06
Hour: l1h16m40s

Flo "'"'"

I~

Fief of JVpe:

IMP£M fjeo$ r ,mpem)

mmr2009-023-08 ' _a

tm r2011-022

Oil

5. Select the
down) the
1. Vehicle
2. Engine
"M")

Veh icle page tab and record Iw rite
following information.
serial number
serial number Iwithout the leading

231

Section 04 FUEL SYSTEM
Subsection 02

(ELECTRONIC FUEL INJECTION (EFI))

3. Vehicle model number
4. Customer name.

BOSS
Web
r
,n"
H~'''I

~;;;;;;==;:;=

Ifib! ,.

Pi,llt~t

"

C!lllom.r

7 .;!!!=-''' -

TS: .

"." ".

"OoU el .·m

.. . . , -

••

~I"'~s-~,,,-

~Here
to Access
mmr2009- 118-01 1

VEHICLE TAB

SERVICE, UNIT HISTORY

6. Enter recorded data in ECM as detailed in
ENTERING THE COLLECTEO INFORMATION
INTO THE ECM

3. Enter the recorded data in the new ECM as de-

2nd Collecting Method: Collect the
Information from the Vehicle and BOSSWeb

Entering the Collected Information Into the
ECM
1. Use the applicable B.U.D.S. version. Refer to
COMMUNICATION TOOLSANOB.U.D.5. subsection.
2. Turn ignition key to ON position.

1. Record engine serial number.

tailed in ENTERING THE COLLECTEO INFORMATION INTO THE ECM

3. In S.U.D.S., click the Read Data button to read
the new ECM .

file )Liew M.EI®

~

J

Read Data

Module lools .!::!elp

...

~

Write Data

TYPICAL · RH SIDE OF ENGINE
1. Engine serial number

2. Record
the
following
numbers
uSing
BOSSWeb. Look In Service menu and
choose Unit history.
1. Vehicle serial number
2. Vehicle model number
3. Customer name.

The following screen w indow wi ll pop up.

8 u.o S (0l'III01 delwnm8 ItK:o type of vefJcle vou ar" COOl9ctQ:li ~elUe Enter til ... appropnllt~whcle

!TI{I(IeIln ~ east b~ 'oekWi

Qk
smr200S..Q23-100

4. Enter the vehicle model number.

232

Imr20 11 ·022

Section 04 FUEL SYSTEM
Subsection 02

(ELECTRONIC FUEL INJECTION (EFI))

'i!t,),fI!1j

Enter only the appropriate product
model number as obtained when gathering the
information.

I

I

I

I

Ad~ !'",'In 11I.10.y

(?

.rxil

P"rtType
r Engrne
BUD S CllMOj dr;IQrm/rw!he type 0( VOOIclQyou O{Q cOflOOctQd 10 beCQUSQ the
vehicle model IS ffilSS!11!I The ~hlcle modelrnu!'ll 81ttlll be "SBOAT", An
elphonum9ricOl ....JIu.. or on Qrttjr9ti numMCal Villu$ EnW!he oppropriBtevehlclQ
mod!'! trllho cdll bO)! beloW

;' EC"' _ 4
,.. ClOster

5

i

3

1349A

&:I~

Ptllln Hltlory

ADDING PART IN HISTORY
1. History page rab

5. Select the Vehicle tab and enter the information you recorded previously.
1. Vehicle serial number
2. Engine number (do not enter the" M" at the
beginning of the engine number)
3. Customer name.

2. Part Replacement tab
3. Add part in history button
4. ECM selection
5. Add ECM serial number here

NOTE: The ECM serial number can be found on
the ECM sticker that also identifies the part number.
8. Click on the OK button.
9. Click on the Write Data button.

j) 1,
VEHICLE TAB

6. Click on the following tabs:
- History
- Part Replacement
- Add Part in History.
7. Enter the old ECM serial number in the Add
Part In History window.

Read Data

I

Write Data

yrru2006.ot2·tOOJwl

10. Perform the ECM FIRST INITIALIZATION reset.
11. Program
the
vehicle
ignition
keys into the new ECM, refer to
Digital Encoded Security System (D.E.SS;
subsection.
12. Reinstal l any remaining removed parts.

FUEL INJECTOR
Fuel Injector Operation Test Using
S.U.D.S. (Dynamic)
NOTE: As a first troubleshooting step, always
check for applicable fault codes using B.U.D.S.
1. Connect vehicle to the applicable B.U.D.S. version. Refer to COMMUNICA TlON TOOLS AND
B. U.D.S subsection.
tmr20 ' ·022

233

Section 04 FUEL SYSTEM
Subsection 02

(ELECTRONIC FUEL INJECTION (EFI))

2. Start engine.

2. Connect vehicle to the applicable B.U.D.S.

3. In B.U.D.S., select the following:

software vers ion. Refer to COMMUNICATION
TOOLS ANO 8.UO.S subsection.
3. Turn the ignition key to ON.

- Read Data button
- Monitoring page tab
- ECM page.
4. Using the B.U.D.S., shut down fuel injection to
each engine cylinder one at a time by clicking
on the button under the applicable cylinder.

4. In B.U .D.S., select the following :

- Read Data button
- Activation page tab.
5. In B.U.D.S., click on the Fuel Pump button to

activate fuel pump.
r Fuel Pump·

I

r Il.isabled

r. Enabled

- Activate- - - - - - - - - - - - - - ,

Fyel Pump ..
Cf----j--1
Fuel- - - - - - - ,

1 _--+--1
... _

"P_" -' __"'_" -,I I

J

Fuel and Ignrtlon

l

Front

~ooling

R'1llr

1

----' -----'

1. Click on cylinder number to be tested

If the engine RPM drops momentarily when clicking on a cylinder, the injector on this cylinder is
functioning normally.

Fan

AccessOlY Relay
lmr2011-!111-{117_d

1. Fuel Pump activation button

6. Fuel pressure must be within specification. Re-

fer to FUEL TANK ANO FUEL PUMP subsection. Re-activate fuel pump as necessary.
7. In B.U.D.S., energize fuel injector no. 1.

If the engine RPM does not drop momentarily
when clicking on a cylinder, this cylinder is not
functioning properly. Check the following:
- Fuel injector operation. Refer to FUEL INJECTOR BALANCE TEST USING 8. UOS
- Spark plug and ignition coil. Refer to IGNITION
SYSTEM subsection.
- Engine condition.

Fuel Injector Balance Test Using
B.U.D.S.

'1'[,).&1 After

fuel injector activation using
B.U.D.S., always crank engine in drowned
mode to ventilate engine and prevent a potential backfire due to fuel accumulation in
engine.
1. Install a fuel pressure gauge as described in

FUEL PUMP PRESSURE TEST of FUEL TANK
ANO FUEL PUMP subsection.

234

1. Click on injector to activate

8. Record the fuel pressure drop for injector no. 1.
9. In B.U.DS., click on the Fuel Pump button to
activate fuel pump.

Imr2011-D22

Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

1o. Repeat the procedure for fuel injector no.2
and record the pressure drop for each injector.
11. The maximum fuel pressure drop between injectors should not exceed the following specification:
MAXIMUM FUEL PRESSURE DROP ALLOWED
BETWEEN FUEL INJECTORS
10 kPa 11.5 PSI)

If the injector does not function, carry out the
FUEL INJECTOR RESISTANCE TEST

Fuel Injector Resistance Test
Disconnect connector" A" from the ECM.
Disconnect the engine connector (HIC).
NOTE: The HIC connector is located to the right
of the ECM.

If pressure drop of any fuel injector is greater than
the specification, replace that injector then repeat
the test.
12. Using the valve on the fuel pressure gauge,
release the pressure in the system (if so
equipped).
13. Remove fuel pressure gauge and reinstall removed parts.

Fuel Injector Leak Test
Carry out the FUEL PUMP PRESSURE TEST as
detailed in the FUEL TANK AND FUEL PUMPsubsection.

Fuel Injector Activation Test Using
B.U.D.S.
Turn ignition key to ON.
On the Activation page of B.U.D.S. software, energize the fuel injector to be tested.

1. Accelerator pedal (not viSible)
2. ECM
3. HIe connector

Using a FLUKE 115 MULTIMETER !PIN 529 035 868),
check resistance value between terminals as follows.
FUEL INJECTOR RESISTANCE TEST AT
HIC CONNECTOR
INJECTOR

ECM
HIC
CONNECTOR RESISTANCE
CONNECTOR
@ 20'C 168'FI
"A"
SOOR and 1000 Engines

FRONT
REAR

A-Jl

D

11.4-12 .60

A-Kl

If resistance value obtained is incorrect, remove
injector connector and check resistance value between injector pins as follows.
FUEL INJECTOR RESISTANCE TEST AT
INJECTOR CONNECTOR
TYPICAL
1. Click on injector to activate

INJECTOR

You should hear the injector functioning.
This will validate the injector mechanical and electrical operation.

tmr2011-022

INJECTOR PIN

RESISTANCE @
20'C (SB'F)

SOOR and 1000 Engines
FRONT
REAR

1

2

11.4-12.6 0

235

Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

CYLINDER

INJECTOR
CONNECTOR

MEASUREMENT

WIRE
FRONT
REAR

Battery
ground

VIOLETI
BLUE

12 Vdc

TYPICAL

If readings are out of specifications, replace injector.
If readings are good, carry out a FUEL INJECTOR
INPUT VOLTAGE test.

Fuel Injector Input Voltage Test
Disconnect the fue l injector connector.
NOTE: If the connector is hard to unlock, gently
use a screwdriver to release connector.

TYPICAL

If supply voltage is not good, check continuity
between fuse F5 and injector (see WIRING DIAGRAMS! .
NOTE: Probe fuse exactly as shown. This validates fuse at the same time.
Use a multimeter and set it to D. Read resistance.
CYLINDER
FRONT
REAR

vmr200S-014-OO'_8

TYPICAL

NOTE: It is not necessary to activate the injector
since it is continuously powered when the ignition
key is set to ON.
Use a multimeter and set it to Vdc. Read voltage.

236

INJECTOR CIRCUIT
WIRE
VIOLETI
BLUE

Fuse F5

MEASUREMENT

Close to 0

n

If continuity is good, check relay and wiring from
battery.
If continuity is faulty, check fuse and if OK,
repair/replace wiring going to injector.
If supply voltage is good, check ground circuit
between injector and ECM (see WIRING DIAGRAMS!.
- If ground circuit is faulty, repair/replace wiring
and connectors.
- If ground circuit is good, refer to ECM REPLACEMENT

Fuel Injector Removal
To remove the injector, first remove the fuel rail
refer to FUEL RAIL for the procedure.

tmr2011-022

Subsection 02

Section 04 FUEL SYSTEM
(ELECTRONIC FUEL INJECTION (EFI))

TYPICAL - FUEL RAIL ASS'Y
1. Fuel rait
2. Fuel injector
3. Injector top O-ring
4. Injector bottom O-ring
5. Manifold O-ring

Then pull fuel injector out of the fuel rail.
Firmly push injector until it bottoms out

Fuel Injector Installation

Reinstall fuel rail.

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

FUEL RAIL

Apply a thin film of engine oil to O-rings to ease
insertion in rail.
Install fuel injector with your hand. Do not use any
tool.
FUEL INJECTOR INSTALLATION
O-RINGS

I

New

I Lubricate with engine oil

Position the manifold O-ring on injector as in following illustration.

Fuel Rail Replacement
Fuel Rail Removal
1. Connect vehicle to the applicable B.U.D.S. software version and select the following:
- Read Data button
- Activation page tab
- ECM page tab
- Fuel pump Disabled.
Fuel Pump

(" .Enabled

)f~-1
., .l2lsabled

Activate

FMel Pump
Cooling Fan
Acce§sory Relay

vmr2006-014..(l7 1_a

TYPICAL - MANIFOLD O-RING POSITION
tmr20 11-011-017 _b

Carefully insert injector in manifold paying attention to the manifold O-ring.

1. Ctick here to disable the fuel pump

IN",I!iOj

2. Release fuel pressure by running engine until it
runs out of gas.

Gently push O-ring in evenly all
around while inserting injector. O-ring must
be completely inserted and not visible, before
completing the insertion of the injector.
tmr2011-022

3. Turn ignition key OFF.
237

Section 04 FUEL SYSTEM
Subsection 02

(ELECTRONIC FUEL INJECTION (EFI))

4. Wrap a rag around the inlet hose and release
the quick fitting.

FUEL RAIL INSTALLATION

RETAINING SCREW
TORQUE

INJECTOR O-RINGS
NEW
(Lubricate with eng ine oil )

10 Nem
(89 Ibl e;n

± 1 Nem
± 9Ibl e;n)

After securing fuel hose quick fitting to injector,
re-enable fuel pump using S.U.D.S.
Fuel pu~m,-p-- 1

/

TYPICAL

.~

" Enabled

5. Unscrew rail retaining screws.

Qjsabled

Activate

6. Gently pull rail off by hand.
Fuel Pump
C.oo!ing Fan
Acce,asory Relay
tmr20 1 T·011 ·0 17_G

1. Click herB to enable the fuel pump

A

WARNING

Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL TANK AND
FUEL PUMP. Run engine and check for leaks.
TYPICAL

To disconnect fuel rail from hose, cut clamp on
fuel hose using OETIKER PLIERS (PIN 295 000 070).
Refer to FUEL TANK AND FUEL PUMPfor clamp
removal/installation procedures.

THROTTLE BODY
Throttle Body Description

NOTE: If fuel rail is removed for access to fuel injector, it is not necessary to cut hose clamp. Only
to repla ce fuel rail.
Fuel Rail Installation

2

For installation, reverse the removal process how ever, pay attention to the following.
Install new clamps using pliers as per removal (if
fuel rail was replaced).
Install fuel rail and evenly tighten screws a little at
a time each side.
1.
2.
3.
4.

238

Throttle body
Throttfe pla te
Electric throttle actuator (electric motor inside)
Throttle position sensor (TPS) (inside)

tmr2 0 11 -02 2

Section 04 FUEL SYSTEM

Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

Throttle Body Access
Refer to AIR INTAKE SYSTEM and remove the following parts:
- Air filter housing
- Air intake adapter.

To remove connector from throttle body, simultaneously press the end of both connector locking
tabs illustrated.

Throttle Body Lubrication
No lubrication is required.

Throttle Body Cleaning
1. Remove air inlet hose from throttle body.
2. Check throttle body cleanliness using a flashlight. Fully open throttle plate and verify:
- Throttle body bore
- Throttle plate edge .

Look for:
- Dirt
- Oily surfaces
- Carbon and salt deposits on throttle plate and
the surrounding bore.

THROTTLE BODY CONNECTOR- PRESS HERE TO UNLOCK

3. Remove screws retaining throttle body to
plenum.

3. Clean as necessary.

4. Use a throttle body cleaner such as GUNK INTAKE MEDIC or an equivalent.

II![,)i[IJOj

Only use an appropriate throttle
body cleaner that will not damage a-rings and
EFI sensors.

2

A

CAUTION Use the product in a well ventilated area. Refer to product manufacturer's
warnings.
5. To avoid getting dirt into engine, spray cleaner
on a clean rag then rub rag against throttle plate
and bore. A toothbrush may also be used.

A

CAUTION Ensure ignition key is removed

so that nobody can activate the electrical system, otherwise the ECM would turn on and the
throttle actuator (ETA) would cycle. This could
cause serious finger injury as the throttle plate
moves quickly.

1
1. Throttle body connector
2. Screws (4)
3. Plenum

4. Pull throttle body off plenum.

Throttle Body Installation

6. Gently open throttle plate and hold fully open to
reach all surfaces.

Installation of the throttle body is the reverse of
the removal procedure. However, pay attention to
the fol lowing.

7. To remove residual dirt, spray cleaner on throttle plate and on bore.

TORQUE FOR THROTTLE BODY RETAINING
SCREWS

8. Reinstall removed parts.

Throttle Body Removal
1. Disconnect air inlet hose from throttle body.
2. Disconnect throttle body connector.

tmr2011 --022

10 Nom ± 1.2 Nom (89lbf oin ± 11 Ibfoin)

1. Perform the THROTTLE POSIT/ON SENSOR
INITIALIZATION reset procedure. Refer to
THROTTLE POSIT/ON SENSOR (TPS) in this
subsection.
239

Section 04 FUEL SYSTEM
Subsection 02

(ELECTRONIC FUEL INJECTION (EFI))

THROTTLE POSITION SENSOR
(TPS)
TPS Description
NOTE: The TPS is part of the throttle body.
The throttle position sensor (TPS) is a double potentiometer that sends signals to the ECM that
are proportional to the throttle plate ang le.
NOTE: As a first troubleshooting step, always
check for applicable fault codes using B.U.D.S.
softw are.

Throttle Position Sensor Initialization
NOTE: The TPS iniatialization procedure must be
carried out whenever the throttle body is replaced,
unless an ECM first initialization reset is carried
out.
This operation performs a reset of the TPS basic
values in the ECM. Th is reset is very important as
the TPS values are part of the basic parameters
for all fuel mapping cal culations and control of several settings such as for idle speed, LIMP HOME
mode and maximum RPM of the engine.

1.Il"WOj An

improperly set TPS may lead to
improper idle speed (too low or too high), poor
engine performance, poor engine starting and
engine stop on deceleration, fault codes and
possible engine damage. Emission compliance may also be affected.
1. Connect vehicle to the applicable B.U.D.S.
software version, refer to COMMUNICATION
TOOLS AND 8.U.D.S. subsection.
2. In
-

B.U.D.S., select the following:
Read Data button
Setting page tab
ECM tab.

3

-

~

.

,

J

~------------

1. Read Data button
2. Setting page tab
3. ECM page tab

3. Ensure the accelerator pedal is fully released
and at the idle position.
4. In the Throttle position sensor initialization
field, click on the Throttle Opening Reset button.
, llnlllle posibon sensm lI1ibawb_---------~

0,0%

Throllle Opening:

BOIS!!!

,,'' '- --t=====-------i

rGeo',..''''''''''''',·,..

1

"".
trTV2011.o22.()()3. D

THROTTLE POSITION SENSOR INITIALIZATION
7. Throttle Opening Reset button

A message will be displayed if the operation is
successful.
If an error occurred or the TPS is not within the
allowed range while resetting, the ECM will generate a fault code and will not accept the setting.
5. If a fault message is displayed, follow the instructions in the message(s).
6. Check for fault codes.
7. If a fault code is generated,
- Carry out the service actions
- Reset the fault
- Repeat the reset procedure.
8. Start engine and make sure it operates normally
throughout its full engine RPM range.
240

tmr2011.022

Section 04 FUEL SYSTEM
Subsection 02

(ELECTRONIC FUEL INJECTION (EFI))

TPS Wear Test
1 . With the engine turned off, slowly press on the
accelerator pedal and pay attention for smooth
operation without physical stops.
2. Activate the electrical system to wake up the
ECM.
3. Connect vehicle to the applicable S.U.D.S.
software version. Refer to COMMUNICATION
TOOLS AND B. U.D.S subsection.
4. In S.U.D.S, select the following:
- Monitoring page tab
- ECM page tab.

1

5. Slowly and regularly move the accelerator
pedal.
6. Observe the Throttle Opening indication movement in S.U.D.S.

---. "'.
I

""

W
-- ..

-.

.

,".

.. I -...

no ,

"

i

-

1

I"take (PSI):

TAS(IJII)

..----.

8. Check the indication movement again
- If the indication moves as expected, check
the throttle accelerator sensor (TAS). Refer to
THROTTLE ACCELERATOR SENSOR (TAS) in
this subsection.
- If the indication does not move as expected,
perform the TPS RESISTANCE TESTin this subsection.

TPS Resistance Test

,,-

TPS(%l

1. Push here

Intak; Air

i ','Vo/hi ..

~

2

tmr201 1'{)2 2'{)09 b

1. MOn/tonng page tab
2. TPS indication

NOTE: The indication should move gradually and
regularly as you move the accelerator pedal. If
the TPS indication is erratic or suddenly drops off,
it may indicate a worn TPS that needs to be replaced. An initial slight delay after the accelerator
pedal is moved and before the indication starts to
move is normal.
If the indication behavior is not as expected, proceed with the following steps.

1. Ensure the throttle body connector is properly
connected.
2. Disconnect ECM connector A from the ECM
and install it on the ECM ADAPTER TOOL (PIN 529
036 166).
3. Use the FLUKE 115 MULTIMETER (PIN 529 035
868) and select n.
4. Probe circuit as per following table while using
your hand to manually move throttle plate.
ECM
ADAPTER

FULLY CLOSED
THROTTLE
PLATE (1)

FULLY OPEN
THROTTLE
PLATE

RESISTANCE
PIN

(m

MIN.

MAX.

MIN.

MAX.

A-A2

A-K4

875

1625

875

1625

7. Manually move the throttle plate in the throttle
body using a blunt tool (without sharp tip).

A-A2

A-K3

954

1934

228

585

A-A2

A-F3

254

634

980

1983

A

A-K3

A-K4

228

585

954

1934

A-K3

A-F3

1385

2315

1385

2315

A-K4

A-F3

980

1983

254

634

CAUTION Do not move throttle plate with
your fingers. Otherwise, if ECM should turn
off, it would quickly close the throttle plate
which could cause finger injury.

(1) To obtain the fully closed position. it is necessary
to push against the throttle plate in the t hrottle body
with your hand and hold it in this position for the
measurement.

m r2D1 '-022

241

Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

CRANKSHAFT POSITION
SENSOR (CPS)

If any resistance value is incorrect, check wire
continuity between ECM and throttle body before
assuming the TPS is at fault. Refer to WIRING
DIAGRAM subsection.
TYPICAL - RH SIDE OF ENGINE
1. CPS IOCBtion

NOTE: Take into account that a CPS fault can be
triggered by bent or missing encoder wheel teeth.
First check fault codes using B.U.DS., then check
the encoder wheel teeth condition if necessary
(refer to MAGNETO SYSTEMJ.
CPS Resistance Test
Disconnect CPS wiring harness connector.

THROTTLE BODY CONNECTOR PIN-OUT

TPS Replacement
Carry out a THROTTLE POSITION SENSOR INITlALIZATIONprocedure as detailed in THROTTLE
BODYof this subsection.

TYPICAL - LH SIDE OF VEHICLE
1. CPS connector location

Probe terminals as per following table.

cps

CONNECTOR

RESISTANCE !'l
@ 20'C (6B'F)

PIN

1

I

MEASUREMENT

2

700 - 900 !'l

If resistance is not within specifications, replace
the CPS.

242

tmr2011·022

Section 04 FUEL SYST EM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

If res istance test s good, reconnect th e CPS connector and disconnect the connector" A" on the
ECM.
Instal l ECM-A connector on ECM ADAPTE R TOOL
(PIN 529 036 166),

52903616<)

Using a multimeter, recheck resistance as per t able.

TYPICAL
1. cps

2. Retaining screw

ECM CONNECTOR

MEASUREMENT

Install new CPS and secure ha rness with a new
locking tie.

PI N

RESISTANCE n
@ 20°C (68°F)

CPS INSTALLATION

A-H1

I

A-K2

700 - 900 n

PRODUCT
O-RING

If resista nce va lue is correct, refer t o ECM RE-

PLACEMENT
If resistance value is incorrect, repair the conn ectors or replace the wiring harness between ECM
con nector and the CPS.

CPS Replacement
Discon nect CPS connector and cut harness locking t ie.

SENSOR
SCREW

XPS SYNTHETIC GREAS E
(PIN 293 550 010)
TORGUE
10N om ± 1 Nom
(89lbf oin ± 9lbf oin)

MANIFOLD AIR PRESSURE
AND TEMPERATURE SENSOR
(MAPTS)

Remove CPS retaining screw and pu ll up on CPS
to remove it.

1. Manifold air pressure and temperature sensor (MAPTS)

NOTE: This sensor is a multifunction device.

tmr2011-022

243

Section 04 FUEL SYSTEM
Subsecti on 02 (ELECTR ONIC FUEL INJECTION (EFI))

M APTS Pressu re Funct ion

MAPTS PRESSURE FUNCTION QUICK TEST

Before the engine is started, when power is applied to the system, the sensor measures the ambient air atmospheric pressure. The ambient pressure is, at that moment, stored in the ECM. Thereafter, once the engine is started, it measures the
air pressure in the inlet end of the plenum at operating RPMs.

RESULT

The sensor must be correctly installed on plenum .
Otherwise, the MAPTS could generate a fault
code for an unexpected sensor range at idle
when it reads the atmospheric pressure. If this is
the case, remove sensor and check for oi l or dirt
on its end and if problem persists, check throttle
plate cond ition/position and the wiring harness.
Perform the following tests .

1. Connect vehicle to the applicable B.U.D .S. softw are version .

2. In B.U.D.S ., select the following:
- Read Data
- Mo nitoring page tab
- ECM page .

~l:.nq_
r "'F
'"

i

NO
RE ADI NG

VALUE IS
OUT OF
RAN GE

""'.'"2

1

Fl.

L,

I

MAPTS
Input
Voltage
Test

Repair or
replace
wi ring

Replace MAPTS

M A PTS Input Voltage Test
Check the voltage output from ECM to the pressu re sensor.

2. Remove electrical connector from MAPTS.
3. Using a FLUKE 115 MULTIMETER (PIN 529 035
868), measure for input voltage as per fol lowing
table.
MAPTS CONNECTOR

MEASURE MENT

PI N

VO LTAGE

1

I

Circuit
Continu ity
Test of
MAPTS
Pressure
Function

1. Turn ignition key ON.

MAPTS Press ure Fun ctio n Quick Test

k!l!ng

SERVICE ACTION

I

5 Vdc

3

If voltage test is good, replace the MAPTS.
If voltage test is not good, carry out the MAPTS

CIRCUIT CONTINUITY TEST (PRESSURE FUNCTION).

- 71

"

MAPTS Circuit Co nti nuity Test (P ress ure
Function)

1. Disconnect the ECM "A" connector.

2. Install ECM-A connector on ECM ADAPTER

<0

Intake Air
•

'0

L -,- l

,p

'

"

' Vo~t. !

",

",

TOOL (PIN 529 036 166),
3. Using a mu ltimeter, check continuity of the fol lowing circuits.
MAPTS CIRCUIT CONTINUITY TEST
(PRESSURE FUNCTION)
EC M-A

MAPTS
CO NN ECTOR

2. MA PTS pressure reading

Pin 84

Pin 3

3. Look for and take note of the MAPTS pressure
reading while th e engine is stopped.

Pin G4

Pin 4

Pin H2

Pin 1

1. MOnitoring page

rao

4. Perform the same test with a new MAPTS and
compare both readings .
Values have to be w ith in :!: 3.4 kPa (0.5 PSI) .

244

RESISTANCE
VALU E
Close to 0 n

If resistance is not within specification, repair or
replace the w iring harness between ECM connector and the MAPTS .

tmr:!011 -on

Section 04 FUEL SYSTEM
Subsection 02 (ELECTRONIC FUEL INJECTION (EFI))

MAPTS Temperature Function

MAPTS

MEASUREMENT

PIN

RESISTANCE [1
@ 20' C (B8' F)

The sensor monitors the temperature in the inlet
of the plenum.
MAPTS Quick Test (Temperature Function)

2. In
-

I

1

1. Connect vehicle to the applicable B.U .D.S. softw are version.
B.U.D.S., se lect the fol lowing:
Read Data
Monitoring page tab
ECM page.

2

2280 - 2740

If resistance is not within specification, replace
the MAPTS.
If resistance tests good, reconnect the MAPTS
and disconnect the connector "A" from the ECM.
In stall ECM-A connector on ECM ADAPTER TOOL
(PIN 529 036 166).

3. Look for the Intake Air temperature reading
whi le the engine is stopped.

"""'[20 "

'u

.

""""

~""'i~

,

1

"

"

"

••

Intake Air

i

Mlntoldabt. PlHS qll

I~- "

I' ,

11

"

'vok '

".

.
,

529036 166

Using a multimeter, recheck resistance value as
per following table .
ECM CONNECTOR

MEASUREMENT

PIN

RESISTANCE [1
@ 20'C (68'F)

2

A-H2
1. Monitoring page tab
2. MAPTS temperature reading

I

NOTE: Both sensors must fee l same ambient air
temperature.
If there is no reading, carry out a MAPTS RESISTANCE TEST (TEMPERATURE FUNCTION).

2280 - 2740

MAPTS TEMPERATURE SENSOR TEST RESULTS
RESULT

4. Perform the same test with a new MAPTS and
compare both readings.

If the engine' s MAPTS temperature reading is significantly different than the new MAPTS, replace
it.

A-H 3

NO
READING

INCORRECT
RESISTANCE
VALUE

SERVICE ACTION
Circuit
Continuity
Test of
MAPTS
Temperature
Function

MAPTS
Input
Voltage
Test

Repair or
replace
wiring

Replace MAPTS

MAPTS Resistance Test (Temperature
Function)
Disconnect the connector from the MAPTS.
Using the FLUKE 115 MULTIMETER (PIN 529 035
868), check the resistance of the se nsor itse lf as
shown.

tmr20 11-022

245

Section 04 FUEL SYSTEM
Subsection 02

(ELECTRONIC FUEL INJECTION (EFI))

MAPTS Circuit Continuity Test (Temperature
Function)
MAPTS CIRCUIT CONTINUITY TEST
(TEMPERATURE FUNCTION)
ECM-A

MAPTS
CONNECTOR

Pin H2

Pin 1

Pin H3

Pin 2

RESISTANCE
VALUE
Close to 0 n

MAPTS Replacement

5

2

1
vnlf2OO6..014-008_8

TYPICAL - LH SIDE OF THE ENGINE, AFT CYLINDER
1. Coolant temperature sensor (eTS)

CTS Resistance Test
1. Disconnect the plug connector from the CTS
and check the resistance of the sensor itself.

1.
2.
3.
4.
5.

CTS SENSOR

MEASUREMENT

PIN

RESISTANCE n
@ 20°C (68°F)

1

MAPTS
MAPTS connector
Re raining screw
Plenum
Throttle body

I

2

2280 - 2740

Disconnect MAPTS connector and remove the
MAPTS from the plenum.
Install new MAPTS as per following table.
TORQUE

PRODUCT

6 Nom ± 0.7 Nom
(53Ibl o;n ± 6Ibl o;n)

LOCTITE 243 (BLUE)
(PIN 293 800 060)

CTS (COOLANT TEMPERATURE
SENSOR)
CTS Access
The CTS is located on the LH of the engine, aft
cylinder. To access it, remove the:
- Driver 's seat
- LH lateral console panel.

TYPICAL

If resistance is out of specification, replace the
CTS.
If resistance test is good, reconnect the CTS and
disconnect the ECM connector "A" from the
ECM.
2. Install ECM-A connector on ECM ADAPTER
TOOL (PIN 529036 166).

246

tmr201l-()22

Section 04 FUEL SYSTEM
Subsection 02

(ELECTRONIC FUEL INJECTION (EFI))

529036166

3. Using a multi meter, recheck resistance from
the ECM connector as per table.
ECM "A CONNECTOR

MEASUREMENT

PIN

Resistance f1
@ 20'C (68'F)

Al

I

J2

2280 - 2736

If resistance va lue is correct, refer to ECM RE-

PLACEMENT
If resistance value is incorrect. repair the connectors or replace the wiring harness between ECM
connector and the CTS.

CTS Replacement
1. Disconnect CTS connector and remove CTS.
2. Install the new CTS and torque as specified .
CTS TORQUE
16N-m ± 2N-m (142Ibf- in ± 18 Ibf- in)

3. Reinstall remaining removed parts .
4. Refill and bleed the cooling system, refer to
COOLING SYSTEM subsection.

tmr201 HI22

247

248

Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

FUEL TANK AND FUEL PUMP
SERVICE TOOLS
Description

Part Number

ECM ADAPTER TOOL .................................................... ...... ..... .
FLUKE 115 MULTI METER .... ...... ........•.........................................
FUEL HOSE ADAPTER ................................................................. .
OETIKER PLIERS .......................................... ................................ .
PR ESSU RE GAUG E............................................. ........... .............. .
VACUUM/PRESSURE PUMP ...................................................... ..

529036166
529035868
529036023
295000070
529035709
529021 800

Page

....................................... 259
..... .... .................. .. ..... . . 258
................................ 253
......................................... 256
..... ............. .. ................... 253
............................... 252, 263

SERVICE TOOLS - OTHER SUPPLIER
Description

Part Number

FLUKE RIGID BACK PROBE ......................................................... TP88

Imr201 1'()23

Page

....................... ............ 258

249

Section 04 FUEL SY STEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

~ Engine

o

,-- ---- I
I

~ = Co m po nent must be rep laced w hen removed.
tm,201

250

CE Model

:

6

: (]!A

:

I

I

: W ~:

H)23-001~a

tmr201 1-023

Section 04 FUEL SYSTEM
Subsection 03

(FUEL TANK AND FUEL PUMP)

SYSTEM DESCRIPTION

GENERAL

A

WARNING

Fuel is flammable and explosive under certain conditions. Ensure work area is well ventilated. Do not smoke or allow open flames or
sparks in the vicinity.

Always disconnect battery prior to working
on the fuel

A

Fuel Tank Vent System
The fuel tank is equipped with a vent system that
ensures the fuel tank remains at ambient pressure.
Air can enter the fuel tank at all times through the
fuel tank vent valve. This prevents negative pressure within the fuel tank which could cause fuel
starvation.

WARNING

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

A

WARNING

Always proceed with care and use appropriate safety equipment when working on pressurized fuel system. Wear safety glasses.
1. Vent valve
2. Air inlet hose

When the repair is completed, ensure that all
hoses are connected and secured. Perform the
FUEL PRESSURE TESTand the FUEL TANK LEAK
TESTas explained in this subsection.
Fuel lines remain under pressure at all times.
Proceed with care when removing/installing high
pressure test equipment.
Use the B.U.D.S. software or disconnect the fuel
pump electrical connector to disable fuel pump
and crank engine to release fuel pressure prior to
disconnecting any fuel hose.
Cover the fuel hose connections with an absorbent shop rag and carefully disconnect them
to minimize spilling.
Wipe off any fuel spillage.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory standards.

The vent valve also prevents fuel from flowing out
through the inlet of the vent system should the
vehicle be overturned.
Fuel Tank Vent Breather Filter
The air inlet hose of the vent system is equipped
with an in-line breather filter that prevents entry
of particles such as dust or small insects. It is
located behind the air filter housing next to the
coolant reservoir. To access the breather filter, remove the service cover.

1

2

1. Fuel tank vent breather filter
2. Coofing system expansion tank

tmr2011'()23

251

Section 04 FUEL SYSTEM
Subsection 03

(FUEL TANK AND FUEL PUMP)

Fuel Pump Module
The fuel pump module is inserted in the fuel tank.
It provides fuel delivery for the EFI system and encompasses the following components:
- Electric fuel pump
- Fuel pre-filter (replaceable)
- Fuel pressure regulator
- Fuel level sender.

Fuel Filters
The system comprises two levels of filtration.
A replaceable prefilter element attached to the
bottom of the pump, and a non-replaceable fine
filter element that is integral to the fuel pump
module.

Fuel Pump Pressure Regulator
The fuel pressure regulator is integral to the fuel
pump module. The pressure regulator maintains
proper fuel pressure for the EFI system.

INSPECTION
FUEL TANK LEAK TEST

A

WARNING

Always carry out a fuel tank leak test whenever the fuel tank shows signs of wear or
damage which may cause a leak, or when the
fuel pump has been removed or replaced,
or if you suspect a leak. If the fuel tank is
damaged, the fuel tank should be replaced
even if no leak is present. Do not attempt to
repair the fuel tank.
1. Refill fuel tank and ensure fuel tank cap is in
good condition and properly installed.
2. Refer to BODYsubsection and remove the fol lowing:
- RH passenger seat
- RH lateral console panel
- Fuel tank cover panel.
3. Remove the vent hose from the fuel tank vent
valve.
4. Using the VACUUM/PRESSURE PUMP (PIN 529
021 8001 and a short piece of hose, pressurize
the fuel tank through the vent valve.

262

1. Fuel tank vent valve

2. Vent hose to vacuum/pressure pump

PRESSURE

TIME WITHOUT
PRESSURE DROP

14 kPa (2 PSI)

3 minutes

If pressure drops, locate fuelleak(s) and repair or
replace leaking component(s).
To locate a leak. check for a fuel smell or leaking
fuel.
To ease locating leakls), spray soapy water on all
hose connections and components; bubbles will
indicate the leak location Is).

FUEL PUMP PRESSURE TEST
The pressure test will show the available pressure
at the fuel pump outlet. It validates the pressure
regulator, the fuel pump and tests for leaks in the
system.
NOTE: Refer to the FUEL SYSTEM DIAGNOSTIC
FLOW CHARTto help diagnose a fuel system related problem.
1. Ensure there are no leaks from hoses and fittings. Repair any leak.
2. Ensure the fuel level in the tank is sufficient.
3. Before proceeding with the pressure test ensure the battery is fully charged. Battery voltage must be over 12 volts.
4. Connect vehicle to the applicable B.U.D.S. software version and select the following:
- Read Data button
- Activation page tab
- ECM page tab
- Fuel pump Disabled.

tmr201, ·023

Section 04 FUEL SYSTEM
Subsect ion 03

Fuel Pump
(' Enabled

(F UE L TANK A ND FUEL PUMP)

j/r--1
r. [lisabled

Activate

Fyel Pump
~ooling

Fan

Accessory Relay

529036023

T-FITTING

1. Click here to disable the fuel pump

5. Release f uel pressure by running engine until it
runs out of gas.
6. Remove the following items, refer to the BODY
subsection
- Passenger seat
- Fuel tank cover
- RH lateral console panel.
7. Carefully disconnect the fuel pump outlet hose
by pressing on the release tab of the quick disconnect fitting.
S. Install fuel PRESSURE GAUGE (PIN 529 035 7091
and FUEL HOSE ADAPTER (PIN 5290360231 between disconnected hose and fuel rail (in-line
installation).

9. Using B.U.D.S., reactivate fuel pump by selecting Enabl ed.
Fuel Pump

Jl'r--

1
r [lisabled

r. Enabled
Activ.le

Fyel Pump
1;ooling Fan
Acce~sory

Relay

1. Click here to disable the fuel pump

10. Turn ignition key ON and observe fuel pressure.
FUEL PRESSURE

350 kPa (51 PSI)

11. Start eng ine and observe fue l pressure.
12. Stop engine .
13. In B. U.D.S., select the fuel pump Disabled
function.
14. Release fuel pressure by running engine until
it runs out of gas.
15. Remove tool and con nect hose on fuel ra il.

Test Conclusion
The fuel pressure should be within specification in
static or dynamic tests.
A rapid pressure drop after the engine is stopped
indicates leakage either from a fuel hose, fuel ra il,
or from t he f uel pump check valve.
- Check fuel hoses, fuel rai l and fittings for leaks.
If not leaking, replace fuel pump.
tmr201 '·023

253

Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

A slow pressure drop after the engine is stopped
indicates leakage either from a fuel injector or
from the fuel pressure regulator.
- Check fuel injectors for leaks. If not leaking, replace fuel pump.

254

tmr2011-Q23

Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

TROUBLESHOOTING
FUEL SYSTEM DIAGNOSTIC FLOW CHART

I

Fuel pump does not run

Activate electric system to enable fuel pump ~

Fuel pump runs

for 2 sec. th en stops

·t
Install fuel pressure gauge
on fuel pressure line

Check fuse.
Check fuel pump operati on.
Repair or replace if necessary.

t
Replace fuel

-: Activate electric system to enable fuel pump:

pump module

t
Fuel pump runs

I

Repair or

replace

...

...

Fuel pressure less

Fuel pressure within
specifications

than specifications

...
Fuel pressure more
than specifi cation s

'f

Fails

Check fuel line/
rail for leaks

t OK

Fails

Perform fuel pump test

Crank or start
engine

OK--.J

t

t

IFa st
pressure drop

t

Fuel pressure less
than specifications

Fuel pressure more
than specifications

Fuel pressure within
specifications

l-

No

Yes
Verify fuel
pump check
valve

Check
fuel line/
rail for leaks

OK

---.

-Fail.-----...

OK

FJils

4

Check fuel
injector

OK l

OK

Repair or

replace

r-

+

Perform fuel
pump test

FUEL SYSTEM OK

,...

Repla ce fuel
pump module

~

Retest

I

h'nt20'().C23-(lOo1_~en

tmr2011-Q23

255

Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

PROCEDURES
FUEL HOSE AND OETIKER
CLAMPS
Fuel Hose Replacement
When replacing fuel hoses, be sure to use hoses
and clamps as available from BRP parts department. This will ensure continued proper and safe
operation.

A

WARNING

Use of fuel lines other than those recommended by BRP may compromise fuel system integrity.

A

1. Securing clamp in limited access

FUEL TANK
Fuel Tank Draining

WARNING

Whenever removing a hose in the fuel system, always use new Oetiker clamps at assembly. Then validate fuel system tightness
by performing a fuel pressure test.

Remove fuel tank cap and siphon gas into an approved fuel container.

Fuel Tank Removal
1. Drain fuel tank. Refer to FUEL TANK DRAINING
above in this subsection.

Oetiker Clamp Replacement
To secure or cut Oetiker clamps on fuel lines, use
OETI KER PLIERS (PIN 295 000 070).

2. Connect the vehicle to the applicable B.U.D.S.
software version.
3. In B.U.D.S , select the follow ing to disable the
fuel pump:
- Read Data button
- Activation page tab
ECM page tab
- Fuel pump Disabled.
Fuel Pump

r Enabled

Jfr--1
r. Qrsabled

Activate
1. Cutting clamp

FyelPump
Qooling Fan
Acce~sory

Relay

1. Click here to disable the fuel pump
FO l e04A

1. Securing clamp

256

1

4. Release fuel pressure by running engine until it
runs out of gas.
5. Disconnect battery, refer to CHARGING SYSTEM subsection.
Imr2011-023

Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

6. Remove RH passenger seat, refer to the BODY
subsection.
7. Refer to BODY subsection and remove the
body parts indicated in the following illustration.

1, Fuel tank mounting screws (2)

12. Pull fuel tank out from the RH side of vehicle .

Fuel Tank Inspection
Imr2011 .023·Q04. a

TYPICAL
1, RH Lateral bodV panel
2. RH side panel on the console
3. Fuel t8nk cover p8nel

8. Disconnect the fuel pump connector.
9. Remove the vent hose from the fuel tank valve.
10. Disconnect the high pressure fuel hose at the
fuel injectors.

Inspect fuel tank for any damages or cracks which
may result in fuel leaks.
Inspect tank and protector attachment points for
damages.
Inspect protector for damages.
If cracks, gouges or other damages whi ch may
lead to a fuel leak, or damages to attachment
points that could prevent the tan k from being
secure are found, replace fuel tank.

Fuel Tank Installation
The installation is the reverse of the removal procedure. However, pay attention to the following.
Be sure to reinstall the 2 rubber washers between
the fuel tank and the frame.

Be sure to properly connect and route:
- Fuel tank vent tube
- Fuel pump pressure hose
- Electrical connector.
Using B.U.D.S" reactivate fuel pump by selecting
Enabled.
1, r:uel pump Qonnector
2. Vont /7ose
3. High pressure fuel hose

11. Remove fuel tank retaining screws (2).

lIw2011 ·023

257

Section 04 FUEL SYSTEM
Subsection 03

Fuel Pump

[

JI
" Enabled

(FUEL TANK AND FUEL PUMP)

1
r Qisabled

Activate

Fyel Pump
~oolingFan

Acce~sory

Relay

1. Click here to enable fuel pump

Refuel tank and ensure there are no leaks by
performing a FUEL TANK LEAK TESTand a FUEL
PRESSURE TESTas described in this subsection .

FUEL PUMP
Fue l Pump Pressure Test
Refer to INSPECTION in this subsection.

Fuel Pump Quick Test
1. Turn ignition key to ON.
2. Listen for fuel pump operation.

1. Fuel pump fuse

Fuel Pump Input Vo ltage Test
1. Remove RH passenger seat and fuel tank
cover, refer to BODY subsection.
Disconn ect the fuel pump connector.
2. Use the FLUKE 115 MULTIMETER (PIN 529
035 868) with the FLUKE RIGID BACK PROBE
!PIN TP88).

Set multi meter to Vdc.

3. Fuel pump should come ON for a fe w seconds,
then stop.
If fuel pump does operate as in previous steps,
carry out the follow ing:
- Check fuel pump fuse.
- Check in B.U.D.S. for applicable fau lt codes .
Refer to COMMUNICATION TOOLS AND
B. u.D.s. subsection.
- Ca rry out a fue l pump input voltage test.
52903585eta

FLUKE 115 M ULTIMETER

FLUKE RIGID BACK PROBE

3. Set multimeter to Vdc.
4. Turn ignition key ON.
5. Read voltage as follows.
258

tmr2Ql1.o23

Section 04 FUEL SYSTEM
Subsection 03

FUEL PUMP INPUT VOLTAGE TEST
TEST PROBES
Fuel pump
connector
Pin 3

VOLTAGE READING

Fuel pump
connector
Pin 4

(FUEL TANK AND FUEL PUMP)

If resistance test failed, disconnect fuel pump
connector and measure resistance at fuel pump
connector.
FUEL PUMP RESISTANCE TEST
(AT FUEL PUMP CONNECTOR)

Battery voltage

Pins 1 and 2
If battery voltage is read, carry out a fuel pump
resistance test.
If battery voltage is not read, test fuel pump
power input as follows.
FUEL PUMP POWER WIRE TEST
TEST PROBES
Fuel pump
connector
Pin 3

VOLTAGE READING

Battery
ground

Battery voltage

If battery voltage is now read, check fuel pump
ground circuit between fuel pump connector
5-FP-4 and ECM connector 3-B-M1.
If battery voltage is still not read, check fuel pump:
- Fuse (F15)
- Power circuit
- Wiring and connectors.

I

Approximately 2 n

If test failed at pump connector, replace fuel
pump.
If test succeeded at pump connector, check
wiring and connectors from fuse box to ECM
connector. Repair or replace as necessary.

Fuel Pump Removal
1. Using B.U.D.S., select the following to disable
the fuel pump:
- Read Data button
- Activation page tab
- ECM page tab
- Fuel pump Disabled.
cFuel Pump

Ir

Enabled

Jf

r. .Qlsabled

Fuel Pump Resistance Test
1. Remove the fuel pump fuse.
2. Remove connector B from the ECM and connect it to the ECM ADAPTER TOO L (PIN 529 036
166).

Activate

1

1

Fyel Pump
Cooling Fan
Acce~sory

Relay

1, Click here to disable the fuel pump

2. Release fuel pressure by running eng ine until it
runs out of gas.
3. Refer to BODY subsection and remove the
body parts indicated in the following illustration.

529036166

3. Set multimeter to

n.

4. Measure fuel pump resistance as follows.
FUEL PUMP RESISTANCE TEST
(AT ECM AND FUSE)
TEST PROBES
Fuse box
contact 50

tmr2011·023

ECM B-M1

RESISTANCE n
@ 20°C (68°F)
Approximately 2 n

259

Section 04 FUEL SYSTEM
Subsection 03

(FUEL TANK AND FUEL PUMP)

6. Using a soft face hammer and a brass drift in
the notched portion of the locking ring, remove
fuel pump locking ring .

A

WARNING

Fuel vapors are flammable and explosive under certain conditions. Use only non-sparking tools.

TYPICAL
1. RH Lateral body panel
2. RH side panel on the console
3. Fuel tank cover panel

4. Disconnect fuel pump electric connector.

FUEL PUMP LOCKING RING REMOVAL
1. Notch in fuel pump locking ring

7. Carefully pullout fuel pump.

A

7. Fuel pump connector

5. Disconnect high pressure fuel hose at fuel rails
(2 disconnects) .

CAUTION While pulling out the fuel
pump, pay attention to fuel sender float arm ,
Float arm can get stuck and bend reducing fuel
sender accuracy.

8. Discard gasket ring.

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

A

CAUTION Manipulate
care.

fuel

pump

with

1. Install a NEW gasket ring .
2. Place gasket so that it is located between pump
and tank mounting surface.

1,
rail (1 eBc!1 cylinder)
2. High pressure fuel hose disconnect ((1 each cylinder)

260

tmr20 11 ·023

Section 04 FUEL SYSTEM
Subsection 03

(FUEL TANK AND FUEL PUMP)

1. Gasket rmg here
2. Fuel pump flange
3. Pump locking ring

FUEL PUMP LOCKING RING INSTALLATION
1. Notch in locking ring
2. Raised portion in locking ring (5 places)
3. Lock position on rank flange (5 places)

3. Pay attention to pump orientation as in following illustration.

7. Using B.U.D.S., enable the fuel pump.
Fuel Pump -

;/
{>

Enabled

1
r Oisabled

Activate

Fuel Pump
!;.ooling Fan
Acce,S.sory Relay

1. Click here to enable the fuel pump

1. Fuel pump index
2. Fuel tank pump index

4. Insert fuel pump locking ring over the fuel pressure hose and electrica l wiring con nector.
5. While firmly holding pump against tank, engage
fuel pump locking ring on fuel tank flange.
6. Using a soft face hammer and a brass drift in
the notched portion of the locking ring, turn
locking ring until it is fu lly engaged.

A

8. Refuel tank and ensure there are no leaks by
performing a FUEL TANK LEAK TEST and a
FUEL PRESSURE TEST as described in this
subsection.
9. Check fuel level sender operation.

Fuel Pump Strainer Replacement
1. Remove FUEL PUMp, see FUEL PUMP REMOVAL procedure in th is subsection.
2. Unlock 3 tabs on plastic ring .

WARNING

Fuel vapors are flammable and explosive under certain conditions. Use only non-sparking tools. Ensure pump locking ring is fully
engaged.

tmr201 Hl23

261

Section 04 FUEL SYSTEM
Subsection 03

(FUEL TANK AND FUEL PUMP)

Step ,; Lift these tabs to unlock ring
Step 2: Pull nng off pump inlet

NOTE: A non serviceable filter is located in fuel
pump. If it is clogged, replace fuel pump.

3. Remove rubber pad.

6. Insert the new strainer on fuel pump making
sure to press it in tightly against pump face.
7. Press in a NEW push nut to secure strai ner.
S. Reinstall remaining removed parts.

J

)

FUEL LEVEL SENDER
The fuel level sender is a float actuated variable
resistance type that is part of the fuel pump.

vmr20DS-13&-221 _a

4. Remove push nut securing strainer to fuel
pump. Be careful not to break the plastic pin.

(
vmr2000 - 13S.901 _~

TYPICAL - FUEL PUMP
,. Fuel level sender

Fuel Level Sender Resistance Test
1. Remove and disconnect multifunction gauge,
refer to the LIGHTS/GAUGE/ACCESSORIES
subsection.
2. Use a multimeter and select fl.
3. Measure the resistance of the sender as follows.
vm r2008- 1 35-222_~

5. Pull strainer off fuel pump.

262

Imr2011-023

Section 04 FUEL SYSTEM
Subsection 03 (FUEL TANK AND FUEL PUMP)

FUEL LEVEL SENDER RESISTANCE TEST
FUEL LEVEL
Fu ll
Empty

GAUGE
CONNECTOR

RESISTANCE f!
@ 20°C (6S0F)
5f!±1

Pins 4 and 21

100 f! ± 5

Fuel Level Sender Replacement
Replace fuel pump. See fuel pump removal and
installation procedures in this subsection.

FUEL TANK VENT VALVE
Fuel Tank Vent Valve Test
Test for Normal Operation
1. Disconnect vent hose from fuel tank vent valve.
2. Connect the VACUUM/PRESSURE PUMP (P/N 529
021 800) and a short piece of hose to the fuel
tank vent valve.

If readings are out of specification, repeat test
at fu el pump connector. If resistance test at fuel
pump connector is not good, replace fuel level
sender.
If reading s are as specified, carry out a FUEL
LEVEL SENDER /NPUT VOLTAGE TEST

Fuel Level Sender Input Voltage Test
1. Set ignition switch to ON.

1. Fuel tank vent valve
2. Vent hose to vacuum/pressure pump

3. Remove fuel tank cap.
4. Set vacuum/pressure pump to PRESSURE and
activate pump. The gauge on the pump should
not change in reading; air should flow through
the vent valve and fuel tank freely.

2. Disconnect fuel pump connector.
3. Use a multimeter and select Vdc.
4. Measure the input voltage as follows.
FUEL LEVEL SENDER INPUT VOLTAGE TEST
FUEL PUMP
CONNECTOR

BATTERY

VOLTAGE

Pi n 1

Negative
terminal

Battery voltage

If batte ry voltage is not read, test wiring continuity
betw een sender and multifunction gauge.
If wiring continuity is good, replace multifunction
gauge.
If continuity is not obtained, repair or replace
wiring.

tmr2011·023

tmr20 11.o23-003_"

7. Air flows freely in through vent valve
2. Air flows out of fuel tank

263

Section 04 FUEL SYSTEM
Subsection 03

(FUEL TANK AND FUEL PUMP)

5. Set vacuum/pressure pump to VACUUM and
activate pump. The gauge should not change
in reading; air should flow through the vent
valve and fuel tank freely.

Fuel Tank Vent Valve Removal and
Installation
1. When removing or installing the fuel tank vent
valve, pay attention to the following:
- Valve lock position index (dual)
- Valve unlock position index.

1. Air is drawn out freely through vent valve
2. Air flows in fuel tank

Test for Rollover Protection
1. Remove the fuel tank valve, refer to FUEL
TANK VALVE REMOVAL AND INSTALLATION
in this subsection.
2. Turn the valve upside down.
3. Set vacuum/pressure pump to VACUUM and
activate pump. The vacuum gauge reading
should increase; air should not flow through
the valve.

1. Lock position index (dua/)
2. Unlock position index

2. Remove the vent hose from the valve .
3. Use an open end wrench of the appropriate size
on the rectangular portion of the valve to rotate
it to the unlock position for removal.
4. Ensure the wave spring and O-ring seal on the
valve to be installed are in good condition.

2-_oC
1

VALVE DOES NOT LET AIR PASS OUT UPSIDE DOWN

The fuel tank vent valve is defective if air flows
freely through the valve when upside down and
the vacuum indication does not increase on the
pump gauge .

1. O-ring seal
2. Wave spring

5. Insert the valve in the tank.
6. Press down on the valve and rotate it so that
its stem rests between the dual valve locking
position index (see first illustration).
7. Reconnect the vent hose to the valve stem.

264

tmr2011-023

Section 05 ELECTRICAL SYSTEM
Subsection 01

(POWER DISTRIBUTION)

POWER DISTRIBUTION
GENERAL
POWER DISTRIBUTION DIAGRAM
FUSE BOX 1

-b -

I
I
I
I

BAT

+

--------- ..
~
~MF1
~
~
fUSE BOX 2

...

I

I
I
I
I

RELAY (A21

-

30A

I

lOA

F4

I
I

~

7.5A

F5

40A

I
I
I
I

1 _ _ _ _ _ _ - - _ ..

>--l
VOLTAGE
REGULATOR/

>----1

RECTIFIER

~

STARTER RELAY

---1

WINCH RELAY

I

COMMUNICATION
CONNECTOR

I

I
l-

IGNITION COil

H

FUEL INJECTORS

Y

I
I

GAUGE

I
I

TAILLIGHTS

l

BRAKE RELAY IR81

SPEED SENSOR

ECM

I
I

RELAY IRJI

I
I

I f)
I
I
I
I
I
I
I

rl

SA

F6

ACCESSORIES

I

I BRAKE LIGHTS
SWITCH

I

I
I
I
I

>--l

I

MF2

I
I
I

MAIN

~

SA

,~

I
I
I
I
I

I

SWITCHES ILLUMINATION

,-

2WD/4WQ SWITCH
WINCH SWITCH

GAUG E

I F8
I

I
I
I
I
I
I
I
I

5AH

IGNITION SWITCH

I
I
I
I
I
I

F9

I
30A I

I
I

FAN RELAYfRl )

I
I

_0-

I
I

FlO

SA

EURO CONTROlS
I
I

FII

30A
I

I

LIGHTS RELAY

-l
.--j

--1

fAN MOTOR

CONSOLE ACCESSORY

CONNECTOR IIDC31
12·VOlT POWER ounET

I

Fl2

I
lSA I

I
I

UNDEA DASH ACCESSORY

CONNECTOR IOC'I

I

H_FI3

SA

I I
I

o-j

COMMUNICATION
CONNECTOR

I

I
I
I
I

I

Y

FI4

15A I •

F15

SA I
I

I
I
I

1_ ............... _ ...... _ ........................

I

I

I

CONSOLE ACCESSORY
CONNECTOR 2IOCSI

I

FUEL PUMP

I

.J

tmr20 l ,024·00 ' _lIn

tmr2011-o24

265

Section 05 ELECTRICAL SYSTEM
Subsection 01 (POWER DISTRIBUTION)

FUSE BOX 1

RELAY IDENTIFICATION

Relays

1

Cooling fan

2

Main

3

Accessories

4

Headlights

8

Brake lights

FUSE BOX 2

tmr20 11·024-004_a

FUSE IDENTIFICATION

Fuse

4

10 A

5

7.5 A

6

5 A

7

5A

8

5A

9

30 A

10

5 A

11

30 A

12

15 A

13

5 A

14

15 A

15

5A

FUSE IDENTIFICATION
Fuse
2

2-~"

Main

30 A

Fan/accessories

40 A

oW--1

4

8

266

3

tmr20 11-024

Section 05 ELECTRICAL SYSTEM
Subsection 02 (CONTROLLER AREA NETWORK (CAN))

CONTROLLER AREA NETWORK (CAN)
GENERAL
SYSTEM DESCRIPTION
The CAN (Controller Area Network) protocol is an
ISO standard for serial data communication. The
CAN bus links the ECM and multifunction gauge
together so that they communicate to interact
as required. The components are connected
together by 2 wires and they are in constant
communication with each other at a rate of about
every 20 milliseconds. CAN lines consist of a pair
of wires (WHITE/BEIGE and BEIGE/GREEN).
If a component or system malfunction is detected,
a module (ECM or multifunction gauge) may generate a fault code, which it transmits through the
CAN bus as a signa l. The fault signal may be used
for various functions such as triggering the display
of an error message in the multifunction gauge
cluster, turning on a fault indicator light, limiting or
inhibiting vehicle or engine operation, or viewed
using the B.U.D.S. software for troubleshooting.

CAN-HI
WHITE/BEIGE

B-C1 l
ECM

00

B- C2 1

DB-2

DB

CI-41
~

~~
DB-1

@;)
CI- 18 1

BEIGE/GREEN

CAN-LO
tmr201 1-cJ25-00 1_8

CLUSTER: Multifunction Gauge
DB: Diagnostic Connector
ECM: Engine Control Module
WH/BE: White/Beige

BElGN: Beige/Green

tm r2011 -025

267

268

Section 05 ELECTRICAL SYSTEM
Subsection 03

(IGNITION SYSTEM)

IGNITION SYSTEM
SERVICE TOOLS
Description

Part Number

ECM ADAPTER TOOL
FLUKE 115 MULTIMETER

529036 166
529035868

GENERAL

A

WARNING

Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners,
cotter pins, etc.) must be replaced.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory standards.

The EMS controls the ignition system. For more
information, refer to ENGINE MANAGEMENT
section.

Ignition Timing

....... 271

.... 271

ENGINE WILL NOT START (ENGINE
TURNS OVER)
1.

Fouled or defective spark plug
- Replace.

2.

Defective CPS
- Check operation of CPS and replace if necessary.
Refer to ELECTRONIC FUEL INJECTION section.

3.

Defective trigger wheel
- Check. Refer to PTO HOUSING/MAGNETO.

4.

Defective ignition circuit
- Check fuse 5 of fuse box 1, ignition coil and wiring
condition.

5.

Defective fuel pump
- Check fuel pump, refer to FUEL SYSTEM.

6.

Defective fuel injectors or circuit
- Check fuel injectors, refer to ENGINE MANAGEMENT

SYSTEM DESCRIPTION
The battery supplies the primary side of ignition
coil through the main relay (R2) while the ECM
completes the circuit for each cylinder by switching it to the ground at the right moment. The ECM
can detect open and short circuit in the primary
winding but it does not check the secondary winding.

Page

ENGINE HARD TO START
1.

Spark plug faulty, fouled or worn out
- Check spark plug condition. Replace if necessary.

2.

Low fuel pressure
- Test fuel pressure, refer to FUEL SYSTEM.

Ignition timing is not adjustable.
ENGINE MISFIRES, RUNS IRREGULARLY

TROUBLESHOOTING

1.

It is good practice to check for fault codes using
the B.U.D.S. software as a first troubleshooting
step. Refer to DIAGNOSTIC SYSTEM AND FAULT
CODES subsection.

Fouled, defective, worn spark plugs
- Check/verify heat range/gap/replace .

2.

Damaged trigger wheel/loose CPS
- Check. Refer to PTO HOUSING/MAGNETO.

Always refer to the WIRING DIAGRAM when
troubleshooting an electrical circuit.

3.

Defective ignition circuit
- Check ignition coil, fuse 5, and wiring condition.

Refer to POWER DISTRIBUTION for fuse and relay information.

4.

Poor engine grounds
- Check/ciean/repair

DIAGNOSTIC GUIDELINES
The following is provided to help in diagnosing the
probable cause of a problem. It is a guideline and
should not be assumed to list all possible causes.
tmr2011-026

269

Section 05 ELECTRICAL SYSTEM
Subsection 03 (IGNITION SYSTEM)

ENGINE CONTINUALLY BACKFIRES

IGNITION COIL

1. Fouled, defective spark plugs
- Clean/ replace.

2.

Damaged trigger wheel/defective or loose CPS
- Check, refer to ELECTRONIC FUEL INJECTION.

PROCEDURES
IGNITION SWITCH
Ignition Switch Quick Test
Turn ignition switch to ON position.
If multifunction gauge turns on (assuming it
works), the ignition switch is good.
If multifunction gauge does not turn on, check the
following in this order:
- Battery
- Fuses 1 and 2 of fuse box 2
- Fuse 4 and 8 of fuse box 1
- ECM is properly powered (refer to ENG/NE

MANAGEMENT!
- Ignition switch.

Ignition Coil Access
Refer to BODYand remove upper console.

Ignition Coil Installation
Install a new elastic nut and tighten to the specified torque.

Ignition Switch Access
Refer to BODY and remove upper console.

IGNITION COIL RETAINING BOLT
TIGHTENING TORQUE

Ignition Switch Wire Identification

8 Nom ± 1 Nom (71 Ibfoin ± 9 lbf oin)

FUNCTION

PIN

WIRE COLOR

Quick Test with S,U.D,S.

12 Vdc output (lights)

A

YELLOW/BLUE

12 Vdc input

B

BEIGE/WHITE

Ground (through
ECM)

Connect to the latest applicable B.U.D.S. software. Refer to COMMUN/CATION TOOLS AND
B.U.D.S. section.

C

ORANGENIOLET

Ground signal to
ECM in OFF position

In B.U.D.S., select the Activation tab and the
ECM tab.

D

YELLOW/ORANGE

D.E.S.S. signal

E

ORANGE/RED

You should hear the spark occurring. In doubt, use
an inductive spark tester. If there is no spark, perform the following checks.

12 Vdc output (ECM,
starter solenoid and
start switch)

F

BLACK/YELLOW

NOTE: Keep in mind that even if there is a spark
during this static test, voltage requirement is
higher to produce a spark in the combustion
chamber when engine is running. Ignition coil
could be not working in real operation. Replacing
ignition coil may be necessary as a test
NOTE: Ensure spark plug cable is on the appropriate cylinder.

Ignition Coil Input Voltage Test
Disconnect the 3-pin connector from the ignition
coil.

270

tmr2011·026

Section 05 ELECTRICAL SYSTEM
Subsection 03 (IGNITION SYSTEM)

COMPONENT

PIN
(IGNITION
COIL
CONNECTOR)

PIN
(ECM
CONNECTOR)

Cylinder 1 (front)

1

A-M1

Cylinder 2 (rear)

3

A-M2

Ignition Coil Resistance Test
An ignition coi l w ith good resistance measurement can still be faulty. Voltage leak can occur
at high voltage level which is not detectable with
an ohmmeter. Replacing the ignition coil may be
necessary as a test.

7. Ignition coil connector

Turn ignition switch to ON.
Using a the FLUKE 115 MULTIMETER !PIN 529035
8681, read voltage.

Disconnect ignition cables from spark plugs.
Primary Windings
Disconnect ECM "A" connector and connect it to
the ECM ADAPTER TOOL (PIN 529036 166).
Using a mu lti meter, check resistance in primary
windings as follows.
PRIMARY
CIRCUIT
Cylinder 1
(front)
Cylinder 2
(rear)

5ze035868

IGNITION COIL
CONNECTOR
Pin 2 with battery ground

ENGINE
CONNECTOR
IHIC)

ECM
RESISTANCE
CONNECTOR
@20°C(WF)
"A"
A-Ml

.3 - .6

Pin E

n

A-M2

VOLTAGE
Battery voltage '

If any resistance is not good, measure resistance
directly on coil. If second test is ok, check wiring

Battery voltage should be read.

Secondary Windings

If Battery voltage is NOT read, check continuity of
ignition coil supply circuit.

Due to the integrated diode, it is not possible
to take any resistance measurement of the secondary winding .

Ignition Coil Ground Circuit Continuity
Test
Disconnect the ECM connector" A" and connect
it to the ECM ADAPTER TOOL !PIN 529 036 166).

SPARK PLUG
For spark plug replacement procedure, refer to
PERIODIC MAINTENANCE PROCEDURE subsection.

Troubleshooting Fouled Spark Plug

529036166

Check wiring continuity as per following table.
tmr2011.o26

Fouling of the spark plug is indicated by irregu lar
running of the engine, decreased engine speed
due to misfiring, reduced performance, and increased fuel consumption. This is due to a loss
of compression. Other possible causes are: prolonged idling or low-speed rid ing, a clogged air
filter, incorrect fuel, defective ignition system,
incorrect spark plug gap, lubricating oil entering
the combustion chamber, or too cold spark plug.
The plug face of a fouled spark plug has either a
271

Section 05 ELECTRICAL SYSTEM
Subsection 03 (IGNITION SYSTEM)

wet black deposit or a black carbon fouling. Such
coatings form a conductive connection between
the center electrode and ground.

Spark Plug Analysis

AOOEOAA

2

3

TYPICAL
1. Overheated (light grey, white)
2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, grey, melted coating)

The plug face reveals the condition of the engine,
operating condition, method of driving and fuel
mixture. For this reason it is advisable to inspect
the spark plug at regular intervals, examining the
plug face (i.e. the part of the plug projecting into
the combustion chamber).

272

tmr2Q II -026

Section 05 ELECTRICAL SYSTEM
Subsection 04 (CHARGING SYSTEM)

CHARGING SYSTEM
SERVICE TOOLS - OTHER SUPPLIER
Description

Part Number

NAPA ULTRA PRO BATIERY LOAD TESTER

95260

Page

"."." "" .""" " .... ,," """...275

SERVICE PRODUCTS
Description

Part Number

Page

DIELECTRIC GREASE. "" " ."" " ". " ." "" """ .,, " " ." ." """.,,"" "."" . 293550004 "" ""."" """" " """" """"" 275

GENERAL
SYSTEM DESCRIPTION
The purpose of the charging system is to keep
the battery at a full state of charge and to provide
the electrical system with the requ ired electrical
power for normal vehicle operation .

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.

rm' 20 1().027-®4

TYPICAL - VOLTAGE REGULATOR/RECTIFIER

Battery
The battery supplies DC power to the electric
starter for cranking the engine. During engine
starting, it also supplies DC power to the entire
electrical system .
At low engine RPM operation and high current
load conditions, it supplements the magneto
output and helps to maintain a steady system
voltage.

INSPECTION
CHARGING SYSTEM OUTPUT
First ensure that battery is in good condition prior
to performing the following tests.
vm,2006<11HlQl

TYPICAL

Voltage Regulator/Rectifier
The rectifier receives AC current from the magneto and transforms it into direct current (DC) .
The voltage regulator. included in the same unit,
limits voltage to prevent any damage to electrical
components.

Imr2011-027

Output Voltage Test Using B.U.D.S.
1. Connect to the latest applicable B.U.D.S. software. Refer to COMMUNICATION TOOLS
AND B. U. D. S. subsection.
2. In B.U.D.S. , select the Monitoring tab then the
ECM tab.
3. Start engine.

273

Section 05 ELECTRICAL SYSTEM
Subsection 04 (CHARGING SYSTEM)

4. Increase engine RPM as specified in the following table and read voltage in the ECM Input
Voltage box.

BATTERY REGULARLY DISCHARGED OR
WEAK
1.

Loose or corroded battery cables connections.
- lighten or repair battery cables connections.

2.

Worn or defective battery.

OUTPUT VOLTAGE TEST USING B.U.D.S.
ENGINE SPEED

VOLTAGE (DC)

4000 RPM

14.8 ± .4 Vdc

- Charge and test battery.
3.

Defective magneto stator.

- Test stator.
4.

Defective regulator/ rectifier.
- Test system voltage.

5.

Damaged magneto rotor or Woodruff key.
- Replace magneto rotor or Woodruff key.

C~~~

&.10014. 1;

o....ido

..

$poI!~ . . _ _ ... _I'SIJ"(i"4

,-

1. ECM Input Voltage box

PROCEDURES
VOLTAGE REGULATOR/
RECTIFIER

If voltage is above specification, replace voltage
reg ulater/rectifie r.
If voltage is below specification, check stator
output and wiring harness prier to concluding that
voltage regulator/rectifier is defective. Refer to
MAGNETO SYSTEM subsection.

Due to internal circuitry, there is no static test
available.

Output Voltage Test Using a
Multimeter

The voltage regulator/rectifier is located on the LH
side, underneath dashboard, on the RH side of the
battery rack.

1. Set multi meter to Vdc.
2. Connect multimeter to battery posts.
3. Start engine.

Voltage Regulator/Rectifier Static Test

Voltage Regulator/Rectifier Access

Voltage Regulator/Rectifier Wire
Identification

4. Increase engine RPM as specified in the following table and read voltage with the multi meter.

FUNCTION

PIN

COLOR

12 Vdc output

RD1-1

RED

OUTPUT VOLTAGE TEST USING A MULTIMETER

12 Vdc ground

RDl-3

BLACK

TEST ENG INE SPEED

VOLTAGE (DC)

12 Vac input

RD2-1

YELLOW

4000 RPM

14.8 ± .4 Vdc

12 Vac input

RD2-2

YELLOW

12 Vac input

RD2-3

YELLOW

If voltage is above specification, replace voltage
reg ulator/rectifi er.
If voltage is below specification, check stater and
wiring harness prior to concluding that voltage
regulator/rectifier is defective. Refer to MAGNETO SYSTEM subsection.

TROUBLESHOOTING
It is good practice to check for fault codes using
the B.U.D.S. software as a first troubleshooting
step. Refer to D/AGNOSTIC SYSTEM AND FAULT
CODES subsection.

274

BATTERY
Battery Information
These vehicles are equipped with a VRLA battery
(Valve Regulated Lead Acid). It is a maintenancefree type battery.
Refer to battery manufacturer's instructions for
proper filling, activation and routine charging procedures.

tmr2011.()27

Section 05 ELECTRICAL SYSTEM
Subsection 04 (CHARGING SYSTEM)

Battery Voltage Test (No Load Applied)
NOTE: A voltage test is carried out on a battery
without discharging current. It is the simplest and
most commonly used. However, be aware that
the voltage test can be good, while the battery
does not have enough power to crank the engine.
A load test gives a more accurate condition of the
battery.
A voltage reading provides an instant indication of
the state of charge of the battery, not of it's current output capacity. A load test gives a more accurate indication of the battery's condition .
If the battery has just received a charge, allow it to
rest for 1 - 2 hours before taking a voltage reading.
Set multi meter to Vdc and connect to battery terminals. Always respect polarity.
FULLY CHARGED BAITERY VOLTAGE

NOTE: A battery that shows a voltage of 12.0 Vdc
is considered completely discharged and need to
be recharged.

Battery Load Test
This is the best test to indicate a battery condition.
Use a load testing device such as the NAPA ULTRA
PRO BAITERY LOAD TESTER (PI N 952601. It has a
500 Amp adjustable load.
Apply a load of 3 times the ampere-hour rating of
the battery. At 14 seconds into the test, check
battery voltage .

14 seconds

VOLTAGE
Min. 10.5 Vdc
20'C (68'F)

3. Unhook the top of battery strap.
4. Remove battery.

Battery Cleaning

12.6 Vdc minimum

TIME TO MEASURE
INTO TEST

1. Battery strap
2. Battery strap retaining nut

@

Battery Removal
1. Disconnect BLACK (-) cable first, then the RED
(+) cable.

Clean the battery rack, cables and battery posts
using a solution of baking soda and water.
Remove corrosion (if so) from battery cable terminals and battery posts using a firm wire brush.
Rinse with clear water and dry well.

Battery Storage
If the battery is in storage or used infrequently,
disconnect the battery cables to eliminate drain
from electrical equipment.
For extended storage, remove the battery from
vehicle.
Clean battery terminals and cable connections using a wire brush. Apply a light coat of DIELECTRIC
GREASE (PIN 293 550004) on terminals.
Clean battery casing using a solution of baking
soda and water. Rinse battery with clear water
and dry wel l using a clean cloth.
Regularly charge battery as per manufacturer's
recommendations.
For other recommendations during storage, refer
to battery manufacturer's instructions.

Il!lnitljOj

Always respect this order for removal; disconnect BLACK (-) cable first.

2. Remove battery strap retaining nut.

Battery Installation

WnWOj Always connect RED (+) cable first
then BLACK (-) cable.

tmr201 1-o27

275

Section 05 ELECTRICAL SYSTEM
Subsection 04 (CHARGING SYSTEM)

Installation is the reverse of removal procedure,
however pay attention to the following:
- Install the battery with the positive post down.
- Tighten battery strap retaining nut to the specified torque.
BATTERY STRAP RETAINING NUT
TIGHTENING TORGUE
3.4 Nom ± 0.3 Nom 130 Ibloin ± 3lbl o in)

276

Imr201'-027

Section 05 ELECTRICAL SYSTEM
Subsection 05

(STARTING SYSTEM)

STARTING SYSTEM
SERVICE TOOLS
Description

Part Number

ECM ADAPTER TOOL
FLUKE 115 MULTIMETER .....

529036 166 ........................................ 278
529035868 ........................................ 279

Page

SERVICE PRODUCTS
Part Number
Page
DIELECTRIC GREASE ............... ........ ........................ . 293 550 004 .......... .................... ........... 281

Description

GENERAL

A

WARNING

Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners,
cotter pins, etc.) must be replaced.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory standards.

SYSTEM DESCRIPTION
The starting system is composed of an electric
starter supplied in current by the battery through
a solenoid.
The starter solenoid receives a 12 volt input from
the ignition switch and the ground signal is provided by the ECM when the following engine
cranking conditions are met.
- Ignition switch ON.
- Transmission in Park or Neutral position and/or
brake pedal held.
- Start button held.
NOTE: If the ignition switch is left ON for more
than 15 minutes, engine will not start unless ignition switch is turned OFF, then ON again.

Always refer to the WIRING DIAGRAM when
troubleshooting an electrical circuit.
Refer to POWER DISTRIBUTION for fuse and relay information.
Check all connections, cables and wires. Tighten
any loose connections. Replace any chafed or corroded wires/cables.

DIAGNOSTIC GUIDELINES
FUSE 8 INFUSE BOX 1 BURNS WHILE
ATIEMPTING TO CRANK ENGINE
1.

- Test diode, see procedure in this subsection.

2.

tmr2011-028

Defective starter solenoid
- Test starter solenoid, see procedure in this subsection.

3. Wiring short to ground
- Check wiring.

ENGINE DOES NOT CRANK AND GAUGE
DOES NOT TURN ON
1.

Burnt main fuse (F1) in fuse box 2
- Check fuse.

2.

Burnt fuse Fa in fuse box 1
- Check fuse.

3.

Defective or discharged battery
- Test battery, refer to CHARGING SYSTEM

TROUBLESHOOTING
It is good practice to check for fault codes using
the B.U.D.S. software as a first troubleshooting
step. Refer to DIAGNOSTIC SYSTEM AND FAULT
CODES subsection.
NOTE: Clear any fault code after solving a problem.

Defective 02 Diode

4.

Defective ignition switch or circuit
- Check ignition switch, refer to IGNITION SYSTEM

277

Section 05 ELECTRICAL SYSTEM
Subsection 05 (STARTING SYSTEM)

ENGINE DOES NOT CRANK BUT GAUGE
TURNS ON
1.

Defective brake switch
- Check brake switch. refer to BRAKES section.

2.

Defective gearbox position sensor (GPBS)
- Check GPBS, refer to GEARBOX AND 4X4 COUPLING UNIT subsection.

3.

Defective start button or circuit
- Test start button, see procedure in this subsection.

4.

Defective starter solenoid or circuit
- Test starter solenoid, see procedure in this sub-

section.
5.

Defective starter motor
- Check starter motor, see procedure in this subsection.

6. Test diode as per following table.
02 DIODE TEST

PROCEDURES
D2 DIODE (STARTER SOLENOID)
Diode Location
The diode is located in the main harness, near
starter solenoid.

Diode Test
1. Make sure ignition switch is OFF.

MULTIMETER
POSITIVE
PROBE

MULTIMETER
NEGATIVE
PROBE

RESULT

ECM-B pin A2

ECM-B pin L4

Overload (open)

ECM-B pin L4

ECM-B pin A2

Approximately
0.5 volts

If diode fail any test, replace it.

2. Disconnect pins SS1 and SS2 from starter solenoid.

START BUTTON

3. Disconnect ECM connector B.

Start Button Access

4. Connect ECM ADAPTER TOOL (P/N 529 036 166)
to the ECM connector B.

Remove upper console.

Start Button Wire Identification
FUNCTION

PIN

COLOR

12 volt input from ignition
switch

1

BLACK/YELLOW

12 volt output to ECM-B
pin 01

2

YELLOW/RED

Start Button Test with B,U,D,S,
529036166

5. Set multi meter to "diode check".

Connect to the latest applicable B.U.D.S. software. Refer to COMMUNICATION TOOLS AND
S.U.D.S. section.
In B.U.D.S., select the Monitoring and ECM tabs.
Press the vehicle's start button and look at the
Start Button LED.

278

lm r2011-028

Section 05 ELECTRICAL SYSTEM
Su bsection 05 (STARTING SYSTEM )

I

Start Button

It should turn on,
reach es the ECM.

o

indicating the start signal

If starter does not run, carry out the STARTER SOLENOID WINDING RESISTANCE TEST

Sta rter Solenoid Input Voltage Test
1. Disconnect connector with BLACK/Y ELLOW
w ire.
2. Turn ignition switch ON.

If it does not turn on, check the start button and
wIring.

3. Measu re vo ltage as pe r fo ll owing tab le.
STARTER SOLENOID INPUT VOLTAGE TEST

Start Button Res istance Test
TEST PROBES

Disconnect start button connector.
Using the FLUKE 115 MULTIMETER (PIN 529 035
868), measure resistance as per the following
table.
POS ITIO N

STA RT BUTTON
CO NNECTOR PI N

Battery voltage

Starter Soleno id Ground Signal Test
Infinite (OL)

1

Battery ground

RESISTANCE

Switch
released
Switch
depressed
and held

BLACK!
YELLOW
wire

RESULT
(START BUTTON
RELEASED )

2
0.6 11 max .

1. Disconnect SS2 (ORANGE/BROWN) from solenoid.
2. Turn ignition switch ON.
3. Measure voltage as per following tab le.
STARTER SOLENOID GROUND SIGNAL TEST

Replace start button if defective.

TEST PR OBE S

STARTER SOLEN OID
Starter Sol eno id Access
The starter solenoid is located on the LH side, underneath dashboard, on top of battery rack.
To access starter solenoid , remove the CVT vent
inlet tube.

Starter Solenoid Wire Identification

ORANGEI
BROWN
wire

Battery
positive post

RESULT
(START BUTTON
DEPRESSED )
Battery voltage

Starte r Solenoid Winding Resistance
Test
Disconnect terminals from solenoid.

FUNCTI ON

PIN

WIRE
COLOR

With a multimeter, check primary winding res istance as f o llows .

12 volt input from
ignition switch

SS1

BLACKI
YELLOW

STARTER SOLENOID WINDING
RESISTANCE TEST

Ground from ECM-B
pin L4

SS2

ORANGEI
BROWN

Starter Soleno id Ope rational Te st
1. Disconnect both termina ls (SS1 and SS2) from
the starter solenoid .

TEST PROBES
Starter
solenoid
SS1 pin

Starter
solenoid SS2
pin

RESULT @ 20°C
(68°F)
Approxi mately 5 11

2. Connect SS1 to the positive battery terminal.

If measurement is out of specification, replace solenoid.

3. Momentarily connect
ground.

Starter Solenoid Voltage Drop Test

SS2

to

the

chassis

If starter runs, carry out the STARTER SOLENOID
INPUT VOLTAGE TEST

tmr2011-028

Turn ign ition key ON.

279

Section 05 ELECTRICAL SYSTEM
Subsection 05

(STARTING SYSTEM)

Measure voltage as per follow ing table w hile
cranking engine in drowned mode (to prevent
engine starting).

Disconnect BLACK (-) cable from battery.

NOTE: For drowned mode, refer to ENGINE
MANAGEMENT subsection .
STARTER SOLENOID VOLTAGE DROP TEST

TEST PROBES
Post com ing
from battery

Post going to
starter

RESULT (WHILE
CRANKING)

Disconnect RED (+) cable from starter.
Clean starter area.
Remove starter retaining screw.

0.2 Vdc max.

vm,2006-01~10_lI

TYPICAL - SOME PARTS REMOVED FOR CLARITY PURPOSE
ONLY

Carefully pry starter out of the engine crankcase.

Starter Installation
If voltage is out of specification, replace solenoid.

ELECTRIC STARTER
Starter Access
To access starter electrical terminal, refer to
BODY and remove LH seat and LH lateral console panel.
To access starter for removal, remove drive pulley, driven pulley and CVT back cover, refer to
CONTINUOUSL Y VARIABLE TRANSMISSION
(CVT) subsection.

Installation is the reverse of removal procedure.
However, pay particular attention to the following.
Make sure that starter and engine mating surfaces
are free of debris. Serious problem may arise if
the starter is not properly aligned.
Bring starter close to its location. Rotate it so
that its mounting ear allows installation in engine
crankcase.
Push starter in place and align mounting ear to install screw. 1ighten to the specified torque.
STARTER MOUNTING SCREW TIGHTENING
TORQUE

Starter Operation Test
Using booster cables , carefully supply current
from a 12 volt battery directly to the starter. Connect the BLACK (-) cable first. Then connect the
remaining jumper cable from the battery then to
the starter.
If starter turns, test other starting system components.

Starter mounting screw

I

25 Nom (18Ibf oft)

Connect the RED (+) cable to the starter and
tighten nut and apply specified product.

A

CAUTION When connecting the RED (+)
cable to the starter motor, make sure the battery cables are disconnected.

Starter Removal
Turn OFF ignition switch.
280

tmr2011.()28

Section 05 ELECTRICAL SYSTEM
Subsection 05 (STARTING SYSTEM)

STARTER CABLE NUT
TIGHTENING TORQUE

PRODUCT

6 Nom (53 Ibf oin)

DIELECTRIC GREASE
(PIN 293 550 004)

First connect RED (+) cable to battery then connect the BLACK (-) cable.
Connect battery cables.

Test starter operation.

tmr2011·028

281

282

Section 05 ELECTRICAL SYSTEM
Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

DIGITALLY ENCODED SECURITY
SYSTEM (D.E.S.S.)
GENERAL
SYSTEM DESCRIPTION
The ignition key contains a ROM chip with a
unique digital code that is the equivalent of a
unique teeth pattern on a conventional key.
When the ignition key is turned ON, the ECM
reads the ignition key and, if it is not recognized,
no engine starting will be possible.
NOTE: When a key is not recognized by the ECM,
INVALID KEY will be displayed in the multifunction
speedometer.
NOTE: All ignition keys have the same teeth
pattern. Therefore, they can be used and turned
in the switch of any D.E.S.S.-equipped vehicle.
However, unless the D.E.S.S. system recognizes
(in the ECM) a valid programmed key, the engine
starting will not be allowed.
NOTE: Actually, it is the memory of the ECM that
is programmed to recognize the digital code of the
ignition key.
Up to 10 ignition keys may be programmed in the
memory of the ECM. They can also be erased individually or all at once.
Note that the D.E.S.S. circuitry is already activated
on all new ECM.

The B.U.D .S. software is designed to allow,
among other things, the programming of ignition
key(s) and entering customer information.
For more information pertaining to the use of the
software B.U.D.S., use its help which contains detailed information on its functions.

A

WARNING

If the computer you are using is connected
to the 110 Vac power outlet, there is a potential risk of electrocution when working in contact with water. Be careful not to touch water
while working with the VCK.
1. Turn ignition switch to ON using any of the key
provided with the vehicle. DO NOT start the
engine.
2. Start B.U.D.S. and logon.
3. Wait during detection setup.
4. Ensure the status bar shows the Kw2000 protocol and the appropriate number of modules to
its right according to the vehicle model.

2

TROUBLESHOOTING
DIAGNOSTIC TIPS
NOTE: It is a good pract ice to check for fault
codes using B.U.D.S. software as a first troubleshooting step.
If D.E.S.S . key is not recognized by the ECM, key
is defective or there is a wiring problem, CHECK
ENGINE light will turn on and a message will be
displayed in the multifunction speedometer.

PROCEDURES
KEY PROGRAMMING
Use the appropriate B.U.D.s. software version
available from BOSSWeb. Refer to COMMUNICATION TOOLS AND S.U.D.S SOFTWARE
subsection for proper connection instructions.

tmr2011·029

TYPICAL - SUCCESSFUL CONNECTION
7. Connection protocol
2. Number of modules

5. Click the Read Data button.
!

file ~iew MEI® Module 100ls !:!elp

~

j
1..'0<:1'; Data

~

"+

Write Data

6. Click on Keys tab .

283

Section 05 ELECTRICAL SYSTEM
Subsection 06 (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

14. Program the other key by selecting the right
type according to above chart.
15. Repeat previous steps to program other keys.
16. Click on Write Data button to transfer new
settings and information to the ECM.

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tmr2011.()29-00,

KEYS TAB

Read Data

7. Click on Erase All Keys button .

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1--:-'-;----1:::
t "::'==_
''''
K

F

ErllseKey

- -,,'::
,,"'
, ..'-'""",- -

I

+
,

WRITE DATA BUTTON

17. Click on EXIT button to end session.

]

Add fMotmance Key

1_ _ "",
--,,,,,,,,,,
__
,,,,;.......

18. Disco nnect all cables and hardware from vehicle .
19. Ensure to reinstall the connector into its housing .

1. Click here to erase all keys

8. Click "Y ES" to confirm the action.
9. Confirm key color in ignition switch .
10. Program the key by selecting the right type
according to chart.
KEY

KEY TYPE

BLACK key

Performance key

GRAY key

Normal key

NOTE: The work key (ORANGE key) is optional.
"

'.
"
"

,,"

'*
""

+

,~

"
- ,,-

"

or . ,I<..,.

, "'! . . . . .

.---------------------------~
PROPELLER SHAFT

~

~&.-)IU
XPS Synthetic
grease

 : Hi-temp bearing grease
NlGI.2 or equivalent

~.

~

'

225±15N·m
1166 ± 11 Ibfoftl

~-~

~!
J

XPS Synthetic
grease

!Em = Component must be replaced
when removed

tm r2 011{132.(lO I.a

306

tmr2011-032

Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

32.5 ± 3.5 N·m
(24 ± 3 Ibfoft)

1

--_/

10

7.5 ± 0.5 Nom
(66::1: 4Ibf·in)

(133 ± 11 Ibfoft)
LEFT HAND
THREADED

XPS
Synthetic
grease

tmr2011·032

11m = Component must be replaced when removed

307

Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

GENERAL
During assembly/installation, use torque values
and service products as in the exploded views.
Clean threads before applying a threadlocker. Refer to SELF·LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

A

WARNING

Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed (e.g .: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory standards.

Remove wheel hub.

Wheel Hub Inspection
Check wheel hub for cracks or other damages.

PROCEDURES

Check inner splines for wear or other damages.
If any damage is detected on wheel hUb, replace
it with a new one.

WHEEL HUB

Check wear ring. If it is loose on hub or deformed,
replace the wear ring.

Wheel Hub Removal
Lift and support vehicle. Refer to INTROOUCTlON section for proper procedure.
Remove the wheel.
Remove the following parts:
- Cotter pin
- Wheel hub nut
- Belleville washer.

2

V07H1SA

TYPICAL - LH WHEEL HUB SHOWN
1. Whee l hub
2. Wear ring

Wheel Hub Installation
The installation is the reverse of removal procedure. Pay attention to the following.
Apply XPS SYNTHETIC GREASE !PIN 293 550 0101 on
drive shaft splines.
1, Cotter pin
2. Wheel hub nut
3. Belleville washer

NOTE: On RH side, remove also the brake caliper.

308

Install Belleville washer with its concave side to·
wards outward.
PART

TORQUE

Wheel hub nut

225Nom ± 15N om
(166lblolt ± 11 Iblolt)

Imr2011-032

Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

NOTE: Tighten further castellated nut if required
to align grooves with drive shaft hole.
Install a NEW cotter pin.

=
V01HOFA

1. Stop ring

After drive shaft insertion in rear final drive, validate if properly locked.

DRIVE SHAFT
Drive Shaft Removal
Lift and support vehicle. Refer to INTRODUCTION section for proper procedure.
Remove the wheel hub. See procedure in this
subsection.
Remove trailing arm. Refer to REAR SUSPENSION
Strongly pull drive shaft out of final drive.

Drive Shaft Inspection
Inspect the condition of boots. If there is any damage or evidence of leaking lubricant, replace them.
Refer to DRIVE SHAFT BOOT.
Check shaft splines. Replace drive shaft if necessary.
Check dust shield on drive shaft end. Replace if
necessary.

Drive Shaft Installation
The installation is the reverse of the removal procedure. However, pay attention to the following.
Install a NEW stop ring.

DRIVE SHAFT BOOT
Drive Shaft Boot Removal
Remove the drive shaft from vehicle. See procedure in this subsection.
Remove drive shaft boot clamps using the following tools:
TOOL
OETIKER PLIERS
(PIN 295 000 069)

~

OETIKER PLIERS
(PIN 295 000 070)

~

Dislodge the large boot end.
Separate the joint from the shaft. Two procedures
can be done.
Without the Special Tool
Clamp joint housing in a vise.
Align shaft with joint.
Pull hard on shaft to remove from joint.
Remove boot from drive shaft.
Remove and discard the circlip. A new one is included in the boot kit.
With the Special Tool
Place drive shaft in vice with the joint downward.
Install the CV JOINT EXTRACTOR !PIN 529036005)
on bearing.

Imr2011-o32

309

Section 06 DRIVE SYSTEM
Subsection 02

(REAR DRIVE)

8. Remove the propeller shaft.

Propeller Shaft Inspection
Inspect if propeller shaft is not bent or twisted.
Check propeller shaft splines for wear or damage.

52 9036005

Check if propeller shaft bellows is pierced or brittle.

1

Propeller Shaft Installation
Installation is essentially the reverse of removal
procedure. Pay attention to the following details.
Apply XPS SYNTHETIC GREASE (PIN 293 550 010) to
splines .
PARTS

TORQUE
75N om ± 5Nom
(55 Ibloft ± 4lbl olt)
75N om ± 5N om
(55lbl oft ± 4lbl olt) +
LOCTITE 271 (RED)
!PIN 293 800 005)

Propeller shaft screw
(final drive side)
TYPICAL - CV JOINT SHOWN
1. Joint ex tractor tool

With an hammer, hit on the tool to separate joint
from shaft.

Propeller shaft screw
(engine side)

When joint and shaft are separated, remove boot
from drive shaft.
Remove and discard the circlip. A new one is included in the boot kit.

PROPELLER SHAFT U-JOINTS

Remove drive shaft boot.

Remove internal snap ring from bearing caps.

Propeller Shaft U-Joint Removal

Drive Shaft Boot Installation
For installation, reverse the removal procedure.
Pay attention to the following.
Pack bearing area w ith grease (included w ith the
new boot kit).
NOTE: Do not use any other grease.

PROPELLER SHAFT
Propeller Shaft Removal
1. Remove the fuel tank. Refer to FUEL TANK
subsection.
2. Remove propeller shaft screw from gearbox
output shaft.
3. Lift and support vehicle. Refer to INTRODUCTION section for prope r procedure.
4. Remove propeller shaft screw from rear final
drive yoke.

V0 1HOYA

1

1. Snap ring

Support inner yoke in vice and drive other yoke
down with a solt hammer.

5. Remove rear final drive bolts. Refer to REAR
FINAL DRIVE in this subsection.
6. Move the rea r final drive rearwa rd to dislodge
the propeller shaft.
7. Dislodge the propel ler shaft from the engine.
310

tmr2011 -032

Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

Using a suitable pusher, fu lly seat bearing cap on
one side.

Support U-joint in vice and drive inner yoke down
to remove remaining bearing caps.
Remove U-joint cross.

Propeller Shaft U-Joint Installation
Install new U-joint in inner yoke.
NOTE: Position propeller shaft U-joint as shown
for proper grease fitting location.

Install snap ring.
Complete installation for the other bea ring caps .
Grease U-joint. Refer to PERIODIC MAINTENANCE PROCEDURES subsection.

REAR FINAL DRIVE
Rear Final Drive Removal
Dra in oil. Refer to PERIODIC MAINTENANCE
PROCEDURES subsection.
Remove drive shafts. See procedure in this subsection.
Remove the rear skid plate.
Remove the propeller shaft screw from the rear
final drive yoke.
Remove final drive lower bolts.

V0 1H l0A

Install bearing caps. Use a vise to push bearing
caps.

tmr2011..()32..()103

1. Lower final drive bolts

Remove final drive upper bolts and the front bolts
of the final drive support.

tmr2011-Q3 2

311

Section 06 DRIVE SYSTEM

Subsection 02 (REAR DRIVE)

Pinion Gear
Remove and discard oil seal no. 4.
Unscre w the pinion nut no. 5. Use the SPANNER
SOCKET (PIN 529 035 649)

529005649

1. Upper final drive bolts
2. Final drive support front bolts

Unplug the vent hose from final drive.
Loosen rear bolts of the final drive support and tilt
the support rearward to make room.
Remove the final drive.

Rear Final Drive Inspection
(Assembled)

NOTE: The pinion nut is left hand threaded. Unscrew by turning clockwise.
Remove the bearing no.6 at the same time as
the pinion gear no. 7. Be careful to keep track of
shims no. 8.
The pinion gear and bea ring can be easily removed
using the following suggested tool:
PART

QTY

Turn rear final drive gear with a finger; it shou ld
turn smoothly. Replace if necessary.
Check backlash and drag torque, see REAR FINAL
DRIVE ADJUSTMENT in this subsection.

Pipe: 89 mm (3-1/2 in) diameter x 127 mm
(5 in) in length

1

Screwed rod: M12 x 1.2 5, 178 mm (7 in)
length

1

Check if oil sea ls are brittle , hard or damaged. Replace if necessary.

M12x l. 25nut

3

Flat bar

1

Rear Final Drive Disassembly
Ring Gear
Unscrew the final drive housing screws no. 1.

Remove and discard the needle bearing no.9.

Rear Final Drive Adjustment
A shimming procedure mu st be done when pinion
gear, ring gear or housing is (are) changed.
Install recommended shims accordingly with the
following table.

"~-- 1

RECOMMENDED SHIMS

PINION GEAR
BACKLASH
PRELOAD

1.67 mm
(.066 in

±
±

0.04 mm
.002 in)

0.5 mm (.02 in)
(for preliminary adjustment)

NOTE: The procedure above sets the pinion shim
thickness and should not be modified thereafter.
Any ch anges should be done on preload and/or
backlash side(s).
1. Housing screws

Split final drive housings.
NOTE : Be careful to keep track of shims no. 2 on
ring gear no. 3.
Extract ring gear out of ha lf housing.
312

tmr2 011-032

Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

Rotate pinion gear 1/2 turn and check backlash
again. Note the result.

1. Backlash side
2. Preload side

Temporarily assemble the final drive. See procedure in REAR FINAL DRIVE ASSEMBLYbelow in
this subsection.
Backlash
Using a dial indicator and the BACKLASH MEASUREMENT TOOL (PIN 529 035 665), measure the
backlash. Place the backlash measurement tool
at the end of pinion gear.
From center of bolt, measure 25.4 mm (1 in) and
scribe a mark on the tab.

Rotate pinion gear 1 turn and check backlash
again.
If backlash is below 0.05 mm (.002 in), increase
backlash shim and check the backlash again.
If backlash is greater than 0.356 mm (.014 in),
decrease backlash shim and check the backlash
again.
Measure preload.
Preload
Screw the propeller shaft adaptor bolt in pinion
gear.

'.--2

"',
vmr2006.Q23-01 1_8

TYPICAL -

1. Tab of backlash measurement tool
2. Mark on tab
A. 25.4 mm (1 in)

FRONT DIFFERENTIAL SHOWN

Using a needle torque wrench, measure the drag
torque.

Position the dial indicator tip against the tab at a
90° angle and right on the previously scribed mark.
Gently, move the tab back and forth. Note the result.

tmr2011-032

313

Section 06 DRIVE SYSTEM
Subsection 02 (REAR DRIVE)

Rear Final Drive Installation
The installation is the reverse of the removal procedure.
PART
Final drive reta ining nuts

TORQUE
70N-m
(52Ibf-ft

±
±

5N-m
4Ibf-ft)

Refill the final drive with recommended oil. Refer to PERIODIC MAINTENANCE PROCEDURES
subsection.
TYPICAL -

FRONT OIFFERENTiAL SHOWN

If the drag torque is greater than 0.5 Nom
(5lbf oinl. reduce preload shim and check drag
torque again .
If the drag torque is less than 0.06 Nom (.5lbf oinl.
increase preload shim and check drag torque
again.

Rear Final Drive Assembly
Ring Gear
To assemble, reverse the removal procedure. Pay
attention to the follow ing.
Check condition of seal no. 10. Replace if damaged .
Check bearings no. 11. Replace if damaged.
Tighten final drive housing screws no. 1.
PART

TORQUE

Final drive housing
screws

32.5 Nom ± 3.5 Nom
(24 Ibf-ft ± 3 Ibf-ft)

Pinion Gear
To install, reverse the removal procedure. Payattention to the following.
Replace the a-ring no. 13.
Install the shim(s) no. 8 then the ball bearing no. 6.
Install a new needle bearing no.9.
Apply LOeTiTE 277 (PIN 293 800 073) to pinion nut
no.5.
NOTE: If a new pinion nut is used, a self-locking
product is already applied, do not use Loctite 277.
Install and tighten the pinion nut
PART
Pinion nut
(LEFT HAND
THREADED)

TORQUE
180 N-m
(133Ibf-ft

±
±

15 N-m
11 Ibf-ft)

Lubricate oil seal no.4.
314

tmr2Q l1-032

Section 07 CHASSIS
Subsection 01

(WHEELS AND TIRES)

WHEELS AND TIRES
SERVICE PRODUCTS
Description

Part Number

LOCTITE 767 (ANTISEIZE LUBRICANT) .

293800070

A

GENERAL

Page

......... .. ........... .. ........... 316

WARNING

- Rep)ace tires only with the same type and
size as original tires.
- For unidirectional tread pattern, ensure
that the tires are installed in the correct
direction of rotation.

Torque wrench tightening
must be
I adhered to.

PROCEDURES
TIRES

A

WARNING

Do not rotate tires. The front and rear tires
have a different size. Respect direction of rotation when applicable.

Tire Pressure

A

WARNING

Tire pressure greatly affects vehicle handling
and stability. Insufficient pressure may cause
tire to deflate and rotate on wheel. Excessive
pressure may burst the tire. Always follow
recommended pressure.
Check pressure when tires are cold before using the vehicle. "TIre pressure changes with temperature and altitude. Recheck pressure if one of
these cond itions has changed.
TIRE PRESSURE

FRONT

REAR

MIN .

69kPa
(10 PSI)

83 kPa
(12 PSI)

MAX.
(USE WHEN TOTAL
LOAD IS GREATER
THAN 180 KG (400 LB))

83kPa
(12 PSI)

152 kPa
(22 PSI)

Tire Inspection
Check tire for presence of slits. bulges, wear or
other damage. Replace if necessary.

TYPICAL

1. Direction of rotation

Tire Mounting on Beadlock Wheels

X Models
NOTE: "TIres should be mounted, by an experienced person, in accordance to good tire mounting practices using acceptable tire mounting
equipment designed for the tire industry.
1. Mount the tire on wheel.
1.1 On the opposite side of beadlock, apply
the tire mounting lube on inner bead of tire
and wheel to ensure proper seating when
inflating.
1.2 Mount the inner bead over the wheel.

,,,,,jiMi Mount tire

from bead lock side

only.
1.3 Seat the tire outer bead in the shoulder of
the bead lock inner ring and center the tire.

Tire Replacement
Use an automotive tire changer to replace tires.

tmr201 1·033

315

Section 07 CHASSIS
Subsection 01 (WHEELS AND TIRES)

5. First tightening sequence: Using a torque
wrench, tighten bead lock screws at first to
3 Nom ± 1 Nom (27lbf oin ± 9lbf oin) following
the illustrated sequence.
NOTE: To ensure even pressure on the bead lock
clamp ring, tighten screws a few turns at a time.

,. Tire outer bead
2. 8eadlock inner ring shoulder

2. Place the bead lock clamp ring on the tire. Align
the valve opening with valve.

FIRST AND SECOND TIGHTENING SEQUENCE

1. Clamp ring valve opening

3. Lubricate all beadlock screws with LOCTITE 767
(ANTI SEIZE LUBRICANT) (PIN 293 800 070) or an

equivalent product to prevent screw sticking.

6. At this time check if the tire is still centered on
wheel. Reposition it if necessary.
7. Second tightening sequence: Retighten all
screws to 8 Nom ± 1 Nom (71 Ibfoin ± 9lbf oin)
using the same sequence.
The beadlock clamp ring should be in contact the
beadlock inner ring.
NOTE: The beadlock clamp ring can flex slightly
to match the tire bead. IT IS NORMAL.
8. Verify the gap between tire and bead lock clamp
ring, it should be practically equal all around the
ring.

4. Install all bead lock screws. To avoid cross
threading, start all screws by hand.

1.'I"IlHI

Do not use an impact wrench for
installing beadlock screws. The risk of screw
breaking or screw stripping is high when using
an impact wrench.

A. Gap equal all around beadlock clamp ring

If the gap is uneven:
- Loosen all screws.
- Check tire position on wheel and reposition it if
necessary.
- Restart the tightening sequence from the beginning.
316

lmr201'-033

Section 07 CHASSIS
Subsection 01 (WHEELS AND TIRES)

9. Final
tightening
step:
8 Nom ± 1 Nom
(71 Ibfoin ± 9lbf oin) following the illustrated
sequence.

TYPICAL
1. Direction of rotation

FINAL TIGHTENING SEQUENCE

Install in the right direction of rotation.
Install lug nuts with the taper towards the wheel.

10. Inflate tire to seat the inner bead on wheel. Always use safe practices, such as a tire safety
cage.

WHEELS
Wheel Removal

1

TYPICAL
1. Taper (towards the wheel)

Loosen nuts just enough to be able to unscrew
them once the vehicle will be off the ground.

lIghten wheel lug nuts to the specified torque using the illustrated sequence.

Lift and support the vehicle. Refer to INTRODUCTION subsection.
Remove nuts, then rem ove wheel.

WHEEL LUG NUTS
TORQUE

I

100 Nom ± 10 Nom
(74lbf oft ± 7lbfoft)

Wheel Inspection
Inspect wheel for wear or damage especially at
the mounting holes.

Wheel Installation
At installation, it is recommended to apply antiseize lubricant on threads.
Check if tires are unidirectional.

tmr2011 -033

317

Section 07 CHASSIS
Subsection 01 (WHEELS AND TIRES)

1tI'lOlO11.oCll-081_.

TIGHTENING SEQUENCE

,.,["'@j Always use the recommended
wheel nuts for the type of wheel. Using a
different nut could cause damages to the rim
or studs.

318

tm12011-()33

Subsection XX (STEERING SYSTEM)

STEERING SYSTEM
SERVICE TOOLS
Description

Part Number

Page

STEERING ALIGNMENT TOOL..................................................... 529 036 059 ............................................. 3

SERVICE PRODUCTS
Description

Part Number

Page

XPS SYNTHETIC GREASE............................................................. 293 550 010 ............................................. 7

tmr2011-034

1

Subsection XX (STEERING SYSTEM)

X, XT Model
2.5 ± 0.5 N•m
(22 ± 4 lbf•in)

50 ± 5 N•m
(37 ± 4 lbf•ft)
50 ± 5 N•m
(37 ± 4 lbf•ft)

Synthetic grease

31 ± 3 N•m
(23 ± 2 lbf•ft)

48 ± 6 N•m
(35 ± 4 lbf•ft)
34 ± 2 N•m
(25 ± 1 lbf•ft)

See tightening
sequence
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)

72 ± 7 N•m
(53 ± 5 lbf•ft)
CE Model
5 ± 1 N•m
(44 ± 9 lbf•in)

NEW

34 ± 2 N•m
(25 ± 1 lbf•ft)
NEW

72 ± 7 N•m
(53 ± 5 lbf•ft)
NEW = Component must be replaced
when removed.

NEW

NEW

tmr2011-034-100_a

2

tmr2011-034

Subsection XX (STEERING SYSTEM)

GENERAL
The procedures described below are the same for
the RH and LH sides, unless otherwise instructed.
During assembly/installation, use the torque values and service products as in the exploded
views.
Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed (e.g.: locking
tabs, cotter pins, etc.) must be replaced.
NOTICE Hoses, cables and locking ties removed during a procedure must be reinstalled
as per factory standards.

ADJUSTMENT
STEERING ALIGNMENT
1. Place vehicle on a level surface.
2. Inflate tires to recommended pressure.
3. Find rack and pinion center to center as follows:
3.1 Calculate the total steering wheel rotations from side to side.
3.2 Position the steering wheel at half the total rotations.
4. Check steering wheel position:
4.1 If steering angle is within ± 3°, go to
step 6.
4.2 If steering angle is above ± 3°, go to
step 5.

tmr2011-034-200_b

A. Steering wheel angle ± 3°

5. Reposition steering wheel onto steering shaft
as follows:
NOTICE Make sure rack and pinion does
not move during steering wheel repositioning.
5.1 Remove steering wheel, refer to STEERING WHEEL REMOVAL.
5.2 Reinstall steering wheel to the closest
centered position (nearest spline).
6. Center steering wheel.

tmr2011-034-200_a

A. Steering wheel centered

7. Remove two wheel lug nuts from a rear wheel.
8. Install STEERING ALIGNMENT TOOL (P/N 529 036
059) using proper spacers.

tmr2011-034

3

Subsection XX (STEERING SYSTEM)

14. Slowly move rope back until it makes contact
with spacer.

vmr2008-068-007
529036059

9. Move vehicle to place the tool level with the
ground.

TYPICAL

15. Keep rope in this position.
16. Measure distance of the front wheel between
rope and rim as follows:
– At the front of rim
– At the rear of rim.

vmr2008-068-006_a

REAR WHEEL
1. Steering adjustment tool
2. Angle gauge or level

10. Place a rope around vehicle tires
11. Using an elastic, link both ends together.
12. Adjust rope at the center of the wheels.
13. From the front of vehicle, near the front of rim,
move rope so that it does not touch the first
spacer of tool.

vmr2008-068-008

TYPICAL — AT THE FRONT OF RIM

vmr2008-068-009

TYPICAL — AT THE REAR OF RIM

17. Calculate the difference between the rear and
the front measurement.
18. The difference must be as per the following
specification:
vmr2008-068-005_a

TYPICAL

4

tmr2011-034

Subsection XX (STEERING SYSTEM)

WHEEL TOE
0 mm ± 4 mm (0 in ± .157 in)

19. If the wheel toe measurement is out of specification:
19.1 Adjust tie-rod end.

WARNING
The maximum tie-rod end length not
engaged in the tie rod must not exceed
32 mm (1.26 in).

4. Remove steering wheel by pulling it upwards.

X and XT Models
1. Remove steering wheel cap using a small
screwdriver.
2. Remove nut securing steering wheel to shaft.
3. Remove steering wheel by pulling it upwards.

Steering Wheel Installation
The installation is the reverse of the removal procedure. However, pay attention to the following.
Prior to installing the steering wheel, place front
wheels parallel with longitudinal plane of vehicle.

tmr2011-034-107_a

A. Maximum tie-rod end length

19.2 Tighten tie-rod end locking nut to specification.
tmr2011-034-010_a

TIE-ROD END LOCKING NUT
TORQUE
34 N•m ± 2 N•m (25 lbf•ft ± 1 lbf•ft)

20. Repeat procedure for the other wheel.

TROUBLESHOOTING

A. Front wheels parallel

Tighten steering wheel retaining nut to specification.
STEERING WHEEL RETAINING NUT TORQUE
50 N•m ± 5 N•m (37 lbf•ft ± 4 lbf•ft)

DIAGNOSTIC TIPS

Check front wheel alignment. Refer to STEERING
ALIGNMENT in this subsection.

Turning Radius Unequal

STEERING COLUMN

If vehicle turns more on one side than the other,
check rack and pinion center to center. Refer to
STEERING ALIGNMENT in this subsection.

Steering Column Removal

PROCEDURES

1. Center steering wheel.
2. Remove bolt and nut securing upper universal
joint to steering shaft.

STEERING WHEEL
Steering wheel Removal
All Models Except X and XT
1. From underneath steering wheel, unscrew cap
retaining screws.
2. Remove steering wheel cap.
3. Remove nut securing steering wheel to shaft.
tmr2011-034

5

Subsection XX (STEERING SYSTEM)

tmr2011-034-101_a

3. Remove steering wheel and steering shaft as
an assembly.

tmr2011-034-104

6. Carefully push steering column downwards to
release it from steering support.

tmr2011-034-105
tmr2011-034-102_a

4. Remove bolt and nut securing lower universal
joint to rack and pinion.

7. Remove steering column from vehicle.

Steering Column Inspection
Check steering column for wear, cracks or bending.
Check steering shaft for wear, cracks or bending.
Check if universal joints move freely.
Check if steering shaft O-rings are brittle, hard or
otherwise damaged.
Replace if necessary.

Steering Column Installation

tmr2011-034-103_a

The installation is the reverse of the removal procedure. However, pay attention to the following.
Prior to installing the steering column, place front
wheels parallel with longitudinal plane of vehicle.

5. Pull steering column upwards to detach it from
rack and pinion.

6

tmr2011-034

Subsection XX (STEERING SYSTEM)

tmr2011-034-013
tmr2011-034-010_a

SOME PARTS REMOVED FOR CLARITY PURPOSE

A. Front wheels parallel

Lubricate steering shaft.
STEERING SHAFT LUBRICATION
XPS SYNTHETIC GREASE (P/N 293 550 010)

Install steering wheel and steering shaft. Make
sure steering wheel is properly centered.
Tighten steering column U-joints to specification.
UPPER U-JOINT NUT TORQUE
31 N•m ± 3 N•m (23 lbf•ft ± 2 lbf•ft)
LOWER U-JOINT NUT TORQUE

6. From the LH side, remove rack and pinion from
vehicle.

Rack and Pinion Installation
The installation is the reverse of the removal procedure. However, pay attention to the following.
Find rack and pinion center to center as follows:
– Calculate the total pinion shaft rotations from
side to side.
– Position the pinion shaft at half the total rotations.
– Align pinion shaft mark onto housing mark.

48 N•m ± 6 N•m (35 lbf•ft ± 4 lbf•ft)

Check front wheels alignment. Refer to STEERING ALIGNMENT in this subsection.

RACK AND PINION
Rack and Pinion Servicing
Rack and pinion is not serviceable except for
boots and tie rods replacements.
tmr2011-034-106_a

Rack and Pinion Removal

MARKS

1. Safely lift and support the front of vehicle. Refer to INTRODUCTION subsection.
2. Remove both front wheels.
3. Remove steering column, refer to STEERING
COLUMN REMOVAL in this subsection.
4. Detach tie-rods from knuckles. Refer to TIE
ROD REPLACEMENT in this subsection.
5. Remove bolts and nuts securing rack and pinion
to frame.

Install all retaining bolts and nuts of rack and pinion
loosely first.
Torque retaining nuts of rack and pinion according
to specification using the following tightening sequence.

tmr2011-034

RACK AND PINION RETAINING NUTS TORQUE
24.5 N•m ± 3.5 N•m (18 lbf•ft ± 3 lbf•ft)

7

Subsection XX (STEERING SYSTEM)

tmr2011-034-107_a

A. Nominal length
tmr2011-034-002_a

TIGHTENING SEQUENCE

Check the steering alignment, refer to STEERING

ALIGNMENT in this subsection.

TIE-ROD ENDS
Tie-rod End Replacement
1. Safely lift and support the front of vehicle. Refer to INTRODUCTION subsection.
2. Remove front wheel.
3. Detach tie-rod end by removing:
– Cotter pin
– Tie-rod end retaining nut
– Hardened washers.

WARNING
The maximum tie-rod end length not engaged in the tie rod must not exceed 32 mm
(1.26 in).
7. Tighten tie-rod end locking nut to specification.
TIE-ROD END LOCKING NUT TORQUE
34 N•m ± 2 N•m (25 lbf•ft ± 1 lbf•ft)

8. Attach tie-rod end on knuckle as the reverse of
removal.
9. Tighten tie-rod end retaining nut to specification.
TIE-ROD END RETAINING NUT TORQUE
72 N•m ± 7 N•m (53 lbf•ft ± 5 lbf•ft)

10. Install NEW cotter pin. Both ends of cotter
pins must be folded.
11. Install front wheel.
12. Check the steering alignment, refer to STEERING ALIGNMENT in this subsection.

KNUCKLES
Knuckle Removal

tmr2011-034-012_a

1. Cotter pin
2. Tie-rod end retaining nut
3. Hardened washers

4. Discard cotter pin.
5. Replace tie-rod end.
6. Adjust tie-rod end to the nominal length.

1. Safely lift and support the front of vehicle. Refer to INTRODUCTION subsection.
2. Remove front wheel.
3. Detach tie-rod end from knuckle, refer to TIEROD END in this subsection.
4. Remove wheel hub, refer to FRONT DRIVE
subsection.
5. Remove caliper, refer to BRAKES subsection.

TIE-ROD END NOMINAL LENGTH
27 mm (1.063 in)

8

tmr2011-034

Subsection XX (STEERING SYSTEM)

tmr2011-034-015_a

1. Seal
2. Circlip
tmr2011-034-108

6. Detach upper suspension arm from knuckle, refer to FRONT SUSPENSION.
7. Detach lower suspension arm from knuckle, refer to FRONT SUSPENSION.
8. Remove knuckle from vehicle.

4. Install knuckle on a press.
5. Use an appropriate bearing remover.
6. Remove bearing from knuckle.

Knuckle Inspection
Check knuckle for cracks or other damages.
Replace if necessary.

Knuckle Installation
The installation is the reverse of the removal procedure.

WHEEL BEARINGS
Wheel Bearing Inspection
(Maintenance)

tmr2011-034-109

Refer to PERIODIC MAINTENANCE PROCEDURES subsection.

WARNING

Wheel Bearing Inspection (During
Component Removal)

Clean all grease, outside and inside, from
knuckle before heating it.

Whenever the drive axle or knuckle is removed,
check wheel bearing as follows:
– Check if wheel bearing turns freely and
smoothly.
– Check seal condition.
Replace if necessary.

Wheel Bearing Removal
1. Remove

knuckle

from

vehicle,

refer

KNUCKLE REMOVAL in this subsection.
2. Remove and discard knuckle seal.
3. Remove circlip.

tmr2011-034

NOTE: It may be necessary to heat the knuckle to
remove bearing.

to

Wheel Bearing Installation
The installation is the reverse of the removal procedure. However, pay attention to the following.
To ease wheel bearing installation:
– Place bearing in a freezer for 10 minutes.
– Place knuckle in oven to 100°C (212°F) for
30 minutes maximum.
When knuckle is cooled down, install NEW circlip
and NEW seal.

9

Section 07 CHASSIS
Subsection 03 (FRONT SUSPENSION)

FRONT SUSPENSION

$
I

'-..

Suspension
grease

/
/ '

p>
Suspension

grease

48:t 6 Nom
(35 • 4 Ibfoftl

----------- "
X model

"-

,,

,,

,,

,,

,,

,

,

/ -

i///(/

<
I

mm::

I
I
I

All except X
model

X model

c)
Suspe nsion
grease

Component must be replaced when removed.

Imr2011.()35·100...

tmrlOll.Q35

329

Section 07 CHASSIS
Subsection 03 (FRONT SUSPENSION)

GENERAL
The procedure explained below is the same for
the RH and LH sides unless otherwise noted.
During assembly/installation, use the torque values and service products as in the exploded view.
Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

A

WARNING

Torque wrench tightening specifications
must strictly be adhered to.
Locking devices when removed (e .g.: locking
tabs, cotter pins, etc.) must be replaced.

1. Lower bolt

3. Remove shock absorber.

Shock Absorber Inspection

'nt,I'@j

Hoses, cables and locking ties removed during a procedure must be reinstalled
as per factory standards.

Remove spring from shock absorber. Refer to
SPRINGS in this subsection.
Secure the end of shock body in a vise with its rod
upward.

PROCEDURES
1

SHOCK ABSORBER
Shock Absorber Removal
1. Safely lift and support the vehicle of the ground.
Refer to INTRODUCTION subsection.
2. Remove bolts and nuts retaining shock absorber.

~

(~

Q

A14F08A

TYPICAL
1. Clamp here

'IIt,lit'"

Do not clamp directly on shock

body.

1. Upper bolt

Extend and compress the piston several times
over its entire stroke. Check that it moves
smoothly and with uniform resistance with its
rod upward.
Check the following conditions that will denote a
defective shock:
- A skip or a hang back when reversing stroke at
mid travel.
- Seizing or binding condition except at extreme
end of either stroke.
- Oil leakage .
- A gurgling noise, after completing one full compression and extension stroke.
Replace if any faults are present.

Shock Absorber Installation
The installation is the reverse of the removal procedure. However, pay attention to the following.

330

tmr20 11 -035

Section 07 CHASSIS
Subsection 03 (FRONT SUSPENSION )

Make sure to install the proper type of shock absorber no. A on the front of veh icle

I. Balf joint nut

4. Remove bolts and nuts securing suspension
arm to frame.
m r2Ql 1.036-01 7_"

A. Front shock absorber (without shock body extension)
B. Rear shock absorber fwith shock body extension)

SHOCK ABSORBER NUTS TORQUE
48 Nom ± 6 Nom (35lbf oft ± 4 lbf oft)

SHOCK ABSORBER BUSHINGS
Refer to SHOCK ABSORBER BUSHINGS in
REAR SUSPENSION subsection for complete
procedures.

SPRINGS
Refer to SPRINGSin REAR SUSPENSIONsubsection for complete procedures.

1. Suspension arm nuts

5. Rem ove suspens ion arm.

LOWER SUSPENSION ARM
Lower Suspension Arm Removal
1. Safely lift and support the vehicle off the
ground. Refer to INTRODUCTION subsection .
2. Remove wheel, refer to WHEELS AND TIRES
subsection.
NOTE: For X model, disconnect anti-sway bar
from suspension arm.
3. Remove bolt and nut securing lower ball joint to
knuckle.
MOVE DOWNWARDS

Lower Suspension Arm Installation
The in stallat ion is t he reverse of the removal procedure . However, pay attention to the following.
Lubri cate suspension arm. Refer to PERIODIC
MAINTENANCE PROCEDURES subsection.
tmr2011-035

331

Section 07 CHASSIS
Subsection 03 (FRONT SUSPENSION)

UPPER SUSPENSION ARM
Upper Suspension Arm Removal
1. Safely lift and support the vehicle off the
ground. Refer to INTRODUCTION subsection.
2. Remove wheel, refer to WHEELS AND TIRES
subsection.
3. Remove fasteners retaining brake hose to vehicle.

1. 8all joint nut
2. 8all joint hardened washer

6. Carefully move brake hose aside.
7. Using a plastic hammer, carefully hit on the
knuckle side to separate ball joint from knuckle.
NOTE: A ball joint remover can be used if the ball
joint is jammed into knuckle.

Ii'c,j'tilj

Never hit on suspension arm to
avoid to damage it permanently.
BRAKE HOSE FASTENERS (4X)

4. Remove and discard cotter pin retaining ball
joint.

CAREFULLY HIT ON KNUCKLE SIDE

1. 88/1 joint cotter pin

8. Remove bolt and nut securing suspension arm
to shock absorber.

5. Remove ball joint nut and washer.

332

mr2011·Q35

Section 07 CHASSIS
Subsect ion 03 (FRONT SU SPE NSION )

SUSPENSION A RM BUSHI NG S
Suspension Arm Bushings Removal
1. Remove wea r plates, cushions and inner bushing from suspension arm.

1. Shock absorbe r nut

9. Rem ove radiator from vehicle. Refer to RADIATOR in COOLING SYSTEM subsection .
10. Remove fasteners securing suspension arm
to fram e.

LOWER SUSPENSION ARM
1. Wear plate
2. Cushion
3. Inner bushing

1. Suspension arm pivot nut
2. Suspension arm pivot bolt
3. Suspension arm pivot washers

11. Remove suspension arm.

Upper Suspension Arm Installation
The installation is the reverse of the removal procedure. Howeve r, pay attention to the fo llowing.
Refer to COOLING SYSTEM subsection for radiator installation .

11!l",tRii

Properly bl eed coo ling syst em. Refer to COOLIN G S YSTEM subsection.

UPPER SUSPENSION A RM
1. Wear pla te
2. Cushion
3. Inner bushing

Suspension Arm Bushings Installation
The insta llation is the reverse of the remova l procedure. However, pay attention to the fol lowing.
Lubricate suspens ion arm. Refer to PERIODIC
MAINTENANCE PROCEDURES subsection.

Lubricate suspension arm. Refer to PERIODIC
MAINTENANCE PROCEDURES subsection.

BALL JOINTS

In stall a NEW cotter pin to secure ba ll joint nut.
Both end of cotter pin must be folded.

Ball Joint Remov al

SHOCK ABSORBER NUTS TORQUE
48 Nom ± 6 Nom (35lbf oft ± 4 lbf°ftl

1. Remove suspension arm from vehicle. Refer to
SUSPENSION A RM REMOVAL in this subsection .
2. Remove circlip from ball joint.

!mr2 01 1-035

333

Section 07 CHASSIS
Subsection 03 (FRONT SUSPENSION)

5. Remove ball joint from suspension arm .

•.ti"ilRj Make

sure that suspension arm is
properly supported on the press during ball
joint removal.

Ball Joint Installation
The installation is the reverse of the removal procedure. However. pay attention to the following.
Install a NEW circlip to secure ball joint.

LOWER BALL JOINT
1. Circfip

UPPER BALL JOINT
1. Circlip

3. Install suspension arm on a press .
4. Use an appropriate ball joint remover.

334

tmr2011-G3S

Section 07 CHASSIS
Subsection 04 (REAR SUSPENSION)

REAR SUSPENSION
SERVICE TOOLS
Description

Part Number

SPR ING COMPRESSOR .................. ......... ................. .

529036 184 ....... ..... .... .............. .......... 337

I

Page

All except X Model

48 ± 6 Nom
(35 • 4 IbfoftJ

48 ± 6 Nom
(35 ± 4 IbfoftJ

51 ± 3 Nom
(38 ± 2 IbfoftJ

48 ±6 Nom
(35 ± 4 IbfoftJ

See tightening sequence

r--------------I

XMode/

110 ± 10Nom
(81 ± 7 Ibf·ftJ

Suspension
grease

111m = Component must be replaced when removed.

tmr2011-036

335

Section 07 CHASSIS
Subsection 04 (REAR SUSPENSION)

GENERAL
The procedure described below is the same for
the RH and LH sides, unless otherwise instructed.
During assembly/installation, use the torque values and service products as in the exploded
views.
Clean threads before applying a thread locker. Refer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

A

WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices must be replaced when removed (e.g.: locking tabs, cotter pins, etc.).

'N,JWj Hoses,

cables and locking ties removed during a procedure must be reinstalled
as per factory standards.

PROCEDURES
SHOCK ABSORBERS
Shock Absorber Removal
1. Safely lift and support the vehicle off the
ground . Refer to INTROOUCTION subsection.
2. Open cargo box.
3. Remove bolts and nuts retaining shock absorber.

1. Upper bolt

1. Lower bolt

4. Remove shock absorber.
Shock Absorber Inspection
Remove spring from shock absorber. Refer to
SPRINGS in this subsection.
Secure the end of shock body in a vise with its rod
upward.

,

~

a

Q

A14FOBA

TYPICAL

1. Clamp here

..q"ltijOiI Do

not clamp directly on shock

body.
Extend and compress the piston several times
over its entire stroke. Check that it moves
smoothly and with uniform resistance with its
rod upward.
Check the following conditions that will denote a
defective shock:
- A skip or a hang back when reversing stroke at
mid travel.
- Seizing or binding condition except at extreme
end of either stroke.
- Oil leakage.
- A gurgling noise, after completing one full compression and extension stroke.
Replace if any faults are present.
Shock Absorber Installation
The installation is the reverse of the removal procedure. However, pay attention to the following.

336

tmr2011·036

Section 07 CHASSIS
Subsection 04 (REAR SUSPENSION)

Make sure to install the proper type of shock absorber no. B on the rear of vehicle.

tmr2011-o36-020

TYPICAL

5. Install a NEW bush ing as the reverse of removal.
tmr201 1~JlWll1_.

A. From shock absorber !Without shock body extension)
B. Reaf shock absorber (with shock body extension)

SHOCK ABSORBER NUTS TORQUE
48 Nom ± 6 Nom (35 lbf oft ± 4lbf oft)

SHOCK ABSORBER BUSHINGS

6. Install shock absorber on vehicle.

SPRINGS
Spring Removal
1. Remove shock absorber from vehicle. Refer to
SHOCK ABSORBERS in this subsection.
2. Use SPRING COMPRESSOR (PIN 529 036 184).

Shock Absorber Bushing Replacement
All Shock Absorbers Except HPG with
Remote Reservoir
1. Remove shock absorber from vehicle. Refer to
SHOCK ABSORBERS in this subsection.
2. Install shock absorber on a press.
3. Use an appropriate socket to push bushing.

529OJ1I164

3. Place the tool in a vise .
4. Position the shock absorber in the tool.
5. Install the spring compressor pins.
6. Tighten spring remover screw until the spring is
sufficiently compressed to remove spring cap.
7. Remove spring cap from shock absorber.
8. Release spring remover screw.
9. Remove spring from shock absorber.

Spring Inspection
Inspect the spring for damage.
Replace if necessary.
TYPICAL

Spring Installation

4. Remove bushing from shock absorber.

The installation is the reverse of the removal procedure. However, pay attention to the following.
Install spring cap open ing at 180 0 from spring
stopper opening .

tmr2011.()36

337

Section 07 CHASSIS
Subsection 04 (REAR SUSPENSION)

lmrl011-il3fHlC).Ca

ANTI-SWAY BAR TIGHTENING SEQUENCE

ANTI-SWAY BAR SCREWS TORQU E
CAP OPENING AT 180 0

ANTI-SWAY BAR
Anti-Sway Bar Removal
1. Safely lift and support the vehicle off the
ground. Refer to INTRODUCTION subsection.
2. Open cargo box.
3. Remove anti-sway bar retaining screws (4 on
each side)

51 Nom ± 3 Nom (38lbfoft ± 2lbfoft)

TRAILING ARM
Trailing Arm Removal
1. Safely lift and support the vehicle off the
ground. Refer to INTRODUCTION subsection .
2. Remove wheel, refer to WHEELS AND TIRES
subsection.
3. Open cargo box.
4. Remove anti-sway bar, refer to ANTI-SWAY
BAR REMOVAL in this subsection.
5. Remove wheel hub, refer to REAR DRIVE subsection.
6. Remove protective plate from trailing arm.

1. Anti-swav bar retaining screw

4. Remove anti-sway bar.

Anti-Sway Bar Inspection
Check anti-sway bar for cracks, bending or other
damages.
Replace if necessary.

Anti-Sway Bar Installation
The installation is the reverse of the removal procedure. However, pay attention to the following .
Install all retaining screws of anti-sway bar loosely
fi rst.
Torque retaining screws of anti-sway bar according to the following sequence.
338

1. Protective plate

NOTE: If applicable, remove fasteners retaining
brake hose to vehicle.
7. Remove nut and washer securing trailing arm
pivot.

tmr2011 -036

Section 07 CHASSIS
Subsection 04 (REAR SUSPENSION)

Trailing Arm Disassembly
Drive Shaft Bearing Removal
1. Remove circlip securing bearing into trailing
arm.

1. Pivot nut
2. Pivot washer

8. Remove lower nut retaining shock absorber.

1. Circfip

2. Install trailing arm on a press.
3. Use an appropriate bearing remover.
4. Remove drive shaft bearing from trailing arm.
Trailing Arm Pivot Bearing Removal
1. Remove both spacers and seals from trailing
arm pivot.

1. Lower nut



9. Firmly hold trailing arm then remove:
- Shock absorber lower bolt
- Trailing arm pivot bolt and washer.

2

1. Spacer

2. Seal

2. Install trailing arm on a press.
3. Use an appropriate bearing remover.
tmr20".()36.(112...a

1. Shock absorber lower bolt
2. Trailing arm pivot bolt

4. Remove pivot bearings and bushing from trailing arm.

1O. Remove trailing arm from vehicle.

tmr2011-Q36

339

Section 07 CHASSIS
Subsection 04 (REAR SUSPENSION)

•
1. Pivot bearings
2. Pivot bushing

Trailing Arm Inspection
Check trailing arms for:
- Cracks
- Bending.
Check seals condition.
Check inner race of each pivot bearing with your
finger:
- Bearings should turn smoothly and quietly.
Replace all damaged parts.

Trailing Arm Assembly and Installation
The installation is the reverse of the removal procedure. However, pay attention to the following.
Install the following NEW parts:
- Pivot bearings
- Seals
- Circlip.
TRAILING ARM PIVOT NUT TORQUE
110 Nom ± 10 Nom 181 Ibfoft ± 71bf oftl

340

tmr2011-036

Section 07 CHASSIS
Subsection 05 (BRAKES)

BRAKES
SERVICE TOOLS
Description

Part Number

ECM ADAPTER TOOl. ....... ... .

529 036 166 .. ....... .. ... .. ....... .. .......... ... 344

Page

SERVICE PRODUCTS
Description

COSMO RUBBER GREASE ........
. ....... ... ........ .... .
LOCTITE 243 (BLUE) ......................................... .
XPS PARTS AND BRAKES CLEANER ........ ........ .............. .... .

tmr2Qll.()37

293 550 055 ....... ... ...... ...... .. .......... ..... 346
293 800 060... .................. .. 347
219701 705 ...... ..... ....................
... 347

341

Section 07 CHASSIS
Subsection 05 (BRAKES)

&G1 Brake Caliper Synthetic Grease
&G2 Cosmo Rubber Grease
&G3 XPS Synthetic Grease
T1
T2
T3
T4
T5
T6

....

T7

5.0 ± 1 Nom (44 j: 9 IbNn)
5.5 ± 1.5 N·m (49 ± 131bfoinl
15 ± 5 N-m (133 ± 441bfoinl

19,3 Nom (168,27 IbfoinJ
25,5 Nom (18,4 Ibf°ftJ
28.5,1.5 Nom (21 , 1 Ibf°ftl
48 , 6 Nom (35,4 Ibf°ftJ

Loctite 243

Loctite 243

mm

= Component must be replaced when removed.

!mr2011.(lJ1.100~a

342

tmr2011-037

Section 07 CHASSIS
Subsection 05

(BRAKES)

GENERAL
During assembly/installation, use the torque values and service products as in the exploded
view(s).
Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

A

WARNING

Torque wrench tightening specifications
must strictly be adhered to.
Locking devices must be replaced when removed (e.g.: locking tabs, cotter pins, etc.).
TYPICAL

A

WARNING

Always check brake system operation after
removing or servicing a brake component. If
brake pedal feels spongy, make sure all components are properly installed and system is
properly bled.

,.q"'(ljj Avoid spilling brake fluid on plastic,
rubber or painted parts. Protect these parts
with a rag when se rvicing brake system.

,"1.).164

Sealing washers must be discarded
and replaced with new ones every time a Banjo
fitting is unscrewed.

'Ml,JIlHIj

Hoses, cables and locking ties removed during a procedure must be reinstalled
as per factory standards.

NOTE: Always clea n the area around a brake component before servicing.

INSPECTION
BRAKE SYSTEM PRESSURE
VALIDATION

'N",lllj Do not pump up the brake pedal repeatedly before doing the validation .

2. Position force gauge on brake pedal at
64 mm ± 5 mm (2.5 in ± .2 in) from lower edge.
3. Position a ruler perpendicularly to brake pedal.

P
i
i
i
i

i

A

~~~""-

iA

;r
!-

A. 64mm::t Smm (2.5in

±

.2in)

4. Push brake pedal from 70 mm (2-3/4 in) using
force gauge.

1. Use an appropriate compression force gauge
such as MARK-l0 EG-200 and a ruler.

tmr2011-037

343

Section 07 CHASSIS
Subsection 05 (BRAKES)

Brake Light Switch Resistance Test
1. Disconnect brake light switch connector.
2. Check switch operation as follows.
BRAKE LIGHT
SWITCH POSITION
Firmly pushed

PIN
1

Released

RESISTANCE
2

Close to 0 0
Infinite (OLI

If switch is defective, replace with a new one.
If the switch tests good, verify wire continuity between harness connector and ECM-B connector.
NOTE: Use the ECM ADAPTER TOOL !PIN 529036
166)

TYPICAL

5. Read the load recorded by the force gauge.

6 Load reading must be as per the following table.
BRAKE PEDAL LOAD AT 70 MM
Minimum 250 N (56Ibf)
7. If load reading is not in accordance with the
specification:
7 .1 Perform a brake system inspection and
cleaning.
7.2

Bleed brake system.

NOTE: Refer to PERIODIC MAINTENANCE
PROCEDURES subsection.

PROCEDURES

529036166

ECM-B
CONNECTOR
PIN

HARNESS
CONNECTOR
WIRES

RESISTANCE

C-3

REDIORANGE

Close to 0 0

BRAKE LIGHT SWITCH

NOTE: If only the LH taillight does not work,
check brake relay (RS) in fuse box 1.

Brake Light Switch Location

Brake Light Switch Replacement

Brake light switch is located underneath LH front
fender on master cylinder.

1. Disconnect brake light switch connector.
2. Drain rear brake line.
3. Remove brake light switch from master cylinder.
NOTE: Use shop rags to catch any spilled brake
fluid.
4. Install NEW sealing washers.
5 Install brake light switch on master cylinder.
BRAKE LIGHT SWITCH NUT TORQUE
19 Nom ± 3 Nom (168lbf oin ± 27lbf oin)
6. Connect brake light switch connector.

tmr20 11-037-102_"

1, Brake light switch

344

7. Refill and bleed brake system, refer to PERIODIC MAINTENANCE PROCEDURES subsection.
tmr2011-037

Section 07 CHASSIS
Subsection 05 (BRAKES)

MASTER CYLINDER
Master Cylinder Removal
1. Drain brake system, refer to PERIODIC MAINTENANCE PROCEDURES subsection.
2. Remove master cylinder protective cover.

o~

r
SOME PARTS REMOVED FOR CLARITY PURPOSE
1. Front brake hoses
2. Sealing washers

5. Remove protective rubber from underneath
dashboard.
1. Master cylinder prorective cover

3. Remove brake light switch retaining rear brake
hose.

~

II
3

Imr2011.Q3NI04_,

SOME PARTS REMOVED FOR CLARITY PURPOSE
,. Brake light switch
2. Rear brake hose
3. Sealing washers

UNOERNEATH OASHBOARO
7. Protective rubber

6. Disconnect master cyl inder rod from brake
pedal.

4. Unscrew front brake hoses from master cylinder.

7. Master cylinder rod

tmr2011'{)37

345

Section 07 CHASSIS
Subsection 05 (BRAKES)

7. Remove master cylinder rod from master cylinder.

BRAKE LIGHT SWITCH NUT TORQUE
19 Nom ± 3 Nom (168lbf oin ± 27lbf oin)

Lubricate push rod end and inside master cylinder
boot.
PUSH ROD END LUBRICATION
COSMO RUBBER GREASE (PIN 293 550 055)
MASTER CYLINDER BOOT LUBRICATION
COSMO RUBBER GREASE (PIN 293 550 055)

Install NEW sealing washers.
Refill and bleed brake system, refer to PERIODIC
MAINTENANCE PROCEDURES subsection .
tml201Hl37·104

MASTER CYLINDER ROO REMOVEO

8. Remove master cylinder retaining bolts and
nuts.

Adjust master cylinder rod, refer to MASTER
CYLINDER ROD ADJUSTMENT in this subsection.

Master Cylinder Rod Adjustment
1. Loosen locking nut of master cylinder rod.
2. Move brake pedal up and down to check if there
is a free play.

1. Master cylinder retaining bolts

9. Remove master cylinder from vehicle .

Master Cylinder Inspection
Check boot for crack.
Check rod for wear and scratch .
Check master cylinder housing for leak or damage.

Master Cylinder Installation
The installation is the reverse of the removal procedure. However, pay attention to the following .
Tighten brake light switch and front brake hoses
to specification.

3. Rotate master cylinder rod to generate a free
play according to specification.
BRAKE PEDAL FREE PLAY

3.5 mm

±

1.5 mm (1/8 in

± 1116

in)

4. Tighten locking nut of master cylinder rod to
specification.
ROD LOCKING NUT TORQUE
5 Nom ± 1 Nom (44lbf oin ± 9lbf oin)

FRONT BRAKE HOSES SCREW TORQUE
28.5 Nom ± 1.5 Nom (21 Ibfoft ± 1 Ibfoft)

346

tmr2011 -037

Section 07 CHASSIS
Subsection 05 (BRAKES)

CALIPER

Caliper Installation

Caliper Removal

The instal lation is the reverse of the removal procedure. However, pay attention to the following.

1. Safely lift and support the vehicle. Refer to INTRODUCTION subsection.
2. Remove wheel, refer to WHEELS AND TIRES
subsection.
3. If caliper is removed from vehicle for replacement:
3.1

Drain brake system, refer to PERIODIC
MAINTENANCE PROCEDURES subsection.

3.2 Unscrew brake hose from caliper.

If caliper was removed for replacement:
- Refill and bleed brake system, refer to PERIODIC MAINTENANCE PROCEDURES subsection.
- Install NEW sealing washers.
Apply threadlocker on ca li per retaining screws.
CALIPER RETAINING SCREWS THREADLOCKER
LOCTITE 243 (BLUE) (PIN 293800060)
lIghten caliper retaining screws to specification.
CALIPER RETAINING SCREWS TORQUE
48N o m ± 6N o m (35lbf o ft

±

4lbf o ft)

BRAKE PADS
Brake Pads Replacement
1. Remove caliper from knuckle, refer to CALIPER
REMOVAL in this subsection.
2. Remove brake pad pins from caliper.

TYPICAL - FRONT CALIPER SHOWN
1. Brake hose
2. Sealing washers

4. Remove fasteners retaining brake hose to
knuckle.
5. Remove screw s securing caliper support to
knuckle.

1
1. Brake pad pins

3. Remove brake pads.
4. Clean pistons end using XPS PARTS AND
BRAKES CLEANER (PIN 219 701 705).
5. Push caliper pistons inward.
NOTE : To avoid damaging pistons, use an old pad
to push it into the caliper using a C-clamp.
tmr20 1 1 -0 37-OO9~ a

TYPICAL - FRONT CALIPER SHOWN
1. Caliper screws

6. Ensure brake pad spring is properly positioned
onto caliper.

6. Place caliper assembly onto a support

'l!toi[l!jOj

Do not let caliper hangs by the hose
and do not stretch or twist hose.

tmr201 1-037

347

Section 07 CHASSIS
Subsection 05 (BRAKES)

1. Brake pad spring

7. Install NEW brake pads.

8. Clean then lubricate brake pad pi ns using
an appropriate BRAKE CALIPER SYNTHETIC
GREASE
9. Install brake pad pins on caliper.
10. Install caliper on knuckle, refer to CALIPER INSTALLATIONin this subsection.

4. Replace brake disc.

5. Install wheel studs using a press.
6. Align wheel stud knurling into hub grooves.
NOTE: If wheel studs are damaged,
them.

replace

7. Install wheel hub then caliper.

BRAKE DISC

8. Install NEW cotter pin to secure wheel hub nut.

Brake Disc Inspection
1 . Check disc surfaces for scratches or grooves on
both sides.

2. Measure thickness of the disc.
DISC MINIMUM THICKNESS
FRONT

4.1 mm (.161 in)

REAR

4.1 mm (. 161 in)

'N"Il!!iI Brake discs must never be machined.
3. Check warpage of the disc.
MAXIMUM DISC WARPAGE
FRONT

0.2 mm (.01 in)

REAR

Brake Disc Replacement
1. Remove caliper from knuckle, refer to CALIPER
REMOVAL in this subsection .
2. Remove wheel hub, refer to FRONT DRIVE or
REAR DRIVE subsection.
3. Remove wheel studs using a press.

348

tmr2011'()J7

Section 07 CHASSIS
Subsection 06 (BODY)

BODY
SERVICE TOOLS
Description

Part Number

OETIKER PLIERS... ............ ........... .. ................................. .

295000070

Page

........ ............................... 359

BODY (Parts Nomenclature)

~-5

Imr2011-038-001_1

1. Driver sear
2. cvr air inlet cover
3. LH front fender
4. LH headlight trim

5. Hood
6.
7.
8.
9.

Front fascia
Service cover
RH headlight trim
RH front fender
10. Front lateral panel
11. Central fareral panel
12. Rear lateral panel
13. Cargo box
14. Passenger seat

tmr2011-038

349

Section 07 CHASSIS
Subsection 06 (BODY)

FRONT BODY PARTS (Torques and Service Products)

•
L

-- ----.
------.

"

-"lll(4~~~~i~n)

(t

,

,

"1

1.6 ± 0.4 N'm
(14 ± 4lbloin)

~

i"

1.6:t 0.4 N.m~
114 ± 4Ibf·in)

~

)

Il
. "~

K /.~
~!f:'<~/

2 ± 0.5 N'm

•

2.5±0.5N·m
(22 ± 4 Ibloin)

(18/ Ibloin) ..

(~~~~~;::I'
4.5 ± 0.5 Nom
(40 ± 4 Ibloin)

J,/

.~
$

,

"

"

V

4,5 ± 0.5 Nom
(40 ± 4 Ibloin)

2.5 ± 0.5 N·m
(22 ± 4 Ibloin)

-j-------,
~~2±0.5N.m ~

-~

. ~&. t
..

;

'.,

~./

352

•

~ ~~~~

)

i<.'. '. .

••

-

(18±4IbIoi

J AJ~'

1.6±0.4N.mJJ
(14 ± 4 Ibf·in)

'

tmr2011.(l38

.:. :. :l4:.:.R~TS~("~qoo"nd
'

SIDE BODY P,

r--_
__
,

Sactloo 07 CH
5"b",,;00 06 IBOOY)
ASSIS

~------_e~_~lc~e~Ar~O~~~:r~=:~:,========~~::::::::~
~ ~

t

S

.

ucts)

>

T1 - {4~
'

IV-

~..

____

"

.....

'" '"

~

T1

~-~~1~ ~T1

T1
T2
T3
T4

2±05N
25 ± 0 5;: (18 ± 41bfoinl
35.05 Nom (22 ± 4 Ibloinl
6.5 ± 0·5 Nom (31 ± 41bfoinl
.
om (58 ± 4 Ibfoinl

•

Imr2011-038

353

Section 07 CHASSIS
Subsection 06 (BODY)

COCKPIT TRIMS - DRIVER SIDE (Torques and Service Products)

~~~~/
2.5 ±O.5 Nom
(22 ± 4 IbNn) ""-

@I---~

.t--

2 ± 0.5 Nom
(18 ± 41bf·in)

2 ± 0.5 Nom
(18 ± 4 Ibfoin)

~

4.5 ± 0.5 Nom

J ~;- i
(40~:tbN~~,
L"

:1/
/'

/ /

I

~

/

I
I

I

"/t:,e.

I

-~ '

1 ___ ____ __ I

354

CE Model

Imr2011-038

Section 07 CHASSIS
Subsection 06 (BODY)

COCKPIT TRIMS - PASSENGER SIDE (Torques and Service Products)

2.5 :t 0.5 N-m
(22 ± 4 lbf-in )

0-2.0.5 Nom

~~~~D~

118.4IbHn)

2.5 ± 0.5 N·m

122.4IbHn)

tnY2Ql1---2-;.-BF"""m""A"...
·

~lii

V 06G1KA

THE SHADED PART INDICATES THE CONNECTOR LOCATION
IN HOUSING

B
A
B
A

~.

Fuel injector
Manifold air pressure and
temperature sensor
2WD/4WD actuator

MG

multifunction swit ch

OPS

Oil pressure switch

OV

Override button

PO

RH headlight

PF l

Fuse Holder (main)

PF2

Fuse Holder

PG

LH headlight

RD

Voltage regulator/rectifier

SB

Seat belt

SO

2WD/4WD actuator switch

SM

Starter motor

SS

SWW

Harness interconnect
(engine/vehicle)

MD

SPKl and SPK2

Winch relay

Cooling fan

HIBM

MAPTS

SW

Brake light switch

Gearbox position sensor

INJl and INJ2

Start switch

Fuel pump

GBPS

HIC

STSW

Engine control module

ETA
FP

390

DESCR IPTION

B
A

B
C

o

A

AOOE4WB

C~

(

~~

B
A

B
C

~

~C

B

TYPICAL

Spark plug
Starter solenoid

mr20 11.04 1

Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

CONNECTOR INFORMATION
SERVICE TOOLS
Description

Part Number

CRIMPING TOOL (HEAVY GAUGE WIRE) .................•....... 529 035
ECM ADAPTER TOOL
529 036
ECM TERMINAL REMOVER 2.25
529036
ECM TERMINAL REMOVER 3.36 ...
529036

730
166
175
174

Page

................. ............ 399
............ ......... .....
• ...... 396
.................. .. ............... 397
........................................ 397

SERVICE TOOLS - OTHER SUPPLIER
Description

GM TERMINAL EXTRACTOR ......... . . . . ... .... ..
SNAP-ON TERMINAL REMOVER TOOL

Part Number

........ 12094430
TI600-4

Page

............................ 398
................................ 394

GENERAL
DEUTSCH CONNECTORS
Deutsch Connector Application
A variety of Deutsch connectors are used on various systems:
- Engine connector
- Magneto connector.
The following procedures may be used on each as
they are similar in construction.

Deutsch Connector Removal from its
Support
1. Insert a small flat screwdriver between the support and the Deutsch connector.
2. Pry the connector away from the support
slightly while sliding it out in the direction
shown.

TYPICAL - MALE CONNECTOR REMOVED FOR CLARITY
1. Insert screwdriver here

Deutsch Connector Disconnect
1. To disconnect a Deutsch connector, press the
release tab and twist a small flat screwdriver
between the male and female housing to disengage and disconnect them.

TYPICAL · MALE CONNECTOR REMOVED FOR CLARITY
1. Insert screwdriver here
mr201HJ42

391

Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

Deutsch Connector Disassembly and
Reassembly

F1BZOMA

2

1

TYPICAL - DEUTSCH CONNECTOR
1. Male connector
2. Female connector
3. Secondary lock
4. Sealing cap

TYPICAL
1. Release tab

2. Deutsch connector

Ilitu'tRj Do not apply dielectric grease on terminal inside connector.
Terminal Removal
To remove terminals from connector, proceed as
follows:
1. Using long nose pliers, pull out the secondary
plastic lock from between the terminals .

F18Z0NA

2

TYPICAL
1. Deutsch connector
2. Press release button

V01GOOA

FEMALE CONNECTOR
1. Female lock

TYPICAL
1. Flat screwdriver
2. Deutsch connector

392

tmr2011 -042

Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

3. Pull back on the terminal wire to be sure the
retention fingers are holding the terminal.
4. After all required terminals have been inserted,
the lock must be installed.

VOIGOPA

MALE CONNECTOR
1. Mel.lock

NOTE: Before pin extraction, push wire forward
to relieve pressure on retaining tab .
2. Insert a 4.8 mm (.189 in) wide screwdriver
blade inside the front of the terminal cavity.
3. Pry the retaining tab away from the terminal
while gently pulling the w ire and terminal out
of the back of the connector.

CONNECTOR PIN·OUT
1. Terminal position identifica tion numbers

PACKARD CONNECTORS
Packard Connector Application
Packard connectors are used to connect:
- Electrical harnesses
- Gauges

- VCM
- EFB.

~

'- "- 1- 1-

3-Pin Packard Connector

1

VG IGOOA

1

FEMALE CONNECTOR
1. Retaining tab

Terminal Insertion
1. For insertion of a terminal, ensure the secondary plastic lock is removed.
2. Insert terminal through the back of the connector in the appropriate position, and push it in as
far as it will go. You should feel or hear the terminal lock engage.
tmr2Ql1.042

F04H45A

VIEW OF A 3·PIN PACKARD CONNECTOR
1. Identification le rrers

NOTE: This type of connector also comes in other
pin configurations.

393

Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

To remove a terminal from a 3-pin Packard connector, use the SNAP-ON TERMINAL REMOVER TOOL
!PIN TI600-4).

Ensure all terminals are properly crimped on
wires and connectors are
fastened.

PACKARD CONNECTOR
(MULTIFUNCTION GAUGE)
3

Firmly push down tab and hold to unlock connector while pull ing it out.
CONNECTOR PINOUT

Push on both tabs to remove retainer.

A33Z01A

2

1

TYPICAL
1. Retainer
2. Tab (one on each side)

Open housing by lifting 4 tabs.

A33Z02A

TYPICAL
1. Tabs (2 on each side)

394

tmr2011-Q42

Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

Lift the top plastic lock of the female terminal to
be removed and hold in position. Lift the female
terminal to unlock from the housing and push out
of housing.

2. Press and hold the locking tab on the connector
to be disconnected.

LOCKING TAB TO PRESS ANO HOLD

3. As you hold the locking tab, rotate the connector locking cam until it stops.
TYPICAL
1. Lift and hold plastic lock
2. Lift to unlock and push out

MOLEX CONNECTOR
Molex Connector Application
The Molex connector is used on the ECM .
There are 2 MOLEX connectors on the ECM.
The engine wiring harness connector is connected to ECM connector "A". The vehicle wiring
harness connector is connected to ECM connector M
8
M

,

Each ECM connector has 48 pins.
CONNECTOR LOCKING CAM ROTATION TO RELEASE

4. Pull connector off ECM.

smr21)()9.{)27-OO5

ECM CONNECTORS

Do not apply any product to the pins in the ECM
connector.

Connector Removal
1. To access the ECM, refer to ELECTRONIC
FUEL INJECTION subsection.

tmr2011-Q42

395

Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

Connector Installation
1. Fully open connector locking cam.

LOCKING TAB FULLY OUT

Connector Inspection
CONNECTOR LOCKING CAM IN RELEASE POSITION

2. Insert connector on ECM.
3. As you push the connector onto the ECM, rotate the connector locking cam until it snaps
locked.

Before replacing an ECM, always check electrical
connections.
1. Ensure connector locking mechanism is functioning properly.
2. Ensure all wire terminals (pins) are properly
locked in the connector.
3. Ensure they are very tight, make good contact
with the pins in the ECM.
4. Ensure the pins in the harness connector
and the ECM connector are clean, shiny and
corrosion-free.
5. Check wiring harness for signs of scoring.
NOTE: A "defective ECM module" could possibly be repaired simply by disconnecting and reconnecting it.

'NuiIHi

Do not apply any lubricant product
to the pins of the ECM connector.

Connector Probing
1. Locked

4. Ensure the locking tab is fully out.

396

The most recommended and safest method to
probe the MOLEX (ECM) connector terminals is
to use the ECM ADAPTER TOOL (PIN 529036166).
This tool will prevent deforming or enlarging of
the terminals, which would lead to bad ECM terminal contact creating intermittent or permanent
problems.

tmr2011-042

Section 09 WIRING DIAGRAM
Subsection 02 (CONNECTOR INFORMATION)

. -

5290~6175

529036166

1. Disconnect the ECM connector to be probed,
and reconnect it on the ECM adapter.

1. Remove rear protector from connector.
2. Pull out the connector lock.

2. Probe wire terminals of the circuit to be tested
directly in the adapter holes.

TYPICAL

3. Insert tool to unlock terminal.

1. ECM connector
2. ECM adapter

m".tIlj Never

probe directly on the ECM
harness connector. This could change the
shape or enlarge the terminals and create intermittent or permanent contact problems.

Connector Terminal Removal (Harness
Connector)
To remove a signal terminal from the ECM harness connector, use the ECM TERMINAL REMOVER 2.25 (PIN 529 036 175).
To remove a power terminal, use the ECM TERMINAL REMOVER 3.36 (PIN 529036 174).
7. Unlock here

4. Gently pull on the wire to extract the terminal
out the back of the connector.

lmr2Ql1..()42

397

Section 09 WIRING DIAGRAM
Subsection 02

(CONNECTOR INFORMATION)

$mr201().()5().()22.,

Step 2: Insert GM extractor toof (PIN 72094430)

1••t,).IHI

Before installing wire terminals in
the connector, ensure all terminals are properly crimped on wires. After installation of
wire terminals in the connectors, ensure they
are properly locked by gently pulling on them
as if to extract them.

3. Gently pull on the wire to extract the pin out the
back of the connector.

FURUKAWA CONNECTOR
Furukawa Connector Application
Voltage regulator/rectifier.

Terminal Removal
1. Remove the secondary lock (plastic insert).
s mr201 0-0SO-023.8

Step 3: Pull wire to extract pin

IN"itliOJ

Before installing terminals in the
connectors, ensure all terminals are properly
crimped on the wires. After installation of the
wire terminals in the connectors, ensure they
are properly locked by gently pushing on them
as if to extract them.

BATTERY AND STARTER CABLE
TERMINALS
Cable Crimping
Step 1.' Remove the secondary lock

2. Carefully insert the GM TERMINAL EXTRACTOR
(PIN 12094430) between the lock and the pin to
release the pin.

Carefully strip the wire approximately to 10 mm
(3/8 in) in length, using a wire stripping tool or
sharp blade/knife.

GM TERMINAL EXTRACTOR (PIN 12094430)

398

tmr20 11 .{)42

Section 09 WIRING DIAGRAM
Subsection 02

(CONNECTOR INFORMATION)

A. 10 mm (3/8 in)

NOTE: Make sure not to cut wire strands while
stripping the wire .
Install the appropriate terminal on the w ire according to the requirement. Refer to appropriate
PARTS CATALOG.

POSITION ING THE CRIMPIN G PLIERS

Step 1: Step 1: Press
Step 2: Step 2: Rotate

After positioning th e cri mping pliers, cri mp t he terminal already installed on w ire.

A32E2RA

INSTALLATION OF TERMINAL

Follow the instructions provided w ith the CRIMPING TOOL (HEAVY GAUGE W IRE) !PIN 529 035 730)
to select the proper position of the tool.

529035130

NOTE: Different w ires require different crimping
pliers settings.

CRIMPING OF WIRE

A32E2:UA

PROPERLY CRIMPED WIRE

To verify, if the w ire is properly crimped, apply
some pulling force on wi re and the term inal at the
same time from both directions.

'NoiMj

Never weld the wire to the terminal.
Welding can change the property of the wire
and it can become brittle and break.

tmr2011-042

399

Section 09 WIRING DIAGRAM
Subsection 02

(CONNECTOR INFORMATION)

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.

RI,JilIJiI

Make sure that the protective heat
shrink rubber tube has been properly installed
and no part of wire is exposed.

400

tm r2011 -Q42

SAFETY NOTICE

SAFETY NOTICE

ls

CAUTION Indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.

ua

NOTICE Indicates an instruction which, if not
followed, could result in severe damage to vehicle components or other property.

NOTE: Indicates supplementary information required to fully complete an instruction.
Although the mere reading of such information
does not eliminate the hazard, your understanding of the information will promote its correct
use. Always use common shop safety practices.
It is understood that this manual may be translated into another language. In the event of any
discrepancy, the English version shall prevail.
BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services
be carried out and/or verified by a highly skilled
professional mechanic.

gr
e

en

-m
an

This manual has been prepared as a guide to correctly service and repair the 2012 Can-Am™ Commander LTD as described in the model list in the
INTRODUCTION.
This SHOP MANUAL SUPPLEMENT must be
used in conjunction with the 2011 CAN-AM
COMMANDER SHOP MANUAL (P/N 219 100
452). Refer to this manual when a particular system is not covered in this supplement.
This edition was primarily published to be used
by technicians who are already familiar with all
service procedures relating to BRP products.
Technicians should attend training courses given
by BRPTI.
Please note that the instructions will apply only
if proper hand tools and special service tools are
used.
The contents of this manual depicts parts and
procedures applicable to the particular product at
the time of writing. Service and warranty bulletins
may be published to update the content of this
manual. Dealer modifications that were carried
out after manufacturing of the product, whether
or not authorized by BRP, are not included.
It is understood that certain modifications may
render use of the vehicle illegal under existing
federal, provincial and state regulations.
In addition, the sole purpose of the illustrations
throughout the manual, is to assist identification
of the general configuration of the parts. They are
not to be interpreted as technical drawings or exact replicas of the parts.
The use of BRP parts is most strongly recommended when considering replacement of any
component. Dealer and/or distributor assistance
should be sought in case of doubt.
The engines and the corresponding components
identified in this document should not be utilized
on product(s) other than those mentioned in this
document.
This manual emphasizes particular information denoted by the following wording and symbols:

WARNING

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

tmr2012-002

I

INTRODUCTION

INTRODUCTION
MODEL NUMBER

Commander 1000 LTD

6GCA, 6GBC, 6GCC,
6GCD

gr
e

en

-m
an

The information and component/system descriptions 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 differences 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, models or equipment without incurring obligation.

ua

MODEL

ls

This shop manual covers the following BRP made
2012 Can-Am side-by-side vehicles.

II

tmr2012-002

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER 1000 LIMITED
COMMANDER
1000 LTD

MODEL

ls

ENGINE

ROTAX®1010
V-twin 4-stroke, Single Over Head Camshaft
(SOHC), liquid cooled
2

Engine type

ua

Number of cylinders
Number of valves

8 valves (mechanical adjustment)

Bore

91 mm (3.583 in)

Stroke

75 mm (2.95 in)

Displacement

976 cm³ (59.6 in³)
10.5:1

Compression ratio

7000 rpm

Exhaust system
Air filter
Intake valve opening
Intake valve closing
Exhaust valve opening
Exhaust valve closing
Valve clearance

-m
an

Maximum HP RPM

Spark arrestor approved by USDA Forest Service

en

Intake and exhaust

gr
e

Intake

Valve seat contact width

Piston diameter

Piston/cylinder clearance

tmr2011-040

5° BTDC

0.11 mm to 0.19 mm (.0043 in to .0075 in)

Valve spring free length

Rocker arm shaft diameter

65° BBDC

Exhaust

Valve guide diameter

Rocker arm bore diameter

60° ABDC

0.06 mm to 0.14 mm (.0024 in to .0055 in)

Exhaust

Valve out of round

5° BTDC

Intake

Intake

Valve stem diameter

Flat corrugated composite fiber

Exhaust

New

Service limit

New

4.966 mm to 4.980 mm (.1955 in to .1961 in)
4.930 mm (.1941 in)

4.956 mm to 4.970 mm (.1951 in to .1957 in)

Service limit

4.930 mm (.1941 in)

New

0.005 mm (.0002 in)

Service limit
New

0.06 mm (.0024 in)
4.998 mm to 5.018 mm (.1968 in to .1976 in)

Service limit

5.050 mm (.1988 in)

New

40.81 mm (1.607 in)

Service limit
New
Service limit
New
Service limit
New
Service limit
New
Service limit
New
Service limit
New
Service limit

39.00 mm (1.535 in)
1.05 mm to 1.35 mm (.041 in to .053 in)
1.8 mm (.071 in)
1.25 mm to 1.55 mm (.049 in to .061 in)
2 mm (.079 in)
12.036 mm to 12.050 mm (.4739 in to .4744 in)
12.060 mm (.4748 in)
12.000 mm to 12.018 mm (.4724 in to .4731 in)
11.990 mm (.472 in)
90.950 mm to 90.966 mm (3.5807 in to 3.5813 in)
90.900 mm (3.5787 in)
0.027 mm to 0.057 mm (.0011 in to .0022 in)
0.100 mm (.0039 in)

1

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
ENGINE (CONT'D)

Lower compression ring, tapered face

3rd

Oil scraper ring

Rectangular
Tapered face

0.20 mm to 0.40 mm (.008 in to .016 in)
New

Oil scraper ring

Ring end gap

0.60 mm (.024 in)

Service limit

Oil scraper ring

0.03 mm to 0.07 mm (.0012 in to .0028 in)

New

Oil scraper ring

0.02 mm to 0.06 mm (.0008 in to .0024 in)

0.01 mm to 0.18 mm (.0004 in to .0071 in)

-m
an

Ring/piston groove clearance

0.70 mm (.028 in)
1.00 mm (.039 in)

Rectangular
Tapered face

0.20 mm to 0.40 mm (.008 in to .016 in)

0.20 mm to 0.70 mm (.008 in to .028 in)

Rectangular
Tapered face

ls

Upper compression ring, rectangular

2nd

ua

Piston ring type

1st

Rectangular

Tapered face

0.15 mm (.0059 in)

Service limit

Oil scraper ring
Cylinder bore

0.25 mm (.0098 in)

New

Cylinder taper
Cylinder out of round

Timing chain side

0.038 mm (.0015 in)

Service limit

0.090 mm (.0035 in)

Maximum New

0.015 mm (.0006 in)

New

Service limit

New

Service limit

en

Spark plug side

Timing chain side

Camshaft main bearing
journal bore

Spark plug side
Intake valve

gr
e

Camshaft lobe

Exhaust valve

90.993 mm to 91.007 mm (3.5824 in to 3.583 in)

Maximum New

Service limit

Camshaft main bearing
journal

0.15 mm (.0059 in)

New
Service limit

New
Wear limit

New
Service limit

New
Service limit

0.020 mm (.0008 in)

34.959 mm to 34.975 mm (1.3763 in to 1.377 in)
34.950 mm (1.376 in)

21.959 mm to 21.980 mm (.8645 in to .8654 in)
21.950 mm (.8642 in)

35.000 mm to 35.025 mm (1.378 in to 1.3789 in)
35.040 mm (1.3795 in)
22.000 mm to 22.021 mm (.8661 in to .867 in)
22.040 mm (.8677 in)
32.960 mm to 33.160 mm (1.2976 in to 1.3055 in)
32.940 mm (1.2969 in)
32.860 mm to 33.060 mm (1.2937 in to 1.3016 in)
32.840 mm (1.2929 in)

Crankshaft main bearing journal diameter
(MAG/PTO side)

New
Service limit

42.000 mm (1.6535 in)

Crankshaft radial play (MAG/PTO side)

Service limit

0.07 mm (.0028 in)

Crankshaft bearing journal diameter (in PTO cover)
Crankshaft radial play (PTO cover bearing)
Crankshaft axial play

2

New

42.016 mm to 42.040 mm (1.6542 in to 1.6551 in)

34.004 mm to 34.020 mm (1.3387 in to 1.3394 in)

Service limit

33.998 mm (1.3385 in)

Service limit

0.10 mm (.0039 in)

New
Service limit

0.200 mm to 0.500 mm (.0079 in to .0197 in)
0.600 mm (.0236 in)

tmr2011-040

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
ENGINE (CONT'D)
New

Crankshaft pin diameter

Crankcase plain bearing

MAG/PTO side

New
Service limit

PTO cover plain bearing

Service limit

Connecting rod big end diameter

Service limit

Connecting rod big end radial play

Service limit

Connecting rod big end axial play

New
Service limit
New
Service limit

42.100 mm (1.6575 in)

34.120 mm (1.3433 in)

42.100 mm (1.6575 in)
0.09 mm (.0035 in)

0.250 mm to 0.550 mm (.0098 in to .0217 in)
0.600 mm (.024 in)

22.010 mm to 22.020 mm (.8665 in to .8669 in)

Service limit

22.050 mm (.8681 in)
21.996 mm to 22.000 mm
(865.984 in to 866.142 in)
21.980 mm (.8654 in)

Service limit

0.080 mm (.0031 in)

-m
an

Connecting rod small end diameter

0.050 mm (.002 in)

ua

MAG/PTO side

41.967 mm (1.6522 in)

ls

Service limit

Crankshaft deflection

Piston pin diameter

41.986 mm to 42.010 mm (1.653 in to 1.6539 in)

New

Connecting rod/piston pin clearance (radial play)
LUBRICATION SYSTEM

Type

Wet sump. Replaceable cartridge oil filter

Oil filter

Engine oil pressure

Lubrication

BRP Rotax paper type, replaceable

Minimum
Capacity
(oil change with filter)

Engine oil

en

Recommended

300 kPa (44 PSI) at 6000 RPM
2.2 L (2.3 qt (U.S. liq.))

For the summer season, use XPS synthetic
blend oil (summer grade) (P/N 293 600 121).
For the winter season, use XPS synthetic
oil (winter grade) (P/N 293 600 112).
If not available, use a 5W40 motor oil that
meets the requirements for API service
classification SM, SL or SJ

COOLING SYSTEM

gr
e

Coolant

Thermostat

Type

Capacity

Starts to open

65°C (149°F)

Fully open

88°C (190°F)

Radiator cap opening pressure

tmr2011-040

Ethyl glycol/water mix (50% coolant, 50% water).
Use premixed coolant sold by
BRP (P/N 219 700 362) or
coolant specifically designed for aluminum engines
4.3 L (1.1 U.S. gal.)

110 kPa (16 PSI)

3

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
TRANSMISSION
Type

CVT (Continuously Variable Transmission)

Drive belt width

Service limit
New

Governor cup roller outer diameter

Service limit
New

Governor cup roller inner diameter

Service limit
New

Centrifugal lever pivot bolt diameter

Service limit
New

Centrifugal lever bore diameter

Service limit

Drive pulley sliding half large bushing
Drive pulley sliding half small bushing
Drive pulley spring free length
Drive pulley spring free squareness
Spring sleeve length
Driven pulley sliding half bushing

New

Service limit

New

13.70 mm to 13.80 mm (.539 in to .543 in)
13.20 mm (.52 in)

8.05 mm to 8.15 mm (.317 in to .321 in)
9.00 mm (.354 in)

6.078 mm to 6.100 mm (.239 in to .24 in)
6.000 mm (.236 in)

6.035 mm to 6.078 mm (.2376 in to .2393 in)
6.200 mm (.244 in)

6.113 mm to 6.171 mm (.241 in to .243 in)
6.300 mm (.248 in)

55.000 mm to 55.040 mm (2.165 in to 2.167 in)
55.200 mm (2.173 in)

32.000 mm to 32.040 mm (1.26 in to 1.261 in)

Service limit

32.200 mm (1.268 in)

Service limit

105 mm (4.134 in)

Service limit

4 mm (.157 in)

New

Service limit

New

Service limit

New

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Driven pulley sliding fixed bushing

30.00 mm (1.181 in)

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Drive pulley sliding half centrifugal lever pivot bolt bore New
diameter
Service limit

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1750 ± 100 RPM

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Engagement RPM

9.2 mm to 9.4 mm (.362 in to .37 in)
9.0 mm (.354 in)

30.060 mm to 30.100 mm (1.183 in to 1.185 in)
30.200 mm (1.189 in)

30.060 mm to 30.100 mm (1.183 in to 1.185 in)

Service limit

30.200 mm (1.189 in)

Torque gear on driven pulley

Service limit

7.500 mm (.295 in)

Driven pulley spring free length

Service limit

125 mm (4.921 in)

Driven pulley spring free squareness

Service limit

3.8 mm (.15 in)

GEARBOX

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Type
Gearbox oil

Coupling sleeve groove width
Coupling fork claw thickness

Shift fork claw thickness
(high, low and reverse gear shift fork)
Width of shift fork engagement groove

4

Capacity
Recommended
New
Service limit
New
Service limit
New
Service limit
New
Service limit

Dual range (HI-LO) with park, neutral and reverse
450 ml (15 U.S. oz)
XPS synthetic gear oil (P/N 293 600 140)
or a 75W140 API GL-5 synthetic gear oil
5.25 mm to 5.35 mm (.207 in to .211 in)
5.50 mm (.217 in)
4.95 mm to 5.05 mm (.195 in to .199 in)
4.80 mm (.189 in)
5.10 mm to 5.20 mm (.201 in to .205 in)
5.00 mm (.197 in)
5.30 mm to 5.40 mm (.209 in to .213 in)
5.50 mm (.217 in)

tmr2011-040

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
GEARBOX (CONT'D)
New

Diameter free pinions

29.000 mm to 29.013 mm (1.1417 in to 1.1422 in)

New

Intermediate gear shaft

29.015 mm (1.1423 in)

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Service limit

24.987 mm to 25.000 mm (.9837 in to .9843 in)

Service limit

Countershaft
CVT side
Free pinion bearing
Main shaft

New
Service limit
New
Service limit
New
Service limit

19.973 mm (.7863 in)

24.977 mm to 24.990 mm (.9833 in to .9839 in)
24.970 mm (.9831 in)

24.987 mm to 25.000 mm (.9837 in to .9843 in)
24.984 mm (.9836 in)

16.980 mm to 16.991 mm (.6685 in to .6689 in)

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Bearing journal
MAG/CVT side

Service limit

24.977 mm (.983 in)

19.977 mm to 19.990 mm (.7865 in to .787 in)

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MAG side

New

16.976 mm (.6683 in)

ELECTRICAL SYSTEM

Magneto generator output
Stator resistance (20C)
Ignition system type
Ignition timing

Quantity

Spark plug

Make and type

Gap

Forward

Engine RPM limiter setting

Reverse

en

Type

Battery

Headlight
Taillight

Turn signals (CE)

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Position light

tmr2011-040

650 W @ 6000 RPM
0.15 to 0.30
IDI (Inductive Discharge Ignition)
Not adjustable
2
NGK DCPR8E

0.7 mm to 0.8 mm (.028 in to .031 in)

8000 rpm
20 km/h to 25 km/h (12 MPH to 16 MPH)
(8000 rpm with Override)
Maintenance free

Voltage

12 volts

Nominal rating

18 A•h

Power starter output

0.7 KW
4 x 60 W
2 X 8/27 W
10 W
LED, 0.7 V approximately (each)

5

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
ELECTRICAL SYSTEM (CONT'D)
F1: Main
Fuses
F2: Main accessories
(fuse block #2)
F3: ACS suspension

50 A
60 A

F4: Speedometer and brake relay

10 A

F5: Fuel injectors and ignition coils

7.5 A

F7: Winch and 2WD/4WD switches
F8: Ignition switch and gauge
Fuses
(fuse block #1)

F9: Cooling fan

5 A

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F6: Engine control module (ECM)

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30 A

5 A

5 A

25 A

F10: Euro controls

5 A

F11: Lights

30 A
15 A

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F12: 12V power outlet

F13: Cooling fan relay (R1) and Accessories relay (R3)

5 A

F14: 12V power (connector DC6)

15 A

F15: Fuel pump

5 A

Cooling fan relay (R1)
Main relay (R2)

Accessories relay (R3)

Relays

Lights relay(R4)

ACS suspension relay (R5)
Brake relay (R8)

FUEL SYSTEM

Fuel pump
Idle speed

Type

en

Fuel delivery

Type

Operating pressure
Type

Octane rating

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Fuel

Fuel tank capacity

Fuel remaining when low fuel light turns ON

6

Inside North America
Outside North America

Electronic Fuel Injection (EFI), 54 mm throttle
body with iTC (Intelligent Throttle Control),
1 injector per cylinder
Electrical (in fuel tank)
350 kPa (51 PSI)
1250 rpm ± 50 (not adjustable)
Regular unleaded gasoline
87 (R+M)/2 or higher
92 RON or higher
38 L (10 U.S. gal.)
± 12 L (3.2 U.S. gal.)

tmr2011-040

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
DRIVE SYSTEM

Visco-lok† front differential

Front drive

3.6:1

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Front drive ratio
Rear drive

Shaft driven/spool
3.6:1

Rear drive ratio
Front differential oil

Recommended
Capacity

Rear final drive oil

Recommended

CV joint grease
STEERING
Steering wheel
Turning radius

Hi-temp bearing grease NLGI-2 or an equivalent

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Propeller shaft grease

500 ml (17 U.S. oz)
XPS synthetic gear oil (P/N 293 600 043)
or synthetic gear oil 75W90 API GL-5
350 ml (11.8 U.S. oz)
XPS synthetic gear oil (P/N 293 600 140)
or synthetic gear oil 75W140 API GL-5
CV joint grease (P/N 293 550 019)

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Capacity

Total toe (vehicle on ground)

Camber angle (vehicle on ground)

Tie-rod maximum length unengaged threads

Adjustable tilt steering
240 cm (94.5 in)
0 mm ± 4 mm (0 in ± .157 in)
0.7° positive
32 mm (1.26 in)

FRONT SUSPENSION
Suspension type
Suspension travel
Shock absorber

Qty

2

Type

HPG clicker with air

en

Spring free length

Double suspension-arm with dive-control
geometry with ACS
254 mm (10 in)

Automatic mode: 6 positions
air compression settings
Manual mode: limitless between
position 1 and position 6 of automatic mode

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Preload adjustment type

358.7 mm (14.122 in)

tmr2011-040

7

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

MODEL

COMMANDER
1000 LTD

REAR SUSPENSION

Suspension travel
Shock absorber

Qty

2

Type

HPG clicker with air
355.6 mm (14 in)

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Spring free length

Automatic mode: 6 positions
air compression settings
Manual mode: limitless between
position 1 and position 6 of automatic mode

Preload adjustment type

Qty
Type
Qty
Rear brake

Type
Capacity

Brake fluid

Type

Caliper
Front
Rear

Minimum brake pad thickness
Front
Rear

Maximum brake disc warpage

Front

Rear

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Minimum tire thread depth
Size

Metallic

Metallic

1 mm (.04 in)

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Minimum brake disc
thickness

Pressure

DOT 4

Floating

Brake pad material

TIRE

2
214 mm cross-drilled disc brakes with
hydraulic twin-piston calipers
1
214 mm cross-drilled disc brake with
hydraulic twin-piston caliper
250 ml (8.5 U.S. oz)

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BRAKES
Front brake

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Torsional Trailing arm Independant (TTI) with
external sway bar with ACS
254 mm (10 in)

Suspension type

4.3 mm (11/64 in)

4.3 mm (11/64 in)
0.2 mm (.01 in)

Maximum: 83 kPa (12 PSI)
Minimum: 69 kPa (10 PSI)
Maximum: 152 kPa (22 PSI)
Minimum: 83 kPa (12 PSI)
3 mm (.118 in)

Front

27 x 9 x 14 (in)

Rear

27 x 11 x 14 (in)

WHEELS
Type

Rim size

Wheel nuts torque

Cast aluminum

Front

14 X 7 (in)

Rear

14 X 8.5 (in)
100 N•m ± 10 N•m (74 lbf•ft ± 7 lbf•ft)

CHASSIS

Cage type

8

50 mm (2 in) diameter, high strength steel,
ROPS-approved cage

tmr2011-040

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
DIMENSION

300.4 cm (118.3 in)

Overall width

148.9 cm (58.6 in)

ls

Overall length
Overall height

182.9 cm (72 in)

Wheel base
Rear

Ground clearance

125.7 cm (49.5 in)
27.9 cm (11 in)

WEIGHT AND LOADING CAPACITY
Dry weight

587 kg (1,295 lb)

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Weight distribution
Front/rear
Cargo box capacity
Total (upper + lower)
(Distribute load evenly in upper and lower
Upper
cargo boxes without exceeding 181 kg (400 lb) in the
Lower
upper cargo box.)
Total vehicle load allowed
(including driver, passenger, all other loads and added
accessories)
Gross vehicle weight rating
Towing capacity (Hitch support of 50.8 mm (2 in) X 50.8 mm (2 in))

44/56

272 kg (600 lb)

181 kg (400 lb)

272 kg (600 lb)
363 kg (800 lb)
990 kg (2,183 lb)
680 kg (1,500 lb)
CE Model: 270 kg (600 lb)
68 kg (150 lb)

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Tongue capacity

121.9 cm (48 in)

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Wheel track

192.4 cm (75.7 in)

Front

tmr2011-040

9

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

AIR CONTROLLED SUSPENSION (ACS)
SERVICE TOOLS
Part Number

Page

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Description

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FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................... 13–15, 17, 20–22

tmr2012-005

1

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

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NEW
48 N•m
(35 lbf•ft)

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NEW
48 N•m
(35 lbf•ft)

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ACS FRONT SUSPENSION

NEW = Component must be replaced when removed.

tmr2012-005-100_a

2

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS REAR SUSPENSION

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10 N•m
(89 lbf•in)

10 N•m
(89 lbf•in)

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NEW

en

48 N•m
(35lbf•ft)
NEW

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10 N•m
(89 lbf•in)

10 N•m
(89 lbf•in)

10 N•m
(89 lbf•in)
24 N•m
(18 lbf•ft)

NEW = Component must be replaced when removed.

tmr2012-005-001_a

tmr2012-005

3

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

GENERAL
During assembly/installation, use torque values
and service products as in the exploded view.

ls

WARNING

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Torque wrench tightening specifications
must be strictly adhered to.
Locking devices must be replaced when removed (e.g.: locking tabs, cotter pins, etc.).
NOTICE Hoses, cables or locking ties removed during a procedure must be reinstalled
as per factory standards. Hoses must be properly inserted.

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Be careful while manipulating nylon hoses, they
must not be kinked.

CAUTION Always wear safety goggles
when working with pressurized air system.

CAUTION The ACS suspension system
may be under high pressure (over 900 kPa
(130 PSI)). Release air pressure prior to working on the system. Refer to AIR PRESSURE
RELEASE FOR SERVICING.

SYSTEM DESCRIPTION
(OPERATION)

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The Commander LTD comes equipped with
front and rear air-controlled suspension and HPG
shocks with remote reservoir (piggyback).
By changing the ACS setting, air pressure in the
front and rear shocks absorbers will change to provide a multitude of different suspension adjustments.
The ACS adjusts the front and rear shocks to 6
rider selectable levels depending on trail conditions or riders preference.
The front shocks pressure is lower than the rear
shocks. The pressure are determined by the setting position.
This system allows the operator to adjust the front
and rear suspension by pressing the suspension
button.

4

vdd2012-001-712

WARNING

Always adjust the ACS suspension setting according to load, riding condition, and speed.

NOTE: The ACS suspension will NOT self-adjust
unless the engine is running, even when key
switch is set to on.
The ACS has 2 modes for suspension adjustment:
– ACS auto mode
– ACS manual mode.

ACS AUTO Mode
The automatic mode allows for simultaneous adjustments on the front and rear suspensions.
In auto mode, the suspension will automatically
be adjusted to the preselected riding comfort position.

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS 1

Softest

ACS 2

Soft

ACS 3

Semi-soft

ACS 4

Semi-firm

ACS 5

Firm with high
ground clearance

ACS 6

Firmest and
highest ground
clearance

RECOMMENDED
LOAD
Operator only
Transporting a passenger
OR a cargo

Transporting a passenger
AND a cargo

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RIDING
COMFORT

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SETTING

To Enter ACS Automatic Mode:
Press the MODE button until either ACS AUTO or
ACS MAN is displayed.
Press SET button to have current ACS mode blink
on screen
Press SET button to select ACS AUTO mode.
NOTE: Selected ACS Setting from ACS1 to ACS6
displayed through gearbox position indicator.

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ACS SUSPENSION SETTINGS

tmo2012-003-221_c

Press and hold SET button to confirm selection.

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ACS MANUAL Mode
In manual mode the front and rear shock pressures can be adjusted independently. The fuel
and temperature indicators will respectively
become front and rear ACS pressure setting indicators.

vdd2012-001-714

ACS AUTO MODE

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Use ACS 1 to ACS 4 for trail riding.
Use the ACS 5 or ACS 6 settings to maximize
ground clearance and increase performance while
riding in the following environments:
– Muddy
– Watery
– Obstacles.
Use the ACS 6 setting is to maximize ground
clearance and increase performance while carrying heavy loads:

WARNING

Always adjust the ACS suspension setting according to load, riding condition, and speed.

tmr2012-005

tmo2012-003-221_b

ACS MANUAL MODE

To Enter ACS Manual Mode:
Press the MODE button until either ACS AUTO or
ACS MAN is displayed.
5

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

tmo2012-003-221_e

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ls

Press SET button to have current ACS mode blink
on screen.
Press SET button to select ACS MAN mode.
NOTE: ACS set points and actual settings displayed through fuel, temp and gearbox position
indicators.

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Press and hold ACS button to lower or raise the
front suspension until desired setting is achieved.

tmo2012-003-221_a

Press and hold SET button to confirm selection.

To Adjust Front Suspension:
Press on the OVERRIDE button until front (F) is
blinking to select front (F) suspension setting.

tmo2012-003-211_a

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1. ACS button

To Adjust Rear Suspension:
Press on the OVERRIDE button until rear (R) is
blinking to select rear (R) suspension setting.

tmo2012-001-001_b

1. Override switch

tmo2012-001-001_b

1. Override switch

6

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

Quick Mode Selection

ls

The last setting utilized in each mode is stored in
the system. This allows for quick selections between the stored automatic mode setting and the
stored manual mode setting.

tmo2012-003-221_d

tmo2012-003-211_a

1. ACS button

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Use the ACS button to lower or raise the rear suspension.

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To Enter Quick Mode Selection:
Press the MODE button until either ACS AUTO or
ACS MAN is displayed.
Press SET button to have current ACS mode blink
on screen.
Press SET button to select desired mode.

tmo2012-003-221_a

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NOTE: Fuel and temperature indicators will respectively become front and rear ACS setting
indicators.

tmo2012-003-221_c

Press and hold SET button to confirm selection.
ACS system will adjust to the last settings.

tmo2012-003-221_b

tmr2012-005

7

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

The ACS compressor also comes with an auxiliary
hose that can be used to inflate tires out on the
trail.
The air outlet fitting is located behind the driver's
seat.

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Tire Inflation Using the ACS
Compressor

NOTE: After activating the System Pressure relief button the system is not completely empty.
The compressor setting does not allowed to drop
pressure under 207 kPa (30 PSI).

SYSTEM DESCRIPTION
(COMPONENTS)
Fuse and Relay

ACS Fuse
The ACS system is protected by the fuse F3 (60 A)
located in the fuse block no.2. This fuse powered
the ACS compressor through the ACS relay (R5).

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SYSTEM DESCRIPTION
(FEATURES)

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ACS Compressor Relay (R5)
ACS compressor relay (R5) is located near ACS
compressor, under driver’s seat.

vdd2012-001-717

Air Pressure Release for Servicing

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It is recommended to release air pressure in the
system before servicing any components.
1. Connect vehicle to the latest appropriate version of B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE subsection
in the 2011 CAN-AM SIDE-BY-SIDE SHOP
MANUAL.
2. Select Activation page.
3. Select ACS folder.
4. Press the System Pressure relief button to
proceed.

tmr2012-005-039_a

1. System Pressure relief button

8

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

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tmr2012-005-003_a

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ACS Main Components

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1. Multifunction gauge
2. ACS module
3. ACS button
4. ACS compressor (including temperature sensor)
5. ACS relay (R5)
6. Air filter
7. Pressure distributor
8. ACS solenoid valve (including pressure sensor)
9. Outlet fitting
10. Rear air reservoir
11. Rear shock absorbers
12. Front air reservoirs
13. Front shock absorbers

tmr2012-005

9

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

TROUBLESHOOTING
DIAGNOSTIC TIPS

TROUBLESHOOTING
GUIDELINES

1. Burn fuse F3 (60 A).
- Replace

2. Faulty compressor.
- Carry out a compressor operation test. Refer to
ACS COMPRESSOR OPERATION TEST.
3. Faulty solenoid valve
- Carry out a solenoid valve operation test. Refer
to ACS SOLENOID VALVE OPERATION TEST.

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AIR FAULT
If this message appears, it indicates a disparity between the requested and the actual suspension
settings. The system should react to correct this
situation and the message will disappear.
If the message remains active for a long period, it
may indicates a major leak in the system. In this
case, the module will automatically shut down the
compressor to prevent it from overheating. The
shut down procedure of the compressor will stay
active until the next restart of the vehicle (key OFF,
key ON).
If there is a major leak in the system, check the
system for leakage, refer to ACS SYSTEM LEAK
TEST.
If there is no leak, the problem can be electrical
or mechanical. In this case, an electrical failure of
the compressor or the solenoid valve will result in
the impossibility to change the actual suspension
setting; a mechanical failure of the solenoid valve
will create the same situation.
After multiple attempts to change suspension setting, the module will activate error message AIR
FAULT. Refer to TROUBLESHOOTING GUIDELINES for further troubleshooting procedure.

GAUGE DISPLAY SETTING (S1 TO S6)
CHANGED BUT SUSPENSION DOES NOT
WORKED

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Two error messages can appear in the multifunction gauge and they are not necessarily related to
a failure of the ACS system.

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In AUTO Mode

Error Message Displayed in
Multifunction Gauge

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COMPRESSOR TEMPERATURE OVERHEAT
This message appears when the compressor temperature is over the calibrated value.
This situation can occur if the compressor or the
solenoid valves are used during a long period of
time (continually or with brief halts).
Let the compressor cool down before using it
again.

4. Faulty ACS module
- Check the ACS module. Refer to ACS MODULE.

GAUGE DISPLAY SETTING (S1 TO S6)
DOES NOT CHANGED BUT SUSPENSION
WORKED
1. Faulty ACS module
- Check the ACS module. Refer to ACS MODULE.
2. Faulty multifunction gauge
- Check the multifunction gauge.

GAUGE DISPLAY DOES NOT CHANGED
AND SUSPENSION DOES NOT WORKED
1. Make sure engine is running
- Start engine.
2. Burn fuse F3 (60 A).
- Replace
3. Faulty ACS module
- Check the ACS module. Refer to ACS MODULE.
4. Faulty ACS button or wiring
- Check ACS button continuity.
- Check ACS button control circuit.

In Manual Mode
GAUGE DISPLAY SETTING (F OR R) DOES
NOT CHANGED
1. Faulty Override button
- Check the Override button.
2. Faulty multifunction gauge
- Check the multifunction gauge.

10

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

1. Faulty solenoid valve
- Carry out a release valve operation test. Refer to
ACS RELEASE VALVE OPERATION TEST.
2. Faulty ACS release valve
- Carry out a solenoid valve operation test. Refer
to ACS SOLENOID VALVE OPERATION TEST.
3. Faulty ACS button or wiring
- Check ACS button continuity. Refer to ACS BUTTON.
- Check ACS button control circuit. Refer to ACS
BUTTON.

7. Faulty ACS module
- Check the ACS module. Refer to ACS MODULE.

AIR OUTLET FITTING DOES NOT WORKS
1. Make sure engine is running
- Start engine.

2. Faulty solenoid valve
- Carry out a solenoid valve operation test. Refer
to ACS SOLENOID VALVE OPERATION TEST.

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4. Faulty ACS module
- Check the ACS module. Refer to ACS MODULE.

6. Faulty ACS button or wiring
- Check ACS button continuity. Refer to ACS BUTTON.
- Check ACS button control circuit. Refer to ACS
BUTTON.

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SUSPENSION PRESSURE CAN BE
INCREASED ONLY

5. Faulty solenoid valve
- Carry out a solenoid valve operation test. Refer
to ACS SOLENOID VALVE OPERATION TEST.

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AUTO and MANUAL Mode

SUSPENSION PRESSURE CAN BE
DECREASED ONLY

1. Faulty relay (R5)
- Check the ACS relay. Refer to ACS RELAY.

2. Faulty compressor.
- Carry out a compressor operation test. Refer to
ACS COMPRESSOR OPERATION TEST.

3. Faulty solenoid valve
- Carry out a solenoid valve operation test. Refer
to ACS SOLENOID VALVE OPERATION TEST.

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4. Faulty ACS button or wiring
- Check ACS button continuity. Refer to ACS BUTTON.
- Check ACS button control circuit. Refer to ACS
BUTTON.

5. Faulty ACS module
- Check the ACS module. Refer to ACS MODULE.

TROUBLESHOOTING WITH
B.U.D.S.
Check battery voltage before performing any
B.U.D.S. test. Battery must be fully charged or
use a power pack to ensure adequate power for
all required tests.

ACS System Leak Test

1. Connect vehicle to the latest appropriate version of B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE subsection
in the 2011 CAN-AM SIDE-BY-SIDE SHOP
MANUAL.
2. Select Activation page.
3. Select ACS folder.
4. In Self Test region, press the leak test button
to proceed.

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SUSPENSION PRESSURE CAN NOT BE
CHANGED
1. Make sure engine is running
- Start engine.
2. Burn fuse F3 (60 A).
- Replace
3. Faulty relay (R5)
- Check the ACS relay. Refer to ACS RELAY.
4. Faulty compressor.
- Carry out a compressor operation test. Refer to
ACS COMPRESSOR OPERATION TEST.

tmr2012-005

tmr2012-005-004_a

1. Activation page
2. ACS folder
3. Leak test button

11

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

Pneumatic hoses may be disconnected by pushing inwards on the air fitting ring (towards the air
fitting) while pulling outwards on the hose.

tmr2012-005-012_a

If a leak is detected, pressurize the system again
and inspect hoses and fittings with soapy water
to locate the faulty component.

1. Fitting ring
2. Pneumatic hose

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ACS Air Pressure Monitoring

tmr2012-005-046_a

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The result will be indicated in the TEST STATUS
box beside the leak test button.

To monitor air pressure in the system during troubleshooting operation, proceed as follows:
1. Connect vehicle to the latest appropriate version of B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE subsection
in the 2011 CAN-AM SIDE-BY-SIDE SHOP
MANUAL.
2. Select Monitoring page.
3. Select ACS folder.

NOTE: Pull the hose slightly and wait during the
release of the remaining air. When all air is released, remove pneumatic hose from its fitting.

Pneumatic hose Installation
Before installing the hose, verify the end of the
pneumatic hose.
If deep nicks are found, cut a small portion of the
hose end.
HOSE END LENGTH TO BE CUT

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3.18 mm to 6.35 mm (1/8 in to 1/4 in)

1. Monitoring page
2. Suspension pressure

PROCEDURES

Push the hose inwards then pull the air fitting ring
outwards to reestablish a good seal and lock the
hose in place.

ACS RELEASE VALVE
ACS Release Valve Access
To access to ACS release valve, remove the following:
– Driver’s seat
– LH lateral console panel
– Floor panel.

PNEUMATIC HOSE

NOTICE Do not attempt to disconnect pneumatic hoses from ACS manifold or ACS exhaust compressor valve.

Pneumatic Hose Removal
Release air pressure from the ACS system. Refer
to AIR PRESSURE RELEASE FOR SERVICING in
this subsection.
12

tmr2012-005

ua

ls

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

tmr2012-005-010_a

1. Release valve button

5. Listen for air exits from underneath dash and
around valve to confirm proper operation.
tmr2012-005-008_a

ACS Release Valve Input Voltage Test
1. Unplug the ACS release valve connector.

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SIDE NET REMOVED FOR CLARITY
1. LH lateral console panel
2. Floor panel

The ACS release valve is a component of the ACS
compressor. The release valve is located at the
left of compressor

en

tmr2012-005-011_a

1. ACS release valve connector

2. Start engine.
3. Measure voltage as per the following table.

tmr2012-005-009_a

REQUIRED TOOL

1. ACS release valve
2. ACS compressor

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ACS Release Valve Operation Test

1. Connect vehicle to the latest appropriate version of B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE subsection
in the 2011 CAN-AM SIDE-BY-SIDE SHOP
MANUAL.
2. Select Activation page.
3. Select ACS folder.
4. Press the Release Valve button to proceed.

tmr2012-005

FLUKE 115 MULTIMETER
(P/N 529 035 868)
TEST PROBES
Pin 1
(release valve
connector)

Battery
negative (–)
post

VOLTAGE
Battery voltage

ACS Release Valve Ground Test
1. With ACS release valve connector unplugged
and engine running, measure voltage as per the
following table.

13

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

REQUIRED TOOL

TEST PROBES

VOLTAGE

Battery
negative (+)
post

Battery voltage

ACS Release Valve Replacement
The ACS release valve is not available separately.
Replace the ACS compressor. Refer to ACS
COMPRESSOR for complete procedure.

1. ACS solenoid valve

ACS Solenoid Valve Operation Test

1. Connect vehicle to the latest appropriate version of B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE subsection
in the 2011 CAN-AM SIDE-BY-SIDE SHOP
MANUAL.
2. Select Activation page.
3. Select ACS folder.
4. Press the valve test button to proceed.

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ACS SOLENOID VALVE

tmr2012-005-013_a

ua

Pin 2
(release valve
connector)

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FLUKE 115 MULTIMETER
(P/N 529 035 868)

ACS Solenoid Valve Access

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en

To access to ACS solenoid valve, remove the following:
– Driver’s seat
– LH lateral console panel
– Floor panel.

tmr2012-005-008_a

SIDE NET REMOVED FOR CLARITY
1. LH lateral console panel
2. Floor panel

The ACS solenoid valve is mounted on the rear
side of the ACS compressor protector.

14

tmr2012-005-014_a

1. Valve test button

The result will be indicated in the TEST STATUS
box beside the valve test button.
If test fails, carry out the ACS SOLENOID VALVE
INPUT VOLTAGE TEST.
If the ACS solenoid valve passed the test, check
the ACS button.

ACS Solenoid Valve Input Voltage Test
1. Unplug the ACS solenoid valve connector.

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS Solenoid Valve Power Wire
Continuity Test

ls

1. Unplug the relay R5.
2. Check the continuity between ACS solenoid
valve connector and relay R5 holder as per the
following table.
REQUIRED TOOL

1. ACS solenoid valve connector

2. Start engine.
3. Measure voltage as per the following table.
REQUIRED TOOL

Pin 5
(solenoid valve
connector)

Position 85

RESISTANCE

Close to 0

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TEST PROBES

Pin 6
(solenoid valve
connector)

TEST PROBES

Pin 6
(solenoid valve
connector)

FLUKE 115 MULTIMETER
(P/N 529 035 868)

Pin 5
(solenoid valve
connector)

ua

FLUKE 115 MULTIMETER
(P/N 529 035 868)

tmr2012-005-015_a

Battery
negative (–)
post

VOLTAGE

Battery voltage

ACS Solenoid Valve Ground Wire
Continuity Test
1. Unplug the ACS module connector.
2. Check the continuity between ACS solenoid
valve connector and ACS module connector as
per the following table.
REQUIRED TOOL

en

If the test fails, carry out an ACS SOLENOID
VALVE POWER WIRE CONTINUITY TEST.
If result is within specification, continue the test
with the ACS SOLENOID VALVE GROUND TEST.

ACS Solenoid Valve Ground Test
With ACS solenoid valve connector unplugged
and engine running, measure voltage as per the
following table.

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Battery
negative (+)
post

Pin 7
(solenoid valve
connector)

Pin 14
(module)

RESISTANCE
Close to 0

1. Remove bolts retaining the air pressure distributor.

FLUKE 115 MULTIMETER
(P/N 529 035 868)

Pin 7
(solenoid valve
connector)

TEST PROBES

ACS Solenoid Valve Removal

REQUIRED TOOL

TEST PROBES

FLUKE 115 MULTIMETER
(P/N 529 035 868)

VOLTAGE
Battery voltage

If the test fails, carry out an ACS SOLENOID
VALVE GROUND WIRE CONTINUITY TEST.
If result is within specification, check the ACS button.

tmr2012-005

15

tmr2012-005-017_a

1. Air pressure distributor
2. Retaining bolts

tmr2012-005-019_a

Air pressure distributor
Air outlet fitting
Rear air reservoir
Front RH air reservoir
Air pressure distributor
Front LH air reservoir

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2. Disconnect pneumatic hoses from:
– Air outlet fitting
– Air reservoirs
– Pressure distributor (except the lower one).
3. Unplug ACS solenoid valve connector.
4. Remove screws securing the ACS solenoid
valve to compressor protector.
5. Remove the ACS solenoid valve from the vehicle.

1.
2.
3.
4.
5.
6.

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Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS Module Access

To access to ACS module, remove the following:
– Driver’s seat
– LH lateral console panel
– Floor panel.

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tmr2012-005-018

ACS MODULE

ACS Solenoid Valve Installation
The installation procedure is the reverse of removal procedure, however pay attention to the
following.
Position the ACS solenoid valve on the compressor and route all pneumatic hoses through corresponding support holes.
Secure the ACS solenoid valve to its support.
Connect pneumatic hoses as per the following illustration.

16

tmr2012-005-008_a

SIDE NET REMOVED FOR CLARITY
1. LH lateral console panel
2. Floor panel

The ACS module is mounted on the wall of the
ACS compressor protector.

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS Module Input Voltage Test
1. Turn ignition switch to ON position.
2. Measure voltage as per the following table.

ls

REQUIRED TOOL
FLUKE 115 MULTIMETER
(P/N 529 035 868)

ua

TEST PROBES

Pin 17
(ACS module
connector)

tmr2012-005-020_a

1. ACS module

ACS Module Signal Circuit Continuity
Test

Pin 18
(ACS module
connector)

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1. Unplug multifunction gauge connector. Refer
to LIGHTS, GAUGE AND ACCESSORIES subsection in the 2011 CAN-AM SIDE-BY-SIDE
SHOP MANUAL.
2. Unplug ACS module connector.

Battery
negative (–)
post

VOLTAGE

Battery voltage

If the test fails, repair or replace wires and connectors.
If result is within specification, continue the test
with the ACS MODULE GROUND TEST.

ACS Module Ground Test
1. Turn ignition switch to ON position.
2. Measure voltage as per the following table.
REQUIRED TOOL

FLUKE 115 MULTIMETER
(P/N 529 035 868)

en

TEST PROBES

Pin 31
(ACS module
connector)

tmr2012-005-021_a

1. ACS module connector

3. Measure resistance as per the following tables.

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REQUIRED TOOL

GAUGE
CONNECTOR

Pin 1

Pin 19

Pin 2

Pin 18

Pin 32
(ACS module
connector)

Battery
positive (+) post

Battery voltage

Pin 33
(ACS module
connector)

FLUKE 115 MULTIMETER
(P/N 529 035 868)

ACS MODULE
CONNECTOR

VOLTAGE

RESISTANCE

ACS Module Removal

Close to 0

1. Remove screws retaining the air reservoir support and the compressor support.

If the test fails, repair or replace wires and connectors.
If result is within specification, continue the test
with the ACS MODULE INPUT VOLTAGE TEST.

tmr2012-005

17

tmr2012-005-022_a

tmr2012-005-025_a

1. Screws to be removed

6. Using a small screwdriver, detach both connector housings from the compressor protector
wall.

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2. Disconnect pneumatic hoses from air reservoirs and air outlet fitting.
3. Place the air reservoir support aside to make
room.

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ls

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

tmr2012-005-026_a

1. Press these tabs inside

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tmr2012-005-023

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4. Unplug the ACS module connector.

7. Unplug the following connectors:
– Compressor connector
– Release valve connector
– Pressure sensor connector.

tmr2012-005-021_a

1. ACS module connector

5. Cut locking ties securing the wiring harness.

tmr2012-005-028_a

1. Compressor connector
2. Release valve connector
3. Pressure sensor connector.

8. Disconnect the lower pneumatic hose from the
pressure distributor.

18

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS Module Installation
The installation procedure is the reverse of removal procedure.

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ACS RELAY (R5)

ACS Relay (R5) Access

tmr2012-005-024_a

1. Disconnect this hose
2. Pressure distributor

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9. Turn the compressor support on the side to remove screws retaining the compressor protector.

ua

To access to ACS relay, remove the following:
– Driver’s seat
– LH lateral console panel
– Floor panel.

tmr2012-005-008_a

SIDE NET REMOVED FOR CLARITY
1. LH lateral console panel
2. Floor panel

tmr2012-005-027_a

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1. Compressor protector retaining screws

The ACS relay is mounted under the top of the
ACS compressor protector.

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10. Separate compressor protector from the compressor support.
11. Remove screws securing the ACS module on
the wall of the compressor protector.

tmr2012-005-029_a

tmr2012-005

tmr2012-005-030_a

1. ACS relay (R5)

ACS Relay Continuity Test
1. Remove relay (R5).
1.1 Remove bolt and nut retaining the relay
holder on the top of the compressor protector.
19

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS Relay Input Voltage Test
1. Measure voltage as per the following table.

FLUKE 115 MULTIMETER
(P/N 529 035 868)
TEST PROBES

tmr2012-005-031_a

Battery voltage

If voltage is not as specified, check wiring, connector and terminal condition.

ACS Relay Ground Wire Continuity
Test

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1.2 From the rear, pull relay out from underneath of compressor protector.
1.3 Remove the relay from its holder holder.

VOLTAGE

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Pin 87
(relay holder)
1. Relay retaining bolt

Battery
negative (–)
post

ls

REQUIRED TOOL

1. Unplug ACS module connector.

tmr2012-005-032_a

en

1. Relay
2. Relay holder

2. Measure resistance as per the following table.

tmr2012-005-021_a

1. ACS module connector

2. Measure resistance as per the following table.

REQUIRED TOOL

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FLUKE 115 MULTIMETER
(P/N 529 035 868)
TEST PROBES

Terminal 30
(relay holder)

Terminal 87
(relay holder)

RESISTANCE
Open (OL)

3. Apply 12 volts on terminals 86 and 85 and measure resistance again as per the following table.
TEST PROBES

Terminal 30
(relay holder)

Terminal 87
(relay holder)

RESISTANCE
Close to 0

If results are not as per the above tables, replace
relay.

20

REQUIRED TOOL
FLUKE 115 MULTIMETER
(P/N 529 035 868)
TEST PROBES
Pin 86
(relay holder)

Pin 28
(ACS module
connector)

RESISTANCE
Close to 0

ACS COMPRESSOR
ACS Compressor Access
To access to ACS compressor, remove the following:
– Driver’s seat
– LH lateral console panel
– Floor panel.
tmr2012-005

ls

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

tmr2012-005-034_a

ua

1. Compressor operation test button

5. Verify if compressor works properly.

ACS Compressor Input Voltage Test
tmr2012-005-008_a

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SIDE NET REMOVED FOR CLARITY
1. LH lateral console panel
2. Floor panel

1. Using a small screwdriver, detach the ACS
compressor connector housings from the compressor protector wall.

The ACS compressor is mounted on the ACS
compressor support.

tmr2012-005-035_a

en

1. ACS compressor connector
2. ACS compressor pressure sensor

tmr2012-005-033_a

1. ACS compressor

ACS Compressor Operation Test

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1. Connect vehicle to the latest appropriate version of B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE subsection
in the 2011 CAN-AM SIDE-BY-SIDE SHOP
MANUAL.
2. Select Activation page.
3. Select ACS folder.
4. Press Compressor button to proceed.

tmr2012-005

2. Unplug ACS compressor connector.
3. Place ignition switch to ON position.
4. Measure voltage as per the following table.
REQUIRED TOOL
FLUKE 115 MULTIMETER
(P/N 529 035 868)
TEST PROBES
Pin 1
(ACS
compressor
connector)

Battery
negative (–)
post

VOLTAGE
Battery voltage

ACS Compressor Ground Test
1. Place ignition switch to ON position.
2. Measure voltage as per the following table.

21

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

REQUIRED TOOL

Pin 2
(ACS
compressor
connector)

VOLTAGE

Battery positive
(+) post

Battery voltage

tmr2012-005-022_a

ACS Compressor Power Wire
Continuity Test (from Relay)
1. Remove relay (R5).
2. Measure resistance as per the following table.

FLUKE 115 MULTIMETER
(P/N 529 035 868)
TEST PROBES
Pin 30
(relay holder)

1. Screws to be removed

2. Disconnect pneumatic hoses from air reservoirs and air outlet fitting.
3. Place the air reservoir support aside to make
room.

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REQUIRED TOOL

ua

TEST PROBES

ls

FLUKE 115 MULTIMETER
(P/N 529 035 868)

Pin 1
(ACS
compressor
connector)

RESISTANCE

Close to 1

ACS Compressor Ground Wire
Continuity Test

en

1. Reconnect the relay (R5).
2. Check the continuity as per the following table.
REQUIRED TOOL

FLUKE 115 MULTIMETER
(P/N 529 035 868)

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TEST PROBES
Pin 2
(ACS
compressor
connector)

Battery
negative (–)
post

tmr2012-005-023

4. Using a small screwdriver, detach both connector housings from the compressor protector
wall.

RESISTANCE

Close to 1

ACS Compressor Removal
1. Remove screws retaining the air reservoir support and the compressor support.

tmr2012-005-026_a

1. Press these tabs inside

5. Unplug the following connectors:
– Compressor connector
– Release valve connector
– Pressure sensor connector.
22

tmr2012-005

tmr2012-005-028_a

ua

ls

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

tmr2012-005-027_b

1. Compressor connector
2. Release valve connector
3. Pressure sensor connector.

9. Remove the ACS compressor.

ACS Compressor Installation

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6. Detach the filter hose from the compressor intake/outlet fitting.

1. Compressor retaining screws

The installation is the reverse of removal procedure.

ACS AIR FILTER
ACS Air Filter Access
To access to ACS air filter, remove the following:
– Driver’s seat
– LH lateral console panel
– Floor panel.

tmr2012-005-036_a

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1. Air filter hose
2. Clamp to be removed

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7. Disconnect the lower pneumatic hose from the
pressure distributor.

tmr2012-005-024_a

1. Disconnect this hose
2. Pressure distributor

tmr2012-005-008_a

SIDE NET REMOVED FOR CLARITY
1. LH lateral console panel
2. Floor panel

The ACS compressor is located in front of air
reservoirs.

8. Turn the compressor support on the side to remove screws retaining the compressor.

tmr2012-005

23

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

SHOCK ABSORBERS
Shock Absorbers Identification

ls

When installing shock absorbers, make sure not
to mix front and rear shock absorbers.
Front and rear shock absorbers can be easily identified by comparing the length of air hoses.
FRONT SHOCK ABSORBER

tmr2012-005-002_a

ua

Shock absorber with
a short air hose on
reservoir side

1. ACS air filter

REAR SHOCK ABSORBER

ACS Air Filter Replacement

Shock absorber with
a long air hose on the
opposite side of reservoir

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1. Remove and discard clamps securing hoses to
air filter.

Rear Shock Absorber Removal
1. Block front wheels.
2. Loosen wheel lug nuts.
3. Open cargo box.
4. Place the jack under the hitch and lift the rear
of vehicle.
5. Install jack stands to support the vehicle.
6. Remove wheel.
7. Disconnect shock absorber hose from vehicle
air supply hose.

tmr2012-005-037_a

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1. Clamps to be removed

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2. Remove the air filter.
3. Install the new air filter with its attachment towards the compressor.
4. Secure air filter using new clamps.

tmr2012-005-042_a

1. Shock absorber hose
2. Vehicle air supply hose

8. Drill the rivet securing the shock absorber hose
to trailing arm.

tmr2012-005-038_a

1. Air filter attachment
2. Air hose from compressor

24

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

TIGHTENING TORQUE
Shock absorber nuts

48 N•m (35 lbf•ft)

tmr2012-005-040_a

REAR LH SIDE OF VEHICLE SHOWN
1. Rivet to be drilled

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9. Remove upper and lower bolts retaining the
shock absorber. Discard nuts.

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Connect shock absorber hoses to vehicle air supply hoses.

tbl2012-003-013_a

TYPICAL
1. RH shock absorber hose
2. Vehicle air supply hose

TIGHTENING TORQUE

Air supply hose

6 N•m ± 0.5 N•m
(53 lbf•in ± 4 lbf•in)

Secure shock absorber hoses to trailing arms. Ensure to position hose clamp between YELLOW
dots.

en

tmr2012-005-041_a

1. Shock absorber retaining bolts

Rear Shock Absorber Installation

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Install shock absorbers with the reservoir rearwards.

tbl2012-003-014_a

RH SIDE OF VEHICLE
1. YELLOW dots
2. Rivet

tbl2012-003-012_a

TYPICAL – RH REAR SHOCK ABSORBER

Secure with new nuts.

tmr2012-005

25

tbl2012-003-015_a

tmr2012-005-044_a

LH SIDE OF VEHICLE
1. YELLOW dot
2. Install the rivet in this hole

ua

ls

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

1. Shock absorber retaining bolts

8. Remove shock absorber from vehicle.

Front Shock Absorber Installation

1. Block rear wheels.
2. Loosen wheel lug nuts.
3. Lift the front of vehicle and support it securely.
3.1 Insert the jack under the vehicle by the
side, behind front wheels.
3.2 Place the jack under the central beam.
3.3 Lift the front of vehicle.
4. Remove front wheels.
5. Cut locking ties securing shock absorber hose
to suspension arm.
6. Disconnect shock absorber hose from vehicle
air supply hose.

Install shock absorbers with the reservoir outwards.
Secure it using previously removed bolts and new
nuts. Tighten nuts to specification.

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Front Shock Absorber Removal

TIGHTENING TORQUE

Shock absorber nuts

48 N•m (35 lbf•ft)

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Route the hose in front of the shock absorber.

tmr2012-005-043_a

TYPICAL
1. RH shock absorber hose
2. Vehicle air supply hose

7. Remove upper and lower bolts retaining the
shock absorber. Discard nuts.

26

tmr2012-005-043_a

TYPICAL
1. RH shock absorber hose
2. Vehicle air supply hose

TIGHTENING TORQUE
Air supply hose

6 N•m ± 0.5 N•m
(53 lbf•in ± 4 lbf•in)

Secure the shock absorber hose to brake hose.
Install a locking tie each side of the brake hose
retaining clamp.

tmr2012-005

tmr2012-005-045_a

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1. Brake hose retaining clamp
2. Shock absorber hose

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ls

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

tmr2012-005

27

Subsection 01 (POWER DISTRIBUTION)

POWER DISTRIBUTION
GENERAL

ls

POWER DISTRIBUTION DIAGRAM
FUSE BOX 1

BAT
F4

VOLTAGE
REGULATOR/
RECTIFIER

F5

FUSE BOX 2

7.5A

IGNITION COIL

BRAKE RELAY (R8)

FUEL INJECTORS

ACS MODULE

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COMMUNICATION
CONNECTOR

MF3

GAUGE

SPEED SENSOR

WINCH RELAY

MF2

BRAKE LIGHTS
SWITCH

10A

TAILLIGHTS

STARTER RELAY

MF1

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COMMUNICATION
CONNECTOR

MAIN
RELAY (R2)

F6

5A

ACCESSORIES
RELAY (R3)

30A

50A

SWITCHES ILLUMINATION

F7

5A

2WD/4WD SWITCH
WINCH SWITCH

60A

F8

5A

GAUGE

IGNITION SWITCH

en

UNDER DASH
ACCESSORY
CONNECTOR
( DC7 )

ACS
MOTOR

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ACS
RELAY (R5)

ACS
MODULE

ECM

F9

30A

F10

5A

EURO CONTROLS

F11

30A

LIGHTS RELAY

FAN RELAY (R1)

COOLING FAN

CONSOLE ACCESSORY
CONNECTOR 1 (DC3)
12-VOLT POWER OUTLET

F12

15A

F13

5A

UNDER DASH ACCESSORY
CONNECTOR (DC4)
COMMUNICATION
CONNECTOR
ACS MODULE

F14

15A

CONSOLE ACCESSORY
CONNECTOR 2 (DC6)

F15

5A

FUEL PUMP

tmr2012-003-001_aen

tmr2012-003

1

Subsection 01 (POWER DISTRIBUTION)

FUSE BOX 2

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FUSE BOX 1

tmr2012-003-002_a

FUSE IDENTIFICATION
10 A

5

7.5 A

6
7
8
Fuse

9
10
11
12
13
14

5 A

5 A

5 A

tmr2012-003-003_a

FUSE IDENTIFICATION

30 A
5 A

30 A
15 A

Fuse

1

Main

30 A

2

Fan/accessories

50 A

3

ACS/accessories

60 A

5 A

15 A
5 A

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15

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4

tmr2012-003-002_b

RELAY IDENTIFICATION

Relays

2

1

Cooling fan

2

Main

3

Accessories

4

Headlights

8

Brake lights

tmr2012-003

Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

LIGHTS, GAUGE AND ACCESSORIES
SERVICE TOOLS
Part Number

Page

ls

Description

FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................................. 4

PROCEDURES

NOTICE It is recommended to always disconnect the battery when replacing any electric
or electronic parts. Always disconnect battery
exactly in the specified order, BLACK (-) cable
first.

CONSOLE SWITCHES

TROUBLESHOOTING

MULTIFUNCTION GAUGE (LCD
AND ANALOG/DIGITAL)

1. Fuse is blown
- In the fuse block #1, check the fuse 14. Replace
if required.
- Remove the glove box and check the in-line fuse
(15A). Replace if required.
2. No Voltage
- Perform the AMPLIFIER POWER VOLTAGE
TEST, refer to AMPLIFIER.

NO SOUND

en

1. Fuse is burn
- See NO POWER above.

2. Wiring is not properly connected or damaged
- Check all wires and connectors. See AMPLIFIER
CONNECTOR IDENTIFICATION.

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3. Faulty amplifier
- Replace the amplifier.

RADIO CONTROL BUTTONS DO NOT
WORK
1. Radio control need to be reset.
- Press the RESET button to the back of the amplifier.

CANNOT TUNE A RADIO STATION OR
THE AUTO-SEEK DOES NOT WORK
1. The antenna is not connected
- Insert the antenna cable firmly.
2. The signals are too weak.
- Select a station manually.
tmr2011-004

Switches Access

Refer to BODY and remove upper console.

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RADIO AND AMPLIFIER
NO POWER

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GENERAL

Multifunction Gauge Wire
Identification
FUNCTION

PIN

COLOR

12 volt input from fuse F4

17

ORANGE/GREEN

12 volt input from fuse F8

16

BEIGE/WHITE

Ground

20

BLACK

CAN LO

18

BEIGE/GREEN

CAN HI

19

WHITE/BEIGE

Fuel level gauge supply

4

BROWN/PINK

Fuel level gauge ground

21

VIOLET/PINK

2WD/4WD switch signal (-)

7

BLACK/BEIGE

HI beam signal (+)

5

BLUE

TURN SIGNALS/HAZARD
(EC MODELS ONLY)
Turn Signal Wire Identification
FLASHER MODULE
FUNCTION

PIN

COLOR

12 volt input from
fuse F10

MC2-1

RED/WHITE

12 volt input from
fuse F4

MC1-5

ORANGE/GREEN

RH turn 12 volt input
from turn signal
switch

MC1-1

BEIGE/ORANGE

LH turn 12 volt input
from turn signal
switch

MC1-2

BEIGE/GREY

1

Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

PIN

COLOR

Output to RH turn
signal lights

MC2-2

BROWN

Output to LH turn
signal lights

MC2-3

GREY

Output to
multifunction gauge
(turn signal indicator)

MC2-4

ORANGE

Ground

MC1-4

BLACK

Hazard 12 volt input
from hazard switch

MC1-6

GREEN/ORANGE

Amplifier Connector Identification

ls

FUNCTION

Go to BODY subsection for glove box removal procedure.

ua

FLASHER MODULE

-m
an

TURN SIGNAL SWITCH
(IN MULTIFUNCTION SWITCH)
PIN

COLOR

12 volt input from
fuse F4

MGB-3

ORANGE/GREEN

RH turn 12 volt output
to flasher module

MGB-4

BEIGE/ORANGE

LH turn 12 volt output
to flasher module

MGB-2

BEIGE/GREY

tmr2012-004-003_a

AMPLIFIER CONNECTOR IDENTIFICATION
1

Front LH RCA line out
(WHITE female RCA connector)

2

Front RH RCA line out
(RED female RCA connector)

3

Rear LH RCA line out
(WHITE female RCA connector)

4

Rear RH RCA line out
(RED female RCA connector)

5

In-line fuse (15 A)

6

Power/audio 16-pin connector

en

FUNCTION

7

AUX in
(WHITE female RCA connector)

8

AUX in
(RED female RCA connector)

9

USB 2.0 connector

10

Wired audio control, 4-pin mini
DIN connector

Turn Signal/Hazard Circuit Protection

11

Antenna connector

HAZARD SWITCH
FUNCTION

PIN

12 volt input from
fuse F10

2

12 volt output to
flasher module

3

8

Hazard indicator
ground
(through bulbs)

7

RED/WHITE

GREEN/ORANGE

ORANGE/BROWN

BLACK/ORANGE

gr
e

Hazard indicator
12 volt input from
fuse F4

COLOR

CONDITION

CIRCUIT PROTECTION

Supplied with main
relay (R2) activated

Fuse 4 of fuse block 1
(from main relay R2)

Supplied at all times

Fuse 10 of fuse block 1
(from fuse 2 of fuse box 2)

AMPLIFIER

Amplifier Access
The amplifier is attached on the top of the glove
box.
2

tmr2011-004

Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

SIRIUS connector, 8-pin mini DIN
connector

13

iPod‡ connector, 8-pin mini DIN
locking connector

‡
iPhone, iPod, iPod nano and iPod touch
are trademarks of Apple Inc. registered in U.S.A. and other
countries. “Made for iPod” and “Made for iPhone” mean that an
electronic accessory has been designed to connect specifically
to iPod or iPhone, respectively, and has been certified by the
developer to meet Apple performance standards. Apple is not
responsible for the operation of this device or its compliance with
safety and regulatory standards. Please note that the use of this
accessory with iPod or iPhone may affect wireless performance.

1

DC +12V (RED)

2

Data (BLUE)

3

No connection

4

Power ground (BLACK)

-m
an

Power/Audio 16-pin
Connector Pins Identification
(Radio Side)

ls

12

Wired Audio Control Connector Pins
Identification

ua

AMPLIFIER CONNECTOR IDENTIFICATION

5

Ground shield

iPOD Connector Pins Identification

A1
A2

Right rear speaker (+)
Right rear speaker (–)

1

Left channel

Right front speaker (+)

2

Audio ground

Right front speaker (–)

3

USB B +

A5

Left front speaker (+)

4

Video out

A6

Left front speaker (–)

5

Right channel

A7

Left rear speaker (+)

6

Power ground

A8

Left rear speaker (–)

7

USB D +

B1

No connection

8

Remote

B2

No connection

9

ACC – ID

B3

No connection

10

ACC – detect

B4

+ 12V ACC switched

11

USB D –

B5

Power antenna

12

iPOD detect

B6

No connection

13

ACC – power

B7

No connection

14

Ground

B8

Ground

A3

gr
e

en

A4

Amplifier Circuit Protection
The amplifier is protected by 2 fuses:
– In-line fuse (15A) on amplifier
– Fuse 14 (15 A) inside vehicle fuse block #1.

tmr2011-004

3

Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

Make sure F14 of fuse box #1 is in good condition
and powered before beginning any voltage test.
If radio does not work, check the radio control before testing the amplifier.

Unplug the audio control connector (4-pin mini
DIN) from the amplifier.

ls

Amplifier Tests Guidelines

Amplifier Input Voltage Test
FLUKE 115 MULTIMETER
(P/N 529 035 868)

TEST PROBE
Pin 13

Pin 15

VOLTAGE DC

Close to battery
voltage

If voltage is within specification, check the in-line
fuse (15 A).
If the voltage is out of specification, carry out AM-

PLIFIER POWER CONTINUITY TEST

Amplifier Power Continuity Test

Test the amplifier power continuity between the
fuse box #1 and the power/audio 16-pin connector
as per the following table.

C10
C11

POWER/AUDIO
CONNECTOR
(BLACK PROBE)

en

FUSE
BOX #1
(RED
PROBE)

tmr2012-004-007_a

1. Audio control connector (4-pin mini DIN)

Turn ignition key to ON position.
Check voltage as per the following table.

-m
an

Remove glove box.
Unplug the power/audio 16-pin connector.
Turn ignition key to ON position

ua

REQUIRED TOOL

CONTINUITY

Pin 13

Close to 6 M

Pin 15

Close to 0

AUDIO CONTROL
CONNECTOR
(AMPLIFIER SIDE)

Pin 1

Pin 4

VOLTAGE DC
Close to battery
voltage

If voltage is within specification, replace the radio
control.
If voltage is out of specification, check the amplifier and connections.

Radio Control Removal

Refer to BODY and remove the following parts:
– Upper console
– Glove box.
Unplug the audio control connector (4-pin mini
DIN) from the amplifier.

gr
e

If continuity is out of specification, repair or replace wiring harness and connectors.
If continuity is within specification, replace the
amplifier.

RADIO CONTROL

Radio Control Input Voltage Test
REQUIRED TOOL

FLUKE 115 MULTIMETER
(P/N 529 035 868)

The radio control receives its power through the
amplifier.
4

tmr2012-004-007_a

1. Audio control connector (4-pin mini DIN)

Cut or release all locking ties retaining the radio
control harness.
Unscrew radio control retaining ring.
tmr2011-004

tmr2012-004-008_a

1. Radio control retaining ring

Remove radio control from upper console. Check
cable routing for reinstallation.

-m
an

Radio Control Installation

ua

ls

Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

gr
e

en

The installation is the reverse of the removal procedure.

tmr2011-004

5

Subsection 01 (WIRING DIAGRAM INFORMATION)

WIRING DIAGRAM INFORMATION
GENERAL

Connector Housing Area
XX/XX-18

The wiring diagram is stored in the back cover
pocket.

4

5

-m
an

2-BF-A

The first number in the connector/pin contact
number represents the area in the vehicle where
the connector is located.

Wire colors
Wire gauge
Connector housing area
Connector identification
Wire location in connector

Wire Colors

2

ua

3

XX/XX-18

V00G0FA

1.
2.
3.
4.
5.

2

2 -BF-A

V06G1HA

WIRING DIAGRAM CODES
1

ls

WIRING DIAGRAM LOCATION

3

5

1

2

4

It identifies the color of a wire. When a 2-color
scheme is used, the first color is the main color
while the second color is the tracer color.

tmr2011-041-001_a

XX/XX
XX/XX

-18

2-BF-A

en

V06G1FA

AREA LOCATION
1

Steering, dashboard and upper console area

2

Under dashboard and front bulkhead area

3

Front of vehicle

4

Engine, seat and lower console area

5

Rear of vehicle

THE SHADED PART INDICATES THE WIRE COLOR

Example: YL/BK is a YELLOW wire with a BLACK
stripe.

Connector Identification

The number after wire color indicates the gauge
of a wire.

The letters in the middle of the connector/pin contact number Indicates the connector's function. If
there are many connectors in the same area, this
helps to identify which wire is in which connector.

gr
e

Wire Gauge

18

XX/XX- 18

V06G1GA

XX/XX-18

2-BF-A

THE SHADED PART INDICATES THE WIRE GAUGE

Example: The number that follows the wire color
indicates the wire size used, in this case 18 gauge
wire.

tmr2012-007

V06G1JA

2- BF -A

BF

THE SHADED PART INDICATES A CONNECTOR

1

Subsection 01 (WIRING DIAGRAM INFORMATION)

ABBREVIATION
ACS

DESCRIPTION
Air Controlled Suspension

M1

DESCRIPTION
ACS compressor
Manifold air pressure and
temperature sensor

BA

Ignition coil

BAT

Battery

MD

2WD/4WD actuator

BD

2WD/4WD switch

OPS

Oil pressure switch

BN

Ground post

BP

Battery power

PDH

BV1

ACS solenoid valve

PDL

BV3

ACS release valve

PF1

CA

Magneto

PF2

Camshaft position sensor

PGH

CC

Ignition switch

PGL

CI

Multifunction gauge

PRD

RH tail light

CPS

Crankshaft position sensor

PRG

LH tail light

CTS

Coolant temperature sensor

RD

CV

Speed sensor

S1

ACS button

DB

Diagnostic connector

SB

Seat belt

DC

DC outlet

SD

2WD/4WD actuator switch

DC3/DC5
DC6/DC7

Accessories connector

SM

Starter motor

ECM

Engine control module

SPK1 and SPK2

ETA

Electric throttle actuator

SPSW

ETC

Electronic throttle control

SS

Fuel pump

en

FP

FRA
FT

ls

MAPTS

Override button

RH headlight (high beam)

ua

OV

RH headlight (low beam)

Fuse Holder (main)
Fuse Holder

LH headlight (high beam)

LH headlight (low beam)

-m
an

CAPS

Brake light switch

Cooling fan

Voltage regulator/rectifier

Spark plug

Sport switch
Starter solenoid

STSW

Start switch

SW

Winch relay

SWW

Winch switch
Temperature sensor (ACS
compressor)

GBPS

Gearbox position sensor

T1

HIBM

High beam (headlights)

TPS

Throttle position sensor

Harness interconnect
(engine/vehicle)

TAS

Throttle accelerator sensor

gr
e

HIC

INJ1 and INJ2

2

ABBREVIATION

Fuel injector

tmr2012-007

Subsection 01 (WIRING DIAGRAM INFORMATION)

Wire Location in Connector

XX/XX-18

A

THE SHADED PART INDICATES THE CONNECTOR LOCATION
IN HOUSING

B

B
A

B

-m
an

A

ua

A
2- BF- A

V06G1KA

B
A

ls

This is the wire position in the connector. The
number or letter given refers to the physical identification stamped or molded on the connector.

C

C

B
A

B

A

A

en

C

D
A

A00E4WB

C
B

C

D
A

C
B

gr
e

TYPICAL

tmr2012-007

3

1

2

3

4

COMMANDER 2012

1

3

GENERAL SYSTEM

J

5

ACCESSORY
CONNECTOR

5

4

2

6

7

DC3
DC5
DC6
DC7

8

9

TERMINAL IDENTIFICATION

GPS
TRUNK BOX
RADIO
LTD

NAME

ZONE #

ZONE-CONNECTOR NAME-TERMINAL #/A

CI

EX:

1 -

CI

-

EX:

CV

4 -

CV

EX:

ME

2 -

ME

10

15

-

A

COLOR CODE

WELDED JOINT

ZONE DESCRIPTION
STEERING AREA

2

MODULE AREA

WIRE BUS

3

FRONT OF VEHICLE

SIMPLE CONDUCTOR WIRE

4

ENGINE AREA

FEMALE TERMINAL

5

REAR OF VEHICLE

LT BU

LIGHT BLUE

CROSSED WIRE

MALE TERMINAL
STEEL LINK (FRAME )
TERMINAL

RD-6

BEIGE
BLACK
BLUE
BROWN
GREEN
GREY
ORANGE
RED
VIOLET
WHITE
YELLOW
PINK

SHRINKED JOINT

1

JT RD/GN

BE
BK
BU
BR
GN
GY
OR
RD
VI
WH
YL
PK

J

JT OR/BE

BD-4

1

RD/GN

OR/GN-16
RD/OR

OR/BE

BR/RD

OR/BE

BK-6

SWWRC-B

RD/GN
RD/YL

FAN
RELAY
(R1)

M

OR/BK

PF1-7C

JT OR/BK

J4

C3

B-

B-

3-

3-

3-

RD/OR

A3-

WH/OR

o - o

1-DC3-1

PGL-1

HI

GN-18

PDL-2

LO

PDH-1

RIGHT
TAIL
LIGHT

PDL-1

WH

RD

WH
PRD-2

B

PRG
LEFT
TAIL
LIGHT

PRG-2

HIC5-A

A

JT BK4
JT BK5
(30 SEPT. 2011 )

2

3

4

5

6

7

8

9

B

BK-16

LO

PDH-2

P

BK-16

HI
PGH-1

JT BK3

PGL-2

BK

PGH-2

B

PRD

BK

2

P

BK

JT
BU

THROTTLE ACCELERATOR SENSOR

1

JT GN

BU-18

1-DC1

DC4

OIL
PRESSURE
SWITCH

5-PRD-3 5-PRD-1 5-PRG-3 5-PRG-1

BK

TAS

OPS

5-HIC5-C

DC

GN-18

CRANKSHAFT
POSITION
SENSOR

P

5-HIC5-D

1-DC2

DC
OUTLET

CPS

OR/GN
OR/GN

GN

BU

RD/BR-16

BK-20

WH-20

GN

E3

E

C

4-OPS

PF1-12A

BK-16

F

PF1-11A

RD

A

PF1-11B

5-HIC5-B

DC
OPTION

TAS-F TAS-E

LT BU-18

B3-

1-DC3-2

DC3

-

MANIFOLD
AIR
PRESSURE /
TEMP
SENSOR

BRK RELAY
(R8)

PF1-12B

RD/BR-16

BU/GN
TAS-A

+ + -

GEAR - BOX
POSITION SENSOR

PF1

JT RD/BR

BU/PK

BU/RD
TAS-B

BU/VI

BU/OR
TAS-C

B

ENGINE
CONTROL
MODULE

A3

B3
B-

E1

BU/BK

BU/YL-18

YL/WH-18

TAS-D

C

HI-BEAM
SWITCH

D

ECM

1-HIBM-3
3-

B3-

B3-

3-

B-

K3

K1

J3
3-

B-

BK-18

BU-18

BK-18

K2
3-

A-

H1

4-CPS-1

P

MAPTS

G1
B-

C2
A3-

LOBM

HIBM

BK-16

OR/WH-18

3-FT-A

RD/OR

LIGHTS
RELAY
(R4)

E

BK-16

PF1

PF1-6C
1-DC5-A

4-HIC7-A

D

GBPS

F

COOLING
FAN

BC4

A-

OR/GY

WH/GY

BK-16

GY/BU-18

BK/OR

4-GBPS-1

3-PF1-3E

BU-16

FT

JT RD/OR

DC
OPTION

BU-18

t

PF1

BR/WH-16

OR/WH-18

RD/OR

OR/GN

3-PF1-1E

YL/BU

PF1-6D

3-

3G1
3-

3-

3-

A-

A-

F4

G4
A3-

A3-

PK/BU-18

BK/BR-18

WH/GY-18

RD-18

LT BU-18

YL/BK
SWWRC-A

SPSW-8

BD-10

BD-8

SWW-8

OVR-8

DPS4-8

HIBM-8

HIBM-10

BE/GN-18

WH/BE-18
C1
B-

M2
3B4

H2
3-

3-

A-

H3
A-

E1

RD/OR-18

WH-18

BK-18

PF1-11C

DC5

BK

A

ACC2
FUSE
(F14)
15A
JT RD/VI

4-HIC7-B

BK

JT BK2

4-GBPS-3
4-GBPS-2

3-PF1-1D

1-DC5-B

1-DC6-A

BK-16

BK-12

BK-6

BK-18

GN-18

1-DC6-B

DC
OPTION

BK-16

JT BK1
BK-12 BK-12 BK-12

BK-12

PF1-8E

ENGINE
CONTROL
MODULE

BD-7

5-BN1

4-MAPTS-4
4-MAPTS-3

G

PF1

HIBM

BD-9

5-BN3

DC OUTLETS
FUSE
(F12)
15A

ECM

SWW-7

5-BN2

PF1

1-HIBM-2

+

VEHICULE
SPEED
SENSOR

3-PF1-12D

PF1-10C

PF1-9E

PF1-7D

WH

OVR-7

OVERRIDE

COOLANT
TEMP
SENSOR

JT RD/YL

BD-5

JT WH/BE

2-SPSW-7

OVR

4-MAPTS-1
4-MAPTS-2

VSS

CTS

3-PF1-10D

RD/VI

DC6

2-HIBM-9

TPS

3-PF1-10E

WINCH
MOTOR

3-WM2

JT RD/BK

RD/BR

BE/GN-18

WH/BE-18
WH/BE-18

GN/BU-18

BK-16

SWW-2

2WD/4WD SWITCH

2-HIBM-7

ELECTRONIC THROTTLE

3-PF1-12E

OR/BK-18

WH/BU

12V
SWWB

WINCH
SWITCH

BD

BD-2

BK-18

ETA

WM

2WD

BK-18

MAGNETO
650 WATTS

OVER
RIDE

2,5k

2

YL/BK
WH/BU-18

WH-18

WH/BK-18

WH

SWW

BD-6

WINCH
2WD/4WD
FUSE
( F7 )
PF1-5A 5 A

IN

HIC-B

ENGINE
CONTROL
MODULE

OV-3

t

OR/GN

RD/GN

RD-6
BK-6

BU-18

BK-18

WH/BK

PF1

FREE

4-CV-A

HALL
- +

PF1
ACCESSORIES
RELAY
(R3)

H
PF1-4C

3-FT-B

HIBM-1

2,5k

4-CV-B

M

FRA-1

3-PF1-3D

PF1-6A

ECM

BK-16

OV-2

WH-18

BK/GN -18

BK-18

BK-18

BK-18

BK/BR-18

BE/OR-18

VI/OR-18

VI/GY

VI/YL

BE/GN

0V-1

FREE

BK-6

BK-12

5

BK-18

+

2

BK-18

-

6

4-CTS-1 4-CTS-2

BK-18

B

BE/GY

BE/WH

BE/YL

BE/RD

BE/BK

BK-6

YL-12

BK-12

1

3

4

M

CA

4-CV-C

1

P

4WD

4-CPS-2

CA-3

300

YL-14

CA-2

YL-14

YL-12

YL-12
YL-14

CA-1

PF1-7E

OUT

JT WH
BD-1

RD/YL

SWW-3

SWW-1

2-DB-1

A-

M1

BR/OR-16

HIC-A

HIC-C

OUT
SWWC

5-RD2-1 5-RD2-2 5-RD2-3 5-RD1-3

C

3-WM1

COOLING
FAN
FUSE
( F9 )
30 A

GN

A-

BK/BU-18

SPARK
PLUG
( FRONT )

SPARK
PLUG
( REAR )

RD/BR

BK-16

SPK1

SPK2

3-

3-

IN
SWWA

RD/BK

2-DB-6

2-SW5

BRAKE
LIGHT
SWITCH

PF1-5C

PF1

FRA

LIGHT
FUSE
(F11)
30A

BK

GN

ONEWAY
DIODE
(D4)

2-DB-2

BR/BK-16

FUEL
INJECTOR
( REAR )

3-

A3-

OR

BK/BE-18

BE/GN-18

BE/GN-18

OR/GN

RD/GY-16

BN/BK-16

BK

BK

4-INJ2-1

A-

D4

L1
3-

B-

M3
B3-

3-

3-

B-

A-

M2

J2

A1
A3-

B-

ONEWAY
DIODE
(D5)

M

BK-18

VI/GN-16
VI/BU-18

BN/OR-16

2-DB-4

ENGINE
CONTROL
MODULE

3-

3-

3-

2WD/4WD
ACTUATOR

2-SW3

2-SW2

2-SW1

BK-18

JT BE/GN

ECM

F3

B1
B-

D3
B-

K3
A3-

3-

A-

A2

F3
A3-

3-

A-

K4

L1

BK/BE-18

RD/BE-14
A-

B3-

3-

INJ2

J1

M4

M1
B-

H2
B3-

B2
B-

E4
B-

3-

3-

3-

B-

B3-

3-

3-

A2

D1

A1
B-

E3
B-

D4
3-

B3-

B-

L4

B4
B3-

4-INJ1-1

BK/RD-18

BE-18

BK/BU

OR/BU

OR/RD

YL/OR

YL/RD

OR/VI

YL/GY

BR/GN

OR/BR-18

GN/BE

BE/BU
A4
B3A3-

3-

A-

L2

W

2-DB-5

2-DB-3

ENGINE
CONTROL
MODULE

RECTIFIER

IGNITION
COIL

2-SW4

FRA-2

PF1

(YL)

(BU)

OUT

IN

SWWRC-C

RD/GY-16

OR/BE

OR/GN-14

5-FP-4

RD

4-BA-3

HIC-G

FUEL
INJECTOR
( FRONT )

MD

BD-3

DIAGNOSTIC
CONNECTOR

INJ1

1-CI-5

4-MD1-1 4-MD1-4 4-MD1-2

DB

M

FUEL
PUMP

DB2-2

JT OR/VI

BA

4-BA-1

4-INJ2-2

ECM

V

4-BA-2

JT VI/BU

K1

START

FP
(1/2)

1-CI-20

4-SD

2WD/4WD
ACTUATOR
SWITCH

VI/BU-18

BU/GY

LOCK

SB2

SB1

FUEL
LEVEL
SENSOR

5-FP-3

FREE

HI
BEAM

1-CI-8

SD

START SWITCH

FREE

2-BN4

HIBM-5

3-PF1-4B

A-

5-BAT2

BK-6

INJECTORS
IGNITION
FUSE
( F5 )
7.5 A

4-INJ1-2

5-RD1-1

U

PF1

STSW

1-STSW-2

DB2

FP (2/2)

HIC-E

HIC-D

OR/BR-18

M

BAT

D

5-FP-2

JT VI/BU

1-STSW-1

RD-6

RD-6

RD-12

3-PF1-4A

3-PF1-5D

VI/BU

3-

RD-6

JT BK/YL

ECM
FUSE
( F6 )
5A

SPSW-2

SPSW-3

DB2-1

PF1

FUEL
PUMP
( F15 )
5A

OR/VI

SEAT BELT

RD-12

PF1

1-CC-E

SPORT

4-SM

4-BN5

1-CC-C

SPORT SWITCH

STARTER
MOTOR

5-BN4

1-CC-D

VI/BU

1-CC-F

OR/BR-18

3-PF1-3A

1-CI-17

HIC-H

3-PF1-3B

BE-18

RD-6

3-PF1-4D

OR/BR-18

SM

RD/BE-14

ON

FREE

BK-6

RD/GY-14

W/LIGHT
WO/LIGHT

5-BP3

E

RD/GY-14

ON

5-SS2

5-BAT1

RD/BE

STARTER
SOLENOID

BATTERY
12 VDC
18 AH

5-FP-1

1-CI-19 1-CI-18 1-CI-7

1-CI-4

OFF

FREE
WEELING
DIODE
( D2 )

SS

F

1-CI-21

PF1-6E

WINCH RELAY

4-BN3

JT RD/BE

CC-A

4WD

ENGINE

5-SS1

5-BP2

G

FUEL

BU

2-DC7-A

3-PF1-7B

SW

(BK)

YL

YL

WH/BE-18

5-BP1

CC-B

RD

DC
OPTION

3-PF1-5B

3-PF1-2B

(RD)

P

DC7

2-BP4

2-HIBM-6

BR/PK-18

IGNITION KEY
( ON & DESS )

BK/YL

RELAY
DRIVER
FUSE
( F13 )
5A

2-DC7-B

VI/PK-18

CC

RD-10

JT
BE/WH

PF1

3-PF1-8B

OR/GN

SPEEDOMETER
& PILOT LAMPS

1-CI-16

RD/BE

1-HIBM-4

3-PF1-2A

3-PF1-6B

RELAY
SPEEDO
FUSE
( F4 )
10 A

MAIN
RELAY
(R2)

PF1-5E

JT OR/GN

RD/BE-14

PF2-1

PF1

PF1

KEY
SWITCH
FUSE
( F8 )
5A

PF1-8A

BK/YL

RD-6

MAIN FAN /
FUSE ACCES.
(F1) FUSE
30 A (F2)
50 A

PF1

CI

3-PF1-1A

RD/BE-14

HP ACC
F3
60 A

3-PF1-1B

OR/BU-18

( 3/3 )

PF1-4E

YL/BU

PF2

PF2 PF2
(1/3 )(2/3 )

H

PF1
CONTROL
EURO
F10
5A

PF2-C

PF2-B

BE/WH

PF1-7A

RD/GY

PF2-A

I

RD/PK

BE/WH

RD/GY-12

I

RD/GN-12

JT RD/GY

(RÉF. BOSCH 2.5)

10

710002625F1

P

N

2

1

3

4

5

6

COMMANDER

ACS SYSTEM

8

7

9

11

10

1

3

4

2

NAME

MAIN
HARNESS
SIDE

YL

BE/GN-18

1-CI-19

1-CI-18

BU
4WD

ENGINE

1-CI-4

BR/PK-18

YL

1-CI-7

START
ER
SOLEN
OID

BATTERY
12 VDC
18 AH

AIR
COMPRES
SOR

OR/BR-18

-

EX:

ME

2 -

ME

M

RD/WH

RD/BR

BE/GN-18

SM

JT BE/GN

STARTER
MOTOR

M1-2

TEMPERATURE
SENSOR

U

BK

4-T1-2

2-DB1-2

4-PCM-9

BK-6

WH/BE

2-DB2-1

BK/VI

4-PCM-6

BK/GY

4-PCM-7

4-PCM-27

SCM

SECTION OF MODULE

STEEL LINK (FRAME )

SLOTTED SCREW

TERMINAL

OPTIONAL

LT BU

LIGHT BLUE

N

M

L

BR/PK

BR/PK

BR/PK

RD/BR

4-BV1-1

4-BV1-3

( VALVE AVANT-GAUCHE )
4-BV1-2

BK/BE

4-PCM-22

+

E

( VALVE USER )
4-BV1-4

( VALVE ARRIERE )

D

4-PCM-14

1-S1-10

1-S1-8

4-BV1-9

P

U
P

BK

4-BV1-10

4-PCM-3

F

( VALVE AVANT-DROIT )

4-PCM-24

4-PCM-25

G

4-BV1-8

BR/YL

PK/BR

S1 (1/2)

FREE

J

4-BV1-5

4-BV1-6

( VALVE VENT )

4-PCM-23

4-PCM-10

CA

S1 (2/2)

PRESSURE
SENSOR

C

1-S1-7

1-S1-9

4-BV1-7

BK-6

BK-12

MALE TERMINAL

( VALVE POMPE VENT )

4-PCM-26

SUSPENSION
CONTROL
MODULE

PK/OR

BK-6

BK-12

YL-12

REAR OF VEHICLE

4-BV3-2

BK/GN

4-PCM-33

1-S1-1

UP

YL-14

YL-14

1-S1-3

BK

2-DB1-3

5-BN3

B

JT BK

JT BK1

BK-12

BK-12

5-BN1

BK-12
BK-12

2

2-DB2-3

JT BK2

BK-12

A
1

5

4-PCM-34

4-PCM-1

WH/BE

2-DB1-1

BE/GN-18

WH/BE-18

CAN HI

1-S1-2

4-BN5

COMPONENT CONNECTION

H

BK/YL

5-RD1-3

5-BN4

FEMALE TERMINAL

4-PCM-16

VI/PK

4-PCM-2

BE/GN

DOWN

BK-6

ENGINE AREA

BV3-1

4-PCM-36

C

B

4

4-PCM-35

4-PCM-18

OR/GN

2-DB2-4

BE/GN

BR/PK

4-PCM-13
BK

T

4-PCM-17

4-PCM-28

4-T1-1

CA-3

MAGNETO
650 WATTS

SPLICE CONNECTION

K

W

CA-2

SIMPLE CONDUCTOR WIRE

M

2-DB2-2

JT WH/BE

RD-12
YL-12

YL-12
YL-14

CA-1

FRONT OF VEHICLE

3

P

SEE MAIN HARNESS DIAGRAM
FOR DETAILS ON DB1 AND DC7

BK/BU

D

NUT CONNECTION

MODULE AREA

RD/BR

4-PCM-32

5-RD2-3

WIRE BUS

2

OR/PK

4-PCM-31

5-RD2-2

PHILLIPS SCREW

BEIGE
BLACK
BLUE
BROWN
GREEN
GREY
ORANGE
RED
VIOLET
WHITE
YELLOW
PINK

DB1 FROM MAIN HARNESS
DIAGNOSTIC CONNECTOR

RECTI
FIER

5-RD2-1

CROSSED WIRE

4-R5-88

2-DB1-4

OR/GN

RD
V

EGINE GROUND

STEERING AREA

BE
BK
BU
BR
GN
GY
OR
RD
VI
WH
YL
PK

JT BR/PK

BR/BE

5-RD1-1

U

A

COLOR CODE

SHRINKED JOINT

1

4-R5-85

2-DB2-5

5-BAT2

E

CV

1450 watts
930 watts
580 watts
365 watts
230 watts
145 watts
85 watts

28

FRAME GROUND

WELDED JOINT

ZONE DESCRIPTION

27

DC7 FROM MAIN HARNESS
HIGH POWER ACC

2-DB1-5

RD/GY

CAN LOW

F

CV

4 -

4-SM

BAT

G

EX:

15

125 amps
80 amps
50 amps
30 amps
20 amps
15 amps
7.5 amps

BR/PK

5-SS2

WH/BE-18
5-BAT1

-

M1-1

1-CI-5

RD/GY

RD-6

RD-6

RD-12

H

CI

100 amps
65 amps
40 amps
25 amps
16 amps
10 amps
6 amps
50°C MAX

ZONE #

MAX. WATT

BR/PK

5-SS1

5-BP3

1 -

RD/GN

4-R5-30

HI
BEAM

1-CI-20

BK-18

FUEL

VI/PK-18

RD-12

SS

J

CI

MAX. FUSE CURRENT

R5

OR/GN-18
5-BP1

# 6
# 8
# 10
# 12
# 14
# 16
# 18
* AT

MAX. CURRENT

26

25

24

RD/BR

4-R5-87

BU-18

RD

1-CI-21

5-BP2

AWG

23

22

21

2-DB2-6

SPEEDOM
ETER
& PILOT
LAMPS

1-CI-17

BK/BE-18

HP
ACCES.
FUSE
(F3)
60 A

K

EX:

20

19

ZONE-CONNECTOR NAME-TERMINAL #/A

2-DB1-6

CI

OR/GN-18

P

PF2
(3/3)

MAIN FAN /
FUSE ACCES.
(F1) FUSE
(F2)
30 A
50 A

ACS
HARNESS
SIDE

2-DC7-B

WH/BE-18

RD/GY-12

L

18

17

JT RD/BR

JT OR/GN

PF2 PF2
(1/3) (2/3)

16

15

5

RD/PK

M

14

TERMINAL IDENTIFICATION

JT RD/BR

JT RD/GY

13

12

3

2-DC7-A

JT BK3
JT BK4

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

30 SEPT. 2011

26

27

710002542F3
28

A

2

1
P

N

3

4

5

6

8

7

9

10

11

12

13

14

16

15

18

17

AWG

TERMINAL IDENTIFICATION

COMMANDER

1

3

RADIO SYSTEM

5

4

2

MAIN
HARNESS
SIDE

NAME

RADIO
SIDE

EX:

CI

1 -

CI

-

EX:

CV

4 -

CV

-

EX:

ME

2 -

ME

15
A

100 amps
65 amps
40 amps
25 amps
16 amps
10 amps
6 amps
50°C MAX

20
MAX. FUSE CURRENT
125 amps
80 amps
50 amps
30 amps
20 amps
15 amps
7.5 amps

22

21

ZONE #

MAX. WATT
1450 watts
930 watts
580 watts
365 watts
230 watts
145 watts
85 watts

23

26

25

24

27

SHRINKED JOINT

EGINE GROUND

CROSSED WIRE

PHILLIPS SCREW

WIRE BUS

NUT CONNECTION

FRONT OF VEHICLE

SIMPLE CONDUCTOR WIRE

SPLICE CONNECTION

4

ENGINE AREA

FEMALE TERMINAL

COMPONENT CONNECTION

5

REAR OF VEHICLE

MALE TERMINAL

SECTION OF MODULE

STEEL LINK (FRAME )

SLOTTED SCREW

TERMINAL

OPTIONAL

1

STEERING AREA

2

MODULE AREA

3

28
COLOR CODE

FRAME GROUND

WELDED JOINT

ZONE DESCRIPTION

RD/VI

BE
BK
BU
BR
GN
GY
OR
RD
VI
WH
YL
PK

BEIGE
BLACK
BLUE
BROWN
GREEN
GREY
ORANGE
RED
VIOLET
WHITE
YELLOW
PINK

LT BU

LIGHT BLUE

P

N

BK

SEE MAIN HARNESS

JT RD/GN

MAX. CURRENT

# 6
# 8
# 10
# 12
# 14
# 16
# 18
* AT

ZONE-CONNECTOR NAME-TERMINAL #/A

2-DC6-B

JT RD/VI

19

JT RD/GY
JT OR/GN

YL

1-CI-19 1-CI-18

1-CI-7

1-CI-5

K

RO1

OR/GN-18
5-BP2

5-SS1

5-BP1

SS

J

L

HI
BEAM

1-CI-20

BK-18

BK/BE-18

BR/PK-18

VI/PK-18

RD-12

K

WH/BE-18

1-CI-4

1-CI-21

AM/FM
ANTENNA

BU
4WD

ENGINE

BE/GN-18

FUEL

YL

DC6 ACCESSORY
POWER CONNECTOR

BU-18

RD

FAN /
ACCES.
FUSE
(F2)
40 A

MAIN
FUSE
(F1)
30 A

SPEEDOMETER
& PILOT LAMPS

1-CI-17

P

PF2 PF2
(1/2) (2/2)

L

M

CI

OR/GN-18

RD/GN-12

RD/GY-12

M

STARTER
SOLENOID

13

BK

15

RD/VI

J

15 A FUSE

5-SS2

5-BP3

RR

RD-6

H

RD-6

RD-12

OR/BR-18

4

VI

VI

RD

B

+

H
SPEAKER
REAR RIGHT

BK/VI

5-BAT1

BAT

G

8

BK/VI

A

BK

B

WH

4-SM

BATTERY
12 VDC
18 AH

M

RADIO

SM

3

GY

FR
GY

+

STARTER
MOTOR

G
SPEAKER
FRONT RIGHT

BK/GY

7

BK/GY

A

BK

B

RD

BK-6

5-BAT2

1

GN

GN

+

RD-12

F

RL

5-RD1-1

RD

E

BK/GN

5

BK/GN

WH

2

WH

A

BK

B

WH

FL

+

RECTIFIER

BK/WH

W

V

6

A

BK/WH

E

SPEAKER
FRONT LEFT

U

F

SPEAKER
REAR LEFT

BK

YL-14

YL-14

CA-1

BK-6

BK-12

YL-12
CA-2

D

CA-3

YL-14

YL-12

D

YL-12

5-RD2-1 5-RD2-2 5-RD2-3 5-RD1-3

DASH REMOTE

C

C

5-BN4

BK-6
4-BN5

5-BN3

BK-12

BK-12

JT BK1

BK-12 BK-12

2

GLOVE BOX
USB / AUX IN

JT BK2

A

1

B

2-DC6-A

SEE MAIN HARNESS

5-BN1

BK-12

B

IPOD
GLOVE BOX

BK-6

MAGNETO
650 WATTS

BK-12

CA

3

A

JT BK3

30 SEPT. 2011

JT BK4

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

710002553F4
27

28

SAFETY NOTICE

SAFETY NOTICE

ls

CAUTION Indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.

ua

NOTICE Indicates an instruction which, if not
followed, could result in severe damage to vehicle components or other property.

NOTE: Indicates supplementary information required to fully complete an instruction.
Although the mere reading of such information
does not eliminate the hazard, your understanding of the information will promote its correct
use. Always use common shop safety practices.
It is understood that this manual may be translated into another language. In the event of any
discrepancy, the English version shall prevail.
BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents. We strongly recommend that any services
be carried out and/or verified by a highly skilled
professional mechanic.

gr
e

en

-m
an

This manual has been prepared as a guide to correctly service and repair the 2012 Can-Am™ Commander LTD as described in the model list in the
INTRODUCTION.
This SHOP MANUAL SUPPLEMENT must be
used in conjunction with the 2011 CAN-AM
COMMANDER SHOP MANUAL (P/N 219 100
452). Refer to this manual when a particular system is not covered in this supplement.
This edition was primarily published to be used
by technicians who are already familiar with all
service procedures relating to BRP products.
Technicians should attend training courses given
by BRPTI.
Please note that the instructions will apply only
if proper hand tools and special service tools are
used.
The contents of this manual depicts parts and
procedures applicable to the particular product at
the time of writing. Service and warranty bulletins
may be published to update the content of this
manual. Dealer modifications that were carried
out after manufacturing of the product, whether
or not authorized by BRP, are not included.
It is understood that certain modifications may
render use of the vehicle illegal under existing
federal, provincial and state regulations.
In addition, the sole purpose of the illustrations
throughout the manual, is to assist identification
of the general configuration of the parts. They are
not to be interpreted as technical drawings or exact replicas of the parts.
The use of BRP parts is most strongly recommended when considering replacement of any
component. Dealer and/or distributor assistance
should be sought in case of doubt.
The engines and the corresponding components
identified in this document should not be utilized
on product(s) other than those mentioned in this
document.
This manual emphasizes particular information denoted by the following wording and symbols:

WARNING

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

tmr2012-002

I

INTRODUCTION

INTRODUCTION
MODEL NUMBER

Commander 1000 LTD

6GCA, 6GBC, 6GCC,
6GCD

gr
e

en

-m
an

The information and component/system descriptions 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 differences 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, models or equipment without incurring obligation.

ua

MODEL

ls

This shop manual covers the following BRP made
2012 Can-Am side-by-side vehicles.

II

tmr2012-002

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER 1000 LIMITED
COMMANDER
1000 LTD

MODEL

ls

ENGINE

ROTAX®1010
V-twin 4-stroke, Single Over Head Camshaft
(SOHC), liquid cooled
2

Engine type

ua

Number of cylinders
Number of valves

8 valves (mechanical adjustment)

Bore

91 mm (3.583 in)

Stroke

75 mm (2.95 in)

Displacement

976 cm³ (59.6 in³)
10.5:1

Compression ratio

7000 rpm

Exhaust system
Air filter
Intake valve opening
Intake valve closing
Exhaust valve opening
Exhaust valve closing
Valve clearance

-m
an

Maximum HP RPM

Spark arrestor approved by USDA Forest Service

en

Intake and exhaust

gr
e

Intake

Valve seat contact width

Piston diameter

Piston/cylinder clearance

tmr2011-040

5° BTDC

0.11 mm to 0.19 mm (.0043 in to .0075 in)

Valve spring free length

Rocker arm shaft diameter

65° BBDC

Exhaust

Valve guide diameter

Rocker arm bore diameter

60° ABDC

0.06 mm to 0.14 mm (.0024 in to .0055 in)

Exhaust

Valve out of round

5° BTDC

Intake

Intake

Valve stem diameter

Flat corrugated composite fiber

Exhaust

New

Service limit

New

4.966 mm to 4.980 mm (.1955 in to .1961 in)
4.930 mm (.1941 in)

4.956 mm to 4.970 mm (.1951 in to .1957 in)

Service limit

4.930 mm (.1941 in)

New

0.005 mm (.0002 in)

Service limit
New

0.06 mm (.0024 in)
4.998 mm to 5.018 mm (.1968 in to .1976 in)

Service limit

5.050 mm (.1988 in)

New

40.81 mm (1.607 in)

Service limit
New
Service limit
New
Service limit
New
Service limit
New
Service limit
New
Service limit
New
Service limit

39.00 mm (1.535 in)
1.05 mm to 1.35 mm (.041 in to .053 in)
1.8 mm (.071 in)
1.25 mm to 1.55 mm (.049 in to .061 in)
2 mm (.079 in)
12.036 mm to 12.050 mm (.4739 in to .4744 in)
12.060 mm (.4748 in)
12.000 mm to 12.018 mm (.4724 in to .4731 in)
11.990 mm (.472 in)
90.950 mm to 90.966 mm (3.5807 in to 3.5813 in)
90.900 mm (3.5787 in)
0.027 mm to 0.057 mm (.0011 in to .0022 in)
0.100 mm (.0039 in)

1

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
ENGINE (CONT'D)

Lower compression ring, tapered face

3rd

Oil scraper ring

Rectangular
Tapered face

0.20 mm to 0.40 mm (.008 in to .016 in)
New

Oil scraper ring

Ring end gap

0.60 mm (.024 in)

Service limit

Oil scraper ring

0.03 mm to 0.07 mm (.0012 in to .0028 in)

New

Oil scraper ring

0.02 mm to 0.06 mm (.0008 in to .0024 in)

0.01 mm to 0.18 mm (.0004 in to .0071 in)

-m
an

Ring/piston groove clearance

0.70 mm (.028 in)
1.00 mm (.039 in)

Rectangular
Tapered face

0.20 mm to 0.40 mm (.008 in to .016 in)

0.20 mm to 0.70 mm (.008 in to .028 in)

Rectangular
Tapered face

ls

Upper compression ring, rectangular

2nd

ua

Piston ring type

1st

Rectangular

Tapered face

0.15 mm (.0059 in)

Service limit

Oil scraper ring
Cylinder bore

0.25 mm (.0098 in)

New

Cylinder taper
Cylinder out of round

Timing chain side

0.038 mm (.0015 in)

Service limit

0.090 mm (.0035 in)

Maximum New

0.015 mm (.0006 in)

New

Service limit

New

Service limit

en

Spark plug side

Timing chain side

Camshaft main bearing
journal bore

Spark plug side
Intake valve

gr
e

Camshaft lobe

Exhaust valve

90.993 mm to 91.007 mm (3.5824 in to 3.583 in)

Maximum New

Service limit

Camshaft main bearing
journal

0.15 mm (.0059 in)

New
Service limit

New
Wear limit

New
Service limit

New
Service limit

0.020 mm (.0008 in)

34.959 mm to 34.975 mm (1.3763 in to 1.377 in)
34.950 mm (1.376 in)

21.959 mm to 21.980 mm (.8645 in to .8654 in)
21.950 mm (.8642 in)

35.000 mm to 35.025 mm (1.378 in to 1.3789 in)
35.040 mm (1.3795 in)
22.000 mm to 22.021 mm (.8661 in to .867 in)
22.040 mm (.8677 in)
32.960 mm to 33.160 mm (1.2976 in to 1.3055 in)
32.940 mm (1.2969 in)
32.860 mm to 33.060 mm (1.2937 in to 1.3016 in)
32.840 mm (1.2929 in)

Crankshaft main bearing journal diameter
(MAG/PTO side)

New
Service limit

42.000 mm (1.6535 in)

Crankshaft radial play (MAG/PTO side)

Service limit

0.07 mm (.0028 in)

Crankshaft bearing journal diameter (in PTO cover)
Crankshaft radial play (PTO cover bearing)
Crankshaft axial play

2

New

42.016 mm to 42.040 mm (1.6542 in to 1.6551 in)

34.004 mm to 34.020 mm (1.3387 in to 1.3394 in)

Service limit

33.998 mm (1.3385 in)

Service limit

0.10 mm (.0039 in)

New
Service limit

0.200 mm to 0.500 mm (.0079 in to .0197 in)
0.600 mm (.0236 in)

tmr2011-040

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
ENGINE (CONT'D)
New

Crankshaft pin diameter

Crankcase plain bearing

MAG/PTO side

New
Service limit

PTO cover plain bearing

Service limit

Connecting rod big end diameter

Service limit

Connecting rod big end radial play

Service limit

Connecting rod big end axial play

New
Service limit
New
Service limit

42.100 mm (1.6575 in)

34.120 mm (1.3433 in)

42.100 mm (1.6575 in)
0.09 mm (.0035 in)

0.250 mm to 0.550 mm (.0098 in to .0217 in)
0.600 mm (.024 in)

22.010 mm to 22.020 mm (.8665 in to .8669 in)

Service limit

22.050 mm (.8681 in)
21.996 mm to 22.000 mm
(865.984 in to 866.142 in)
21.980 mm (.8654 in)

Service limit

0.080 mm (.0031 in)

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Connecting rod small end diameter

0.050 mm (.002 in)

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MAG/PTO side

41.967 mm (1.6522 in)

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Service limit

Crankshaft deflection

Piston pin diameter

41.986 mm to 42.010 mm (1.653 in to 1.6539 in)

New

Connecting rod/piston pin clearance (radial play)
LUBRICATION SYSTEM

Type

Wet sump. Replaceable cartridge oil filter

Oil filter

Engine oil pressure

Lubrication

BRP Rotax paper type, replaceable

Minimum
Capacity
(oil change with filter)

Engine oil

en

Recommended

300 kPa (44 PSI) at 6000 RPM
2.2 L (2.3 qt (U.S. liq.))

For the summer season, use XPS synthetic
blend oil (summer grade) (P/N 293 600 121).
For the winter season, use XPS synthetic
oil (winter grade) (P/N 293 600 112).
If not available, use a 5W40 motor oil that
meets the requirements for API service
classification SM, SL or SJ

COOLING SYSTEM

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Coolant

Thermostat

Type

Capacity

Starts to open

65°C (149°F)

Fully open

88°C (190°F)

Radiator cap opening pressure

tmr2011-040

Ethyl glycol/water mix (50% coolant, 50% water).
Use premixed coolant sold by
BRP (P/N 219 700 362) or
coolant specifically designed for aluminum engines
4.3 L (1.1 U.S. gal.)

110 kPa (16 PSI)

3

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
TRANSMISSION
Type

CVT (Continuously Variable Transmission)

Drive belt width

Service limit
New

Governor cup roller outer diameter

Service limit
New

Governor cup roller inner diameter

Service limit
New

Centrifugal lever pivot bolt diameter

Service limit
New

Centrifugal lever bore diameter

Service limit

Drive pulley sliding half large bushing
Drive pulley sliding half small bushing
Drive pulley spring free length
Drive pulley spring free squareness
Spring sleeve length
Driven pulley sliding half bushing

New

Service limit

New

13.70 mm to 13.80 mm (.539 in to .543 in)
13.20 mm (.52 in)

8.05 mm to 8.15 mm (.317 in to .321 in)
9.00 mm (.354 in)

6.078 mm to 6.100 mm (.239 in to .24 in)
6.000 mm (.236 in)

6.035 mm to 6.078 mm (.2376 in to .2393 in)
6.200 mm (.244 in)

6.113 mm to 6.171 mm (.241 in to .243 in)
6.300 mm (.248 in)

55.000 mm to 55.040 mm (2.165 in to 2.167 in)
55.200 mm (2.173 in)

32.000 mm to 32.040 mm (1.26 in to 1.261 in)

Service limit

32.200 mm (1.268 in)

Service limit

105 mm (4.134 in)

Service limit

4 mm (.157 in)

New

Service limit

New

Service limit

New

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Driven pulley sliding fixed bushing

30.00 mm (1.181 in)

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Drive pulley sliding half centrifugal lever pivot bolt bore New
diameter
Service limit

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1750 ± 100 RPM

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Engagement RPM

9.2 mm to 9.4 mm (.362 in to .37 in)
9.0 mm (.354 in)

30.060 mm to 30.100 mm (1.183 in to 1.185 in)
30.200 mm (1.189 in)

30.060 mm to 30.100 mm (1.183 in to 1.185 in)

Service limit

30.200 mm (1.189 in)

Torque gear on driven pulley

Service limit

7.500 mm (.295 in)

Driven pulley spring free length

Service limit

125 mm (4.921 in)

Driven pulley spring free squareness

Service limit

3.8 mm (.15 in)

GEARBOX

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Type
Gearbox oil

Coupling sleeve groove width
Coupling fork claw thickness

Shift fork claw thickness
(high, low and reverse gear shift fork)
Width of shift fork engagement groove

4

Capacity
Recommended
New
Service limit
New
Service limit
New
Service limit
New
Service limit

Dual range (HI-LO) with park, neutral and reverse
450 ml (15 U.S. oz)
XPS synthetic gear oil (P/N 293 600 140)
or a 75W140 API GL-5 synthetic gear oil
5.25 mm to 5.35 mm (.207 in to .211 in)
5.50 mm (.217 in)
4.95 mm to 5.05 mm (.195 in to .199 in)
4.80 mm (.189 in)
5.10 mm to 5.20 mm (.201 in to .205 in)
5.00 mm (.197 in)
5.30 mm to 5.40 mm (.209 in to .213 in)
5.50 mm (.217 in)

tmr2011-040

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
GEARBOX (CONT'D)
New

Diameter free pinions

29.000 mm to 29.013 mm (1.1417 in to 1.1422 in)

New

Intermediate gear shaft

29.015 mm (1.1423 in)

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Service limit

24.987 mm to 25.000 mm (.9837 in to .9843 in)

Service limit

Countershaft
CVT side
Free pinion bearing
Main shaft

New
Service limit
New
Service limit
New
Service limit

19.973 mm (.7863 in)

24.977 mm to 24.990 mm (.9833 in to .9839 in)
24.970 mm (.9831 in)

24.987 mm to 25.000 mm (.9837 in to .9843 in)
24.984 mm (.9836 in)

16.980 mm to 16.991 mm (.6685 in to .6689 in)

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Bearing journal
MAG/CVT side

Service limit

24.977 mm (.983 in)

19.977 mm to 19.990 mm (.7865 in to .787 in)

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MAG side

New

16.976 mm (.6683 in)

ELECTRICAL SYSTEM

Magneto generator output
Stator resistance (20C)
Ignition system type
Ignition timing

Quantity

Spark plug

Make and type

Gap

Forward

Engine RPM limiter setting

Reverse

en

Type

Battery

Headlight
Taillight

Turn signals (CE)

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Position light

tmr2011-040

650 W @ 6000 RPM
0.15 to 0.30
IDI (Inductive Discharge Ignition)
Not adjustable
2
NGK DCPR8E

0.7 mm to 0.8 mm (.028 in to .031 in)

8000 rpm
20 km/h to 25 km/h (12 MPH to 16 MPH)
(8000 rpm with Override)
Maintenance free

Voltage

12 volts

Nominal rating

18 A•h

Power starter output

0.7 KW
4 x 60 W
2 X 8/27 W
10 W
LED, 0.7 V approximately (each)

5

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
ELECTRICAL SYSTEM (CONT'D)
F1: Main
Fuses
F2: Main accessories
(fuse block #2)
F3: ACS suspension

50 A
60 A

F4: Speedometer and brake relay

10 A

F5: Fuel injectors and ignition coils

7.5 A

F7: Winch and 2WD/4WD switches
F8: Ignition switch and gauge
Fuses
(fuse block #1)

F9: Cooling fan

5 A

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F6: Engine control module (ECM)

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30 A

5 A

5 A

25 A

F10: Euro controls

5 A

F11: Lights

30 A
15 A

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F12: 12V power outlet

F13: Cooling fan relay (R1) and Accessories relay (R3)

5 A

F14: 12V power (connector DC6)

15 A

F15: Fuel pump

5 A

Cooling fan relay (R1)
Main relay (R2)

Accessories relay (R3)

Relays

Lights relay(R4)

ACS suspension relay (R5)
Brake relay (R8)

FUEL SYSTEM

Fuel pump
Idle speed

Type

en

Fuel delivery

Type

Operating pressure
Type

Octane rating

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Fuel

Fuel tank capacity

Fuel remaining when low fuel light turns ON

6

Inside North America
Outside North America

Electronic Fuel Injection (EFI), 54 mm throttle
body with iTC (Intelligent Throttle Control),
1 injector per cylinder
Electrical (in fuel tank)
350 kPa (51 PSI)
1250 rpm ± 50 (not adjustable)
Regular unleaded gasoline
87 (R+M)/2 or higher
92 RON or higher
38 L (10 U.S. gal.)
± 12 L (3.2 U.S. gal.)

tmr2011-040

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
DRIVE SYSTEM

Visco-lok† front differential

Front drive

3.6:1

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Front drive ratio
Rear drive

Shaft driven/spool
3.6:1

Rear drive ratio
Front differential oil

Recommended
Capacity

Rear final drive oil

Recommended

CV joint grease
STEERING
Steering wheel
Turning radius

Hi-temp bearing grease NLGI-2 or an equivalent

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Propeller shaft grease

500 ml (17 U.S. oz)
XPS synthetic gear oil (P/N 293 600 043)
or synthetic gear oil 75W90 API GL-5
350 ml (11.8 U.S. oz)
XPS synthetic gear oil (P/N 293 600 140)
or synthetic gear oil 75W140 API GL-5
CV joint grease (P/N 293 550 019)

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Capacity

Total toe (vehicle on ground)

Camber angle (vehicle on ground)

Tie-rod maximum length unengaged threads

Adjustable tilt steering
240 cm (94.5 in)
0 mm ± 4 mm (0 in ± .157 in)
0.7° positive
32 mm (1.26 in)

FRONT SUSPENSION
Suspension type
Suspension travel
Shock absorber

Qty

2

Type

HPG clicker with air

en

Spring free length

Double suspension-arm with dive-control
geometry with ACS
254 mm (10 in)

Automatic mode: 6 positions
air compression settings
Manual mode: limitless between
position 1 and position 6 of automatic mode

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Preload adjustment type

358.7 mm (14.122 in)

tmr2011-040

7

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

MODEL

COMMANDER
1000 LTD

REAR SUSPENSION

Suspension travel
Shock absorber

Qty

2

Type

HPG clicker with air
355.6 mm (14 in)

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Spring free length

Automatic mode: 6 positions
air compression settings
Manual mode: limitless between
position 1 and position 6 of automatic mode

Preload adjustment type

Qty
Type
Qty
Rear brake

Type
Capacity

Brake fluid

Type

Caliper
Front
Rear

Minimum brake pad thickness
Front
Rear

Maximum brake disc warpage

Front

Rear

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Minimum tire thread depth
Size

Metallic

Metallic

1 mm (.04 in)

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Minimum brake disc
thickness

Pressure

DOT 4

Floating

Brake pad material

TIRE

2
214 mm cross-drilled disc brakes with
hydraulic twin-piston calipers
1
214 mm cross-drilled disc brake with
hydraulic twin-piston caliper
250 ml (8.5 U.S. oz)

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BRAKES
Front brake

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Torsional Trailing arm Independant (TTI) with
external sway bar with ACS
254 mm (10 in)

Suspension type

4.3 mm (11/64 in)

4.3 mm (11/64 in)
0.2 mm (.01 in)

Maximum: 83 kPa (12 PSI)
Minimum: 69 kPa (10 PSI)
Maximum: 152 kPa (22 PSI)
Minimum: 83 kPa (12 PSI)
3 mm (.118 in)

Front

27 x 9 x 14 (in)

Rear

27 x 11 x 14 (in)

WHEELS
Type

Rim size

Wheel nuts torque

Cast aluminum

Front

14 X 7 (in)

Rear

14 X 8.5 (in)
100 N•m ± 10 N•m (74 lbf•ft ± 7 lbf•ft)

CHASSIS

Cage type

8

50 mm (2 in) diameter, high strength steel,
ROPS-approved cage

tmr2011-040

Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (COMMANDER 1000 LIMITED)

COMMANDER
1000 LTD

MODEL
DIMENSION

300.4 cm (118.3 in)

Overall width

148.9 cm (58.6 in)

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Overall length
Overall height

182.9 cm (72 in)

Wheel base
Rear

Ground clearance

125.7 cm (49.5 in)
27.9 cm (11 in)

WEIGHT AND LOADING CAPACITY
Dry weight

587 kg (1,295 lb)

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Weight distribution
Front/rear
Cargo box capacity
Total (upper + lower)
(Distribute load evenly in upper and lower
Upper
cargo boxes without exceeding 181 kg (400 lb) in the
Lower
upper cargo box.)
Total vehicle load allowed
(including driver, passenger, all other loads and added
accessories)
Gross vehicle weight rating
Towing capacity (Hitch support of 50.8 mm (2 in) X 50.8 mm (2 in))

44/56

272 kg (600 lb)

181 kg (400 lb)

272 kg (600 lb)
363 kg (800 lb)
990 kg (2,183 lb)
680 kg (1,500 lb)
CE Model: 270 kg (600 lb)
68 kg (150 lb)

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Tongue capacity

121.9 cm (48 in)

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Wheel track

192.4 cm (75.7 in)

Front

tmr2011-040

9

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

AIR CONTROLLED SUSPENSION (ACS)
SERVICE TOOLS
Part Number

Page

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Description

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FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................... 13–15, 17, 20–22

tmr2012-005

1

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

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NEW
48 N•m
(35 lbf•ft)

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NEW
48 N•m
(35 lbf•ft)

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ACS FRONT SUSPENSION

NEW = Component must be replaced when removed.

tmr2012-005-100_a

2

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS REAR SUSPENSION

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10 N•m
(89 lbf•in)

10 N•m
(89 lbf•in)

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NEW

en

48 N•m
(35lbf•ft)
NEW

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10 N•m
(89 lbf•in)

10 N•m
(89 lbf•in)

10 N•m
(89 lbf•in)
24 N•m
(18 lbf•ft)

NEW = Component must be replaced when removed.

tmr2012-005-001_a

tmr2012-005

3

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

GENERAL
During assembly/installation, use torque values
and service products as in the exploded view.

ls

WARNING

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Torque wrench tightening specifications
must be strictly adhered to.
Locking devices must be replaced when removed (e.g.: locking tabs, cotter pins, etc.).
NOTICE Hoses, cables or locking ties removed during a procedure must be reinstalled
as per factory standards. Hoses must be properly inserted.

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Be careful while manipulating nylon hoses, they
must not be kinked.

CAUTION Always wear safety goggles
when working with pressurized air system.

CAUTION The ACS suspension system
may be under high pressure (over 900 kPa
(130 PSI)). Release air pressure prior to working on the system. Refer to AIR PRESSURE
RELEASE FOR SERVICING.

SYSTEM DESCRIPTION
(OPERATION)

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The Commander LTD comes equipped with
front and rear air-controlled suspension and HPG
shocks with remote reservoir (piggyback).
By changing the ACS setting, air pressure in the
front and rear shocks absorbers will change to provide a multitude of different suspension adjustments.
The ACS adjusts the front and rear shocks to 6
rider selectable levels depending on trail conditions or riders preference.
The front shocks pressure is lower than the rear
shocks. The pressure are determined by the setting position.
This system allows the operator to adjust the front
and rear suspension by pressing the suspension
button.

4

vdd2012-001-712

WARNING

Always adjust the ACS suspension setting according to load, riding condition, and speed.

NOTE: The ACS suspension will NOT self-adjust
unless the engine is running, even when key
switch is set to on.
The ACS has 2 modes for suspension adjustment:
– ACS auto mode
– ACS manual mode.

ACS AUTO Mode
The automatic mode allows for simultaneous adjustments on the front and rear suspensions.
In auto mode, the suspension will automatically
be adjusted to the preselected riding comfort position.

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS 1

Softest

ACS 2

Soft

ACS 3

Semi-soft

ACS 4

Semi-firm

ACS 5

Firm with high
ground clearance

ACS 6

Firmest and
highest ground
clearance

RECOMMENDED
LOAD
Operator only
Transporting a passenger
OR a cargo

Transporting a passenger
AND a cargo

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RIDING
COMFORT

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SETTING

To Enter ACS Automatic Mode:
Press the MODE button until either ACS AUTO or
ACS MAN is displayed.
Press SET button to have current ACS mode blink
on screen
Press SET button to select ACS AUTO mode.
NOTE: Selected ACS Setting from ACS1 to ACS6
displayed through gearbox position indicator.

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ACS SUSPENSION SETTINGS

tmo2012-003-221_c

Press and hold SET button to confirm selection.

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ACS MANUAL Mode
In manual mode the front and rear shock pressures can be adjusted independently. The fuel
and temperature indicators will respectively
become front and rear ACS pressure setting indicators.

vdd2012-001-714

ACS AUTO MODE

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Use ACS 1 to ACS 4 for trail riding.
Use the ACS 5 or ACS 6 settings to maximize
ground clearance and increase performance while
riding in the following environments:
– Muddy
– Watery
– Obstacles.
Use the ACS 6 setting is to maximize ground
clearance and increase performance while carrying heavy loads:

WARNING

Always adjust the ACS suspension setting according to load, riding condition, and speed.

tmr2012-005

tmo2012-003-221_b

ACS MANUAL MODE

To Enter ACS Manual Mode:
Press the MODE button until either ACS AUTO or
ACS MAN is displayed.
5

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

tmo2012-003-221_e

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ls

Press SET button to have current ACS mode blink
on screen.
Press SET button to select ACS MAN mode.
NOTE: ACS set points and actual settings displayed through fuel, temp and gearbox position
indicators.

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Press and hold ACS button to lower or raise the
front suspension until desired setting is achieved.

tmo2012-003-221_a

Press and hold SET button to confirm selection.

To Adjust Front Suspension:
Press on the OVERRIDE button until front (F) is
blinking to select front (F) suspension setting.

tmo2012-003-211_a

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1. ACS button

To Adjust Rear Suspension:
Press on the OVERRIDE button until rear (R) is
blinking to select rear (R) suspension setting.

tmo2012-001-001_b

1. Override switch

tmo2012-001-001_b

1. Override switch

6

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

Quick Mode Selection

ls

The last setting utilized in each mode is stored in
the system. This allows for quick selections between the stored automatic mode setting and the
stored manual mode setting.

tmo2012-003-221_d

tmo2012-003-211_a

1. ACS button

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Use the ACS button to lower or raise the rear suspension.

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To Enter Quick Mode Selection:
Press the MODE button until either ACS AUTO or
ACS MAN is displayed.
Press SET button to have current ACS mode blink
on screen.
Press SET button to select desired mode.

tmo2012-003-221_a

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NOTE: Fuel and temperature indicators will respectively become front and rear ACS setting
indicators.

tmo2012-003-221_c

Press and hold SET button to confirm selection.
ACS system will adjust to the last settings.

tmo2012-003-221_b

tmr2012-005

7

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

The ACS compressor also comes with an auxiliary
hose that can be used to inflate tires out on the
trail.
The air outlet fitting is located behind the driver's
seat.

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Tire Inflation Using the ACS
Compressor

NOTE: After activating the System Pressure relief button the system is not completely empty.
The compressor setting does not allowed to drop
pressure under 207 kPa (30 PSI).

SYSTEM DESCRIPTION
(COMPONENTS)
Fuse and Relay

ACS Fuse
The ACS system is protected by the fuse F3 (60 A)
located in the fuse block no.2. This fuse powered
the ACS compressor through the ACS relay (R5).

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SYSTEM DESCRIPTION
(FEATURES)

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ACS Compressor Relay (R5)
ACS compressor relay (R5) is located near ACS
compressor, under driver’s seat.

vdd2012-001-717

Air Pressure Release for Servicing

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It is recommended to release air pressure in the
system before servicing any components.
1. Connect vehicle to the latest appropriate version of B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE subsection
in the 2011 CAN-AM SIDE-BY-SIDE SHOP
MANUAL.
2. Select Activation page.
3. Select ACS folder.
4. Press the System Pressure relief button to
proceed.

tmr2012-005-039_a

1. System Pressure relief button

8

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Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

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tmr2012-005-003_a

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ACS Main Components

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1. Multifunction gauge
2. ACS module
3. ACS button
4. ACS compressor (including temperature sensor)
5. ACS relay (R5)
6. Air filter
7. Pressure distributor
8. ACS solenoid valve (including pressure sensor)
9. Outlet fitting
10. Rear air reservoir
11. Rear shock absorbers
12. Front air reservoirs
13. Front shock absorbers

tmr2012-005

9

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

TROUBLESHOOTING
DIAGNOSTIC TIPS

TROUBLESHOOTING
GUIDELINES

1. Burn fuse F3 (60 A).
- Replace

2. Faulty compressor.
- Carry out a compressor operation test. Refer to
ACS COMPRESSOR OPERATION TEST.
3. Faulty solenoid valve
- Carry out a solenoid valve operation test. Refer
to ACS SOLENOID VALVE OPERATION TEST.

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AIR FAULT
If this message appears, it indicates a disparity between the requested and the actual suspension
settings. The system should react to correct this
situation and the message will disappear.
If the message remains active for a long period, it
may indicates a major leak in the system. In this
case, the module will automatically shut down the
compressor to prevent it from overheating. The
shut down procedure of the compressor will stay
active until the next restart of the vehicle (key OFF,
key ON).
If there is a major leak in the system, check the
system for leakage, refer to ACS SYSTEM LEAK
TEST.
If there is no leak, the problem can be electrical
or mechanical. In this case, an electrical failure of
the compressor or the solenoid valve will result in
the impossibility to change the actual suspension
setting; a mechanical failure of the solenoid valve
will create the same situation.
After multiple attempts to change suspension setting, the module will activate error message AIR
FAULT. Refer to TROUBLESHOOTING GUIDELINES for further troubleshooting procedure.

GAUGE DISPLAY SETTING (S1 TO S6)
CHANGED BUT SUSPENSION DOES NOT
WORKED

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Two error messages can appear in the multifunction gauge and they are not necessarily related to
a failure of the ACS system.

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In AUTO Mode

Error Message Displayed in
Multifunction Gauge

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COMPRESSOR TEMPERATURE OVERHEAT
This message appears when the compressor temperature is over the calibrated value.
This situation can occur if the compressor or the
solenoid valves are used during a long period of
time (continually or with brief halts).
Let the compressor cool down before using it
again.

4. Faulty ACS module
- Check the ACS module. Refer to ACS MODULE.

GAUGE DISPLAY SETTING (S1 TO S6)
DOES NOT CHANGED BUT SUSPENSION
WORKED
1. Faulty ACS module
- Check the ACS module. Refer to ACS MODULE.
2. Faulty multifunction gauge
- Check the multifunction gauge.

GAUGE DISPLAY DOES NOT CHANGED
AND SUSPENSION DOES NOT WORKED
1. Make sure engine is running
- Start engine.
2. Burn fuse F3 (60 A).
- Replace
3. Faulty ACS module
- Check the ACS module. Refer to ACS MODULE.
4. Faulty ACS button or wiring
- Check ACS button continuity.
- Check ACS button control circuit.

In Manual Mode
GAUGE DISPLAY SETTING (F OR R) DOES
NOT CHANGED
1. Faulty Override button
- Check the Override button.
2. Faulty multifunction gauge
- Check the multifunction gauge.

10

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

1. Faulty solenoid valve
- Carry out a release valve operation test. Refer to
ACS RELEASE VALVE OPERATION TEST.
2. Faulty ACS release valve
- Carry out a solenoid valve operation test. Refer
to ACS SOLENOID VALVE OPERATION TEST.
3. Faulty ACS button or wiring
- Check ACS button continuity. Refer to ACS BUTTON.
- Check ACS button control circuit. Refer to ACS
BUTTON.

7. Faulty ACS module
- Check the ACS module. Refer to ACS MODULE.

AIR OUTLET FITTING DOES NOT WORKS
1. Make sure engine is running
- Start engine.

2. Faulty solenoid valve
- Carry out a solenoid valve operation test. Refer
to ACS SOLENOID VALVE OPERATION TEST.

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4. Faulty ACS module
- Check the ACS module. Refer to ACS MODULE.

6. Faulty ACS button or wiring
- Check ACS button continuity. Refer to ACS BUTTON.
- Check ACS button control circuit. Refer to ACS
BUTTON.

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SUSPENSION PRESSURE CAN BE
INCREASED ONLY

5. Faulty solenoid valve
- Carry out a solenoid valve operation test. Refer
to ACS SOLENOID VALVE OPERATION TEST.

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AUTO and MANUAL Mode

SUSPENSION PRESSURE CAN BE
DECREASED ONLY

1. Faulty relay (R5)
- Check the ACS relay. Refer to ACS RELAY.

2. Faulty compressor.
- Carry out a compressor operation test. Refer to
ACS COMPRESSOR OPERATION TEST.

3. Faulty solenoid valve
- Carry out a solenoid valve operation test. Refer
to ACS SOLENOID VALVE OPERATION TEST.

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4. Faulty ACS button or wiring
- Check ACS button continuity. Refer to ACS BUTTON.
- Check ACS button control circuit. Refer to ACS
BUTTON.

5. Faulty ACS module
- Check the ACS module. Refer to ACS MODULE.

TROUBLESHOOTING WITH
B.U.D.S.
Check battery voltage before performing any
B.U.D.S. test. Battery must be fully charged or
use a power pack to ensure adequate power for
all required tests.

ACS System Leak Test

1. Connect vehicle to the latest appropriate version of B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE subsection
in the 2011 CAN-AM SIDE-BY-SIDE SHOP
MANUAL.
2. Select Activation page.
3. Select ACS folder.
4. In Self Test region, press the leak test button
to proceed.

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SUSPENSION PRESSURE CAN NOT BE
CHANGED
1. Make sure engine is running
- Start engine.
2. Burn fuse F3 (60 A).
- Replace
3. Faulty relay (R5)
- Check the ACS relay. Refer to ACS RELAY.
4. Faulty compressor.
- Carry out a compressor operation test. Refer to
ACS COMPRESSOR OPERATION TEST.

tmr2012-005

tmr2012-005-004_a

1. Activation page
2. ACS folder
3. Leak test button

11

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

Pneumatic hoses may be disconnected by pushing inwards on the air fitting ring (towards the air
fitting) while pulling outwards on the hose.

tmr2012-005-012_a

If a leak is detected, pressurize the system again
and inspect hoses and fittings with soapy water
to locate the faulty component.

1. Fitting ring
2. Pneumatic hose

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ACS Air Pressure Monitoring

tmr2012-005-046_a

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The result will be indicated in the TEST STATUS
box beside the leak test button.

To monitor air pressure in the system during troubleshooting operation, proceed as follows:
1. Connect vehicle to the latest appropriate version of B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE subsection
in the 2011 CAN-AM SIDE-BY-SIDE SHOP
MANUAL.
2. Select Monitoring page.
3. Select ACS folder.

NOTE: Pull the hose slightly and wait during the
release of the remaining air. When all air is released, remove pneumatic hose from its fitting.

Pneumatic hose Installation
Before installing the hose, verify the end of the
pneumatic hose.
If deep nicks are found, cut a small portion of the
hose end.
HOSE END LENGTH TO BE CUT

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tmr2012-005-005_a

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3.18 mm to 6.35 mm (1/8 in to 1/4 in)

1. Monitoring page
2. Suspension pressure

PROCEDURES

Push the hose inwards then pull the air fitting ring
outwards to reestablish a good seal and lock the
hose in place.

ACS RELEASE VALVE
ACS Release Valve Access
To access to ACS release valve, remove the following:
– Driver’s seat
– LH lateral console panel
– Floor panel.

PNEUMATIC HOSE

NOTICE Do not attempt to disconnect pneumatic hoses from ACS manifold or ACS exhaust compressor valve.

Pneumatic Hose Removal
Release air pressure from the ACS system. Refer
to AIR PRESSURE RELEASE FOR SERVICING in
this subsection.
12

tmr2012-005

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ls

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

tmr2012-005-010_a

1. Release valve button

5. Listen for air exits from underneath dash and
around valve to confirm proper operation.
tmr2012-005-008_a

ACS Release Valve Input Voltage Test
1. Unplug the ACS release valve connector.

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SIDE NET REMOVED FOR CLARITY
1. LH lateral console panel
2. Floor panel

The ACS release valve is a component of the ACS
compressor. The release valve is located at the
left of compressor

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tmr2012-005-011_a

1. ACS release valve connector

2. Start engine.
3. Measure voltage as per the following table.

tmr2012-005-009_a

REQUIRED TOOL

1. ACS release valve
2. ACS compressor

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ACS Release Valve Operation Test

1. Connect vehicle to the latest appropriate version of B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE subsection
in the 2011 CAN-AM SIDE-BY-SIDE SHOP
MANUAL.
2. Select Activation page.
3. Select ACS folder.
4. Press the Release Valve button to proceed.

tmr2012-005

FLUKE 115 MULTIMETER
(P/N 529 035 868)
TEST PROBES
Pin 1
(release valve
connector)

Battery
negative (–)
post

VOLTAGE
Battery voltage

ACS Release Valve Ground Test
1. With ACS release valve connector unplugged
and engine running, measure voltage as per the
following table.

13

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

REQUIRED TOOL

TEST PROBES

VOLTAGE

Battery
negative (+)
post

Battery voltage

ACS Release Valve Replacement
The ACS release valve is not available separately.
Replace the ACS compressor. Refer to ACS
COMPRESSOR for complete procedure.

1. ACS solenoid valve

ACS Solenoid Valve Operation Test

1. Connect vehicle to the latest appropriate version of B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE subsection
in the 2011 CAN-AM SIDE-BY-SIDE SHOP
MANUAL.
2. Select Activation page.
3. Select ACS folder.
4. Press the valve test button to proceed.

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ACS SOLENOID VALVE

tmr2012-005-013_a

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Pin 2
(release valve
connector)

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FLUKE 115 MULTIMETER
(P/N 529 035 868)

ACS Solenoid Valve Access

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To access to ACS solenoid valve, remove the following:
– Driver’s seat
– LH lateral console panel
– Floor panel.

tmr2012-005-008_a

SIDE NET REMOVED FOR CLARITY
1. LH lateral console panel
2. Floor panel

The ACS solenoid valve is mounted on the rear
side of the ACS compressor protector.

14

tmr2012-005-014_a

1. Valve test button

The result will be indicated in the TEST STATUS
box beside the valve test button.
If test fails, carry out the ACS SOLENOID VALVE
INPUT VOLTAGE TEST.
If the ACS solenoid valve passed the test, check
the ACS button.

ACS Solenoid Valve Input Voltage Test
1. Unplug the ACS solenoid valve connector.

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS Solenoid Valve Power Wire
Continuity Test

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1. Unplug the relay R5.
2. Check the continuity between ACS solenoid
valve connector and relay R5 holder as per the
following table.
REQUIRED TOOL

1. ACS solenoid valve connector

2. Start engine.
3. Measure voltage as per the following table.
REQUIRED TOOL

Pin 5
(solenoid valve
connector)

Position 85

RESISTANCE

Close to 0

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TEST PROBES

Pin 6
(solenoid valve
connector)

TEST PROBES

Pin 6
(solenoid valve
connector)

FLUKE 115 MULTIMETER
(P/N 529 035 868)

Pin 5
(solenoid valve
connector)

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FLUKE 115 MULTIMETER
(P/N 529 035 868)

tmr2012-005-015_a

Battery
negative (–)
post

VOLTAGE

Battery voltage

ACS Solenoid Valve Ground Wire
Continuity Test
1. Unplug the ACS module connector.
2. Check the continuity between ACS solenoid
valve connector and ACS module connector as
per the following table.
REQUIRED TOOL

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If the test fails, carry out an ACS SOLENOID
VALVE POWER WIRE CONTINUITY TEST.
If result is within specification, continue the test
with the ACS SOLENOID VALVE GROUND TEST.

ACS Solenoid Valve Ground Test
With ACS solenoid valve connector unplugged
and engine running, measure voltage as per the
following table.

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Battery
negative (+)
post

Pin 7
(solenoid valve
connector)

Pin 14
(module)

RESISTANCE
Close to 0

1. Remove bolts retaining the air pressure distributor.

FLUKE 115 MULTIMETER
(P/N 529 035 868)

Pin 7
(solenoid valve
connector)

TEST PROBES

ACS Solenoid Valve Removal

REQUIRED TOOL

TEST PROBES

FLUKE 115 MULTIMETER
(P/N 529 035 868)

VOLTAGE
Battery voltage

If the test fails, carry out an ACS SOLENOID
VALVE GROUND WIRE CONTINUITY TEST.
If result is within specification, check the ACS button.

tmr2012-005

15

tmr2012-005-017_a

1. Air pressure distributor
2. Retaining bolts

tmr2012-005-019_a

Air pressure distributor
Air outlet fitting
Rear air reservoir
Front RH air reservoir
Air pressure distributor
Front LH air reservoir

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2. Disconnect pneumatic hoses from:
– Air outlet fitting
– Air reservoirs
– Pressure distributor (except the lower one).
3. Unplug ACS solenoid valve connector.
4. Remove screws securing the ACS solenoid
valve to compressor protector.
5. Remove the ACS solenoid valve from the vehicle.

1.
2.
3.
4.
5.
6.

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Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS Module Access

To access to ACS module, remove the following:
– Driver’s seat
– LH lateral console panel
– Floor panel.

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tmr2012-005-018

ACS MODULE

ACS Solenoid Valve Installation
The installation procedure is the reverse of removal procedure, however pay attention to the
following.
Position the ACS solenoid valve on the compressor and route all pneumatic hoses through corresponding support holes.
Secure the ACS solenoid valve to its support.
Connect pneumatic hoses as per the following illustration.

16

tmr2012-005-008_a

SIDE NET REMOVED FOR CLARITY
1. LH lateral console panel
2. Floor panel

The ACS module is mounted on the wall of the
ACS compressor protector.

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS Module Input Voltage Test
1. Turn ignition switch to ON position.
2. Measure voltage as per the following table.

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REQUIRED TOOL
FLUKE 115 MULTIMETER
(P/N 529 035 868)

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TEST PROBES

Pin 17
(ACS module
connector)

tmr2012-005-020_a

1. ACS module

ACS Module Signal Circuit Continuity
Test

Pin 18
(ACS module
connector)

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1. Unplug multifunction gauge connector. Refer
to LIGHTS, GAUGE AND ACCESSORIES subsection in the 2011 CAN-AM SIDE-BY-SIDE
SHOP MANUAL.
2. Unplug ACS module connector.

Battery
negative (–)
post

VOLTAGE

Battery voltage

If the test fails, repair or replace wires and connectors.
If result is within specification, continue the test
with the ACS MODULE GROUND TEST.

ACS Module Ground Test
1. Turn ignition switch to ON position.
2. Measure voltage as per the following table.
REQUIRED TOOL

FLUKE 115 MULTIMETER
(P/N 529 035 868)

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TEST PROBES

Pin 31
(ACS module
connector)

tmr2012-005-021_a

1. ACS module connector

3. Measure resistance as per the following tables.

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REQUIRED TOOL

GAUGE
CONNECTOR

Pin 1

Pin 19

Pin 2

Pin 18

Pin 32
(ACS module
connector)

Battery
positive (+) post

Battery voltage

Pin 33
(ACS module
connector)

FLUKE 115 MULTIMETER
(P/N 529 035 868)

ACS MODULE
CONNECTOR

VOLTAGE

RESISTANCE

ACS Module Removal

Close to 0

1. Remove screws retaining the air reservoir support and the compressor support.

If the test fails, repair or replace wires and connectors.
If result is within specification, continue the test
with the ACS MODULE INPUT VOLTAGE TEST.

tmr2012-005

17

tmr2012-005-022_a

tmr2012-005-025_a

1. Screws to be removed

6. Using a small screwdriver, detach both connector housings from the compressor protector
wall.

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2. Disconnect pneumatic hoses from air reservoirs and air outlet fitting.
3. Place the air reservoir support aside to make
room.

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ls

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

tmr2012-005-026_a

1. Press these tabs inside

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tmr2012-005-023

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4. Unplug the ACS module connector.

7. Unplug the following connectors:
– Compressor connector
– Release valve connector
– Pressure sensor connector.

tmr2012-005-021_a

1. ACS module connector

5. Cut locking ties securing the wiring harness.

tmr2012-005-028_a

1. Compressor connector
2. Release valve connector
3. Pressure sensor connector.

8. Disconnect the lower pneumatic hose from the
pressure distributor.

18

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS Module Installation
The installation procedure is the reverse of removal procedure.

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ACS RELAY (R5)

ACS Relay (R5) Access

tmr2012-005-024_a

1. Disconnect this hose
2. Pressure distributor

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9. Turn the compressor support on the side to remove screws retaining the compressor protector.

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To access to ACS relay, remove the following:
– Driver’s seat
– LH lateral console panel
– Floor panel.

tmr2012-005-008_a

SIDE NET REMOVED FOR CLARITY
1. LH lateral console panel
2. Floor panel

tmr2012-005-027_a

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1. Compressor protector retaining screws

The ACS relay is mounted under the top of the
ACS compressor protector.

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10. Separate compressor protector from the compressor support.
11. Remove screws securing the ACS module on
the wall of the compressor protector.

tmr2012-005-029_a

tmr2012-005

tmr2012-005-030_a

1. ACS relay (R5)

ACS Relay Continuity Test
1. Remove relay (R5).
1.1 Remove bolt and nut retaining the relay
holder on the top of the compressor protector.
19

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

ACS Relay Input Voltage Test
1. Measure voltage as per the following table.

FLUKE 115 MULTIMETER
(P/N 529 035 868)
TEST PROBES

tmr2012-005-031_a

Battery voltage

If voltage is not as specified, check wiring, connector and terminal condition.

ACS Relay Ground Wire Continuity
Test

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1.2 From the rear, pull relay out from underneath of compressor protector.
1.3 Remove the relay from its holder holder.

VOLTAGE

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Pin 87
(relay holder)
1. Relay retaining bolt

Battery
negative (–)
post

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REQUIRED TOOL

1. Unplug ACS module connector.

tmr2012-005-032_a

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1. Relay
2. Relay holder

2. Measure resistance as per the following table.

tmr2012-005-021_a

1. ACS module connector

2. Measure resistance as per the following table.

REQUIRED TOOL

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FLUKE 115 MULTIMETER
(P/N 529 035 868)
TEST PROBES

Terminal 30
(relay holder)

Terminal 87
(relay holder)

RESISTANCE
Open (OL)

3. Apply 12 volts on terminals 86 and 85 and measure resistance again as per the following table.
TEST PROBES

Terminal 30
(relay holder)

Terminal 87
(relay holder)

RESISTANCE
Close to 0

If results are not as per the above tables, replace
relay.

20

REQUIRED TOOL
FLUKE 115 MULTIMETER
(P/N 529 035 868)
TEST PROBES
Pin 86
(relay holder)

Pin 28
(ACS module
connector)

RESISTANCE
Close to 0

ACS COMPRESSOR
ACS Compressor Access
To access to ACS compressor, remove the following:
– Driver’s seat
– LH lateral console panel
– Floor panel.
tmr2012-005

ls

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

tmr2012-005-034_a

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1. Compressor operation test button

5. Verify if compressor works properly.

ACS Compressor Input Voltage Test
tmr2012-005-008_a

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SIDE NET REMOVED FOR CLARITY
1. LH lateral console panel
2. Floor panel

1. Using a small screwdriver, detach the ACS
compressor connector housings from the compressor protector wall.

The ACS compressor is mounted on the ACS
compressor support.

tmr2012-005-035_a

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1. ACS compressor connector
2. ACS compressor pressure sensor

tmr2012-005-033_a

1. ACS compressor

ACS Compressor Operation Test

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1. Connect vehicle to the latest appropriate version of B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE subsection
in the 2011 CAN-AM SIDE-BY-SIDE SHOP
MANUAL.
2. Select Activation page.
3. Select ACS folder.
4. Press Compressor button to proceed.

tmr2012-005

2. Unplug ACS compressor connector.
3. Place ignition switch to ON position.
4. Measure voltage as per the following table.
REQUIRED TOOL
FLUKE 115 MULTIMETER
(P/N 529 035 868)
TEST PROBES
Pin 1
(ACS
compressor
connector)

Battery
negative (–)
post

VOLTAGE
Battery voltage

ACS Compressor Ground Test
1. Place ignition switch to ON position.
2. Measure voltage as per the following table.

21

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

REQUIRED TOOL

Pin 2
(ACS
compressor
connector)

VOLTAGE

Battery positive
(+) post

Battery voltage

tmr2012-005-022_a

ACS Compressor Power Wire
Continuity Test (from Relay)
1. Remove relay (R5).
2. Measure resistance as per the following table.

FLUKE 115 MULTIMETER
(P/N 529 035 868)
TEST PROBES
Pin 30
(relay holder)

1. Screws to be removed

2. Disconnect pneumatic hoses from air reservoirs and air outlet fitting.
3. Place the air reservoir support aside to make
room.

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REQUIRED TOOL

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TEST PROBES

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FLUKE 115 MULTIMETER
(P/N 529 035 868)

Pin 1
(ACS
compressor
connector)

RESISTANCE

Close to 1

ACS Compressor Ground Wire
Continuity Test

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1. Reconnect the relay (R5).
2. Check the continuity as per the following table.
REQUIRED TOOL

FLUKE 115 MULTIMETER
(P/N 529 035 868)

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TEST PROBES
Pin 2
(ACS
compressor
connector)

Battery
negative (–)
post

tmr2012-005-023

4. Using a small screwdriver, detach both connector housings from the compressor protector
wall.

RESISTANCE

Close to 1

ACS Compressor Removal
1. Remove screws retaining the air reservoir support and the compressor support.

tmr2012-005-026_a

1. Press these tabs inside

5. Unplug the following connectors:
– Compressor connector
– Release valve connector
– Pressure sensor connector.
22

tmr2012-005

tmr2012-005-028_a

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Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

tmr2012-005-027_b

1. Compressor connector
2. Release valve connector
3. Pressure sensor connector.

9. Remove the ACS compressor.

ACS Compressor Installation

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6. Detach the filter hose from the compressor intake/outlet fitting.

1. Compressor retaining screws

The installation is the reverse of removal procedure.

ACS AIR FILTER
ACS Air Filter Access
To access to ACS air filter, remove the following:
– Driver’s seat
– LH lateral console panel
– Floor panel.

tmr2012-005-036_a

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1. Air filter hose
2. Clamp to be removed

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7. Disconnect the lower pneumatic hose from the
pressure distributor.

tmr2012-005-024_a

1. Disconnect this hose
2. Pressure distributor

tmr2012-005-008_a

SIDE NET REMOVED FOR CLARITY
1. LH lateral console panel
2. Floor panel

The ACS compressor is located in front of air
reservoirs.

8. Turn the compressor support on the side to remove screws retaining the compressor.

tmr2012-005

23

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

SHOCK ABSORBERS
Shock Absorbers Identification

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When installing shock absorbers, make sure not
to mix front and rear shock absorbers.
Front and rear shock absorbers can be easily identified by comparing the length of air hoses.
FRONT SHOCK ABSORBER

tmr2012-005-002_a

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Shock absorber with
a short air hose on
reservoir side

1. ACS air filter

REAR SHOCK ABSORBER

ACS Air Filter Replacement

Shock absorber with
a long air hose on the
opposite side of reservoir

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1. Remove and discard clamps securing hoses to
air filter.

Rear Shock Absorber Removal
1. Block front wheels.
2. Loosen wheel lug nuts.
3. Open cargo box.
4. Place the jack under the hitch and lift the rear
of vehicle.
5. Install jack stands to support the vehicle.
6. Remove wheel.
7. Disconnect shock absorber hose from vehicle
air supply hose.

tmr2012-005-037_a

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1. Clamps to be removed

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2. Remove the air filter.
3. Install the new air filter with its attachment towards the compressor.
4. Secure air filter using new clamps.

tmr2012-005-042_a

1. Shock absorber hose
2. Vehicle air supply hose

8. Drill the rivet securing the shock absorber hose
to trailing arm.

tmr2012-005-038_a

1. Air filter attachment
2. Air hose from compressor

24

tmr2012-005

Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

TIGHTENING TORQUE
Shock absorber nuts

48 N•m (35 lbf•ft)

tmr2012-005-040_a

REAR LH SIDE OF VEHICLE SHOWN
1. Rivet to be drilled

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9. Remove upper and lower bolts retaining the
shock absorber. Discard nuts.

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Connect shock absorber hoses to vehicle air supply hoses.

tbl2012-003-013_a

TYPICAL
1. RH shock absorber hose
2. Vehicle air supply hose

TIGHTENING TORQUE

Air supply hose

6 N•m ± 0.5 N•m
(53 lbf•in ± 4 lbf•in)

Secure shock absorber hoses to trailing arms. Ensure to position hose clamp between YELLOW
dots.

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tmr2012-005-041_a

1. Shock absorber retaining bolts

Rear Shock Absorber Installation

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Install shock absorbers with the reservoir rearwards.

tbl2012-003-014_a

RH SIDE OF VEHICLE
1. YELLOW dots
2. Rivet

tbl2012-003-012_a

TYPICAL – RH REAR SHOCK ABSORBER

Secure with new nuts.

tmr2012-005

25

tbl2012-003-015_a

tmr2012-005-044_a

LH SIDE OF VEHICLE
1. YELLOW dot
2. Install the rivet in this hole

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Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

1. Shock absorber retaining bolts

8. Remove shock absorber from vehicle.

Front Shock Absorber Installation

1. Block rear wheels.
2. Loosen wheel lug nuts.
3. Lift the front of vehicle and support it securely.
3.1 Insert the jack under the vehicle by the
side, behind front wheels.
3.2 Place the jack under the central beam.
3.3 Lift the front of vehicle.
4. Remove front wheels.
5. Cut locking ties securing shock absorber hose
to suspension arm.
6. Disconnect shock absorber hose from vehicle
air supply hose.

Install shock absorbers with the reservoir outwards.
Secure it using previously removed bolts and new
nuts. Tighten nuts to specification.

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Front Shock Absorber Removal

TIGHTENING TORQUE

Shock absorber nuts

48 N•m (35 lbf•ft)

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Route the hose in front of the shock absorber.

tmr2012-005-043_a

TYPICAL
1. RH shock absorber hose
2. Vehicle air supply hose

7. Remove upper and lower bolts retaining the
shock absorber. Discard nuts.

26

tmr2012-005-043_a

TYPICAL
1. RH shock absorber hose
2. Vehicle air supply hose

TIGHTENING TORQUE
Air supply hose

6 N•m ± 0.5 N•m
(53 lbf•in ± 4 lbf•in)

Secure the shock absorber hose to brake hose.
Install a locking tie each side of the brake hose
retaining clamp.

tmr2012-005

tmr2012-005-045_a

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1. Brake hose retaining clamp
2. Shock absorber hose

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Subsection 09 (AIR CONTROLLED SUSPENSION (ACS))

tmr2012-005

27

Subsection 01 (POWER DISTRIBUTION)

POWER DISTRIBUTION
GENERAL

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POWER DISTRIBUTION DIAGRAM
FUSE BOX 1

BAT
F4

VOLTAGE
REGULATOR/
RECTIFIER

F5

FUSE BOX 2

7.5A

IGNITION COIL

BRAKE RELAY (R8)

FUEL INJECTORS

ACS MODULE

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COMMUNICATION
CONNECTOR

MF3

GAUGE

SPEED SENSOR

WINCH RELAY

MF2

BRAKE LIGHTS
SWITCH

10A

TAILLIGHTS

STARTER RELAY

MF1

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COMMUNICATION
CONNECTOR

MAIN
RELAY (R2)

F6

5A

ACCESSORIES
RELAY (R3)

30A

50A

SWITCHES ILLUMINATION

F7

5A

2WD/4WD SWITCH
WINCH SWITCH

60A

F8

5A

GAUGE

IGNITION SWITCH

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UNDER DASH
ACCESSORY
CONNECTOR
( DC7 )

ACS
MOTOR

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ACS
RELAY (R5)

ACS
MODULE

ECM

F9

30A

F10

5A

EURO CONTROLS

F11

30A

LIGHTS RELAY

FAN RELAY (R1)

COOLING FAN

CONSOLE ACCESSORY
CONNECTOR 1 (DC3)
12-VOLT POWER OUTLET

F12

15A

F13

5A

UNDER DASH ACCESSORY
CONNECTOR (DC4)
COMMUNICATION
CONNECTOR
ACS MODULE

F14

15A

CONSOLE ACCESSORY
CONNECTOR 2 (DC6)

F15

5A

FUEL PUMP

tmr2012-003-001_aen

tmr2012-003

1

Subsection 01 (POWER DISTRIBUTION)

FUSE BOX 2

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FUSE BOX 1

tmr2012-003-002_a

FUSE IDENTIFICATION
10 A

5

7.5 A

6
7
8
Fuse

9
10
11
12
13
14

5 A

5 A

5 A

tmr2012-003-003_a

FUSE IDENTIFICATION

30 A
5 A

30 A
15 A

Fuse

1

Main

30 A

2

Fan/accessories

50 A

3

ACS/accessories

60 A

5 A

15 A
5 A

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15

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4

tmr2012-003-002_b

RELAY IDENTIFICATION

Relays

2

1

Cooling fan

2

Main

3

Accessories

4

Headlights

8

Brake lights

tmr2012-003

Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

LIGHTS, GAUGE AND ACCESSORIES
SERVICE TOOLS
Part Number

Page

ls

Description

FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................................. 4

PROCEDURES

NOTICE It is recommended to always disconnect the battery when replacing any electric
or electronic parts. Always disconnect battery
exactly in the specified order, BLACK (-) cable
first.

CONSOLE SWITCHES

TROUBLESHOOTING

MULTIFUNCTION GAUGE (LCD
AND ANALOG/DIGITAL)

1. Fuse is blown
- In the fuse block #1, check the fuse 14. Replace
if required.
- Remove the glove box and check the in-line fuse
(15A). Replace if required.
2. No Voltage
- Perform the AMPLIFIER POWER VOLTAGE
TEST, refer to AMPLIFIER.

NO SOUND

en

1. Fuse is burn
- See NO POWER above.

2. Wiring is not properly connected or damaged
- Check all wires and connectors. See AMPLIFIER
CONNECTOR IDENTIFICATION.

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3. Faulty amplifier
- Replace the amplifier.

RADIO CONTROL BUTTONS DO NOT
WORK
1. Radio control need to be reset.
- Press the RESET button to the back of the amplifier.

CANNOT TUNE A RADIO STATION OR
THE AUTO-SEEK DOES NOT WORK
1. The antenna is not connected
- Insert the antenna cable firmly.
2. The signals are too weak.
- Select a station manually.
tmr2011-004

Switches Access

Refer to BODY and remove upper console.

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RADIO AND AMPLIFIER
NO POWER

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GENERAL

Multifunction Gauge Wire
Identification
FUNCTION

PIN

COLOR

12 volt input from fuse F4

17

ORANGE/GREEN

12 volt input from fuse F8

16

BEIGE/WHITE

Ground

20

BLACK

CAN LO

18

BEIGE/GREEN

CAN HI

19

WHITE/BEIGE

Fuel level gauge supply

4

BROWN/PINK

Fuel level gauge ground

21

VIOLET/PINK

2WD/4WD switch signal (-)

7

BLACK/BEIGE

HI beam signal (+)

5

BLUE

TURN SIGNALS/HAZARD
(EC MODELS ONLY)
Turn Signal Wire Identification
FLASHER MODULE
FUNCTION

PIN

COLOR

12 volt input from
fuse F10

MC2-1

RED/WHITE

12 volt input from
fuse F4

MC1-5

ORANGE/GREEN

RH turn 12 volt input
from turn signal
switch

MC1-1

BEIGE/ORANGE

LH turn 12 volt input
from turn signal
switch

MC1-2

BEIGE/GREY

1

Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

PIN

COLOR

Output to RH turn
signal lights

MC2-2

BROWN

Output to LH turn
signal lights

MC2-3

GREY

Output to
multifunction gauge
(turn signal indicator)

MC2-4

ORANGE

Ground

MC1-4

BLACK

Hazard 12 volt input
from hazard switch

MC1-6

GREEN/ORANGE

Amplifier Connector Identification

ls

FUNCTION

Go to BODY subsection for glove box removal procedure.

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FLASHER MODULE

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TURN SIGNAL SWITCH
(IN MULTIFUNCTION SWITCH)
PIN

COLOR

12 volt input from
fuse F4

MGB-3

ORANGE/GREEN

RH turn 12 volt output
to flasher module

MGB-4

BEIGE/ORANGE

LH turn 12 volt output
to flasher module

MGB-2

BEIGE/GREY

tmr2012-004-003_a

AMPLIFIER CONNECTOR IDENTIFICATION
1

Front LH RCA line out
(WHITE female RCA connector)

2

Front RH RCA line out
(RED female RCA connector)

3

Rear LH RCA line out
(WHITE female RCA connector)

4

Rear RH RCA line out
(RED female RCA connector)

5

In-line fuse (15 A)

6

Power/audio 16-pin connector

en

FUNCTION

7

AUX in
(WHITE female RCA connector)

8

AUX in
(RED female RCA connector)

9

USB 2.0 connector

10

Wired audio control, 4-pin mini
DIN connector

Turn Signal/Hazard Circuit Protection

11

Antenna connector

HAZARD SWITCH
FUNCTION

PIN

12 volt input from
fuse F10

2

12 volt output to
flasher module

3

8

Hazard indicator
ground
(through bulbs)

7

RED/WHITE

GREEN/ORANGE

ORANGE/BROWN

BLACK/ORANGE

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Hazard indicator
12 volt input from
fuse F4

COLOR

CONDITION

CIRCUIT PROTECTION

Supplied with main
relay (R2) activated

Fuse 4 of fuse block 1
(from main relay R2)

Supplied at all times

Fuse 10 of fuse block 1
(from fuse 2 of fuse box 2)

AMPLIFIER

Amplifier Access
The amplifier is attached on the top of the glove
box.
2

tmr2011-004

Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

SIRIUS connector, 8-pin mini DIN
connector

13

iPod‡ connector, 8-pin mini DIN
locking connector

‡
iPhone, iPod, iPod nano and iPod touch
are trademarks of Apple Inc. registered in U.S.A. and other
countries. “Made for iPod” and “Made for iPhone” mean that an
electronic accessory has been designed to connect specifically
to iPod or iPhone, respectively, and has been certified by the
developer to meet Apple performance standards. Apple is not
responsible for the operation of this device or its compliance with
safety and regulatory standards. Please note that the use of this
accessory with iPod or iPhone may affect wireless performance.

1

DC +12V (RED)

2

Data (BLUE)

3

No connection

4

Power ground (BLACK)

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Power/Audio 16-pin
Connector Pins Identification
(Radio Side)

ls

12

Wired Audio Control Connector Pins
Identification

ua

AMPLIFIER CONNECTOR IDENTIFICATION

5

Ground shield

iPOD Connector Pins Identification

A1
A2

Right rear speaker (+)
Right rear speaker (–)

1

Left channel

Right front speaker (+)

2

Audio ground

Right front speaker (–)

3

USB B +

A5

Left front speaker (+)

4

Video out

A6

Left front speaker (–)

5

Right channel

A7

Left rear speaker (+)

6

Power ground

A8

Left rear speaker (–)

7

USB D +

B1

No connection

8

Remote

B2

No connection

9

ACC – ID

B3

No connection

10

ACC – detect

B4

+ 12V ACC switched

11

USB D –

B5

Power antenna

12

iPOD detect

B6

No connection

13

ACC – power

B7

No connection

14

Ground

B8

Ground

A3

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A4

Amplifier Circuit Protection
The amplifier is protected by 2 fuses:
– In-line fuse (15A) on amplifier
– Fuse 14 (15 A) inside vehicle fuse block #1.

tmr2011-004

3

Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

Make sure F14 of fuse box #1 is in good condition
and powered before beginning any voltage test.
If radio does not work, check the radio control before testing the amplifier.

Unplug the audio control connector (4-pin mini
DIN) from the amplifier.

ls

Amplifier Tests Guidelines

Amplifier Input Voltage Test
FLUKE 115 MULTIMETER
(P/N 529 035 868)

TEST PROBE
Pin 13

Pin 15

VOLTAGE DC

Close to battery
voltage

If voltage is within specification, check the in-line
fuse (15 A).
If the voltage is out of specification, carry out AM-

PLIFIER POWER CONTINUITY TEST

Amplifier Power Continuity Test

Test the amplifier power continuity between the
fuse box #1 and the power/audio 16-pin connector
as per the following table.

C10
C11

POWER/AUDIO
CONNECTOR
(BLACK PROBE)

en

FUSE
BOX #1
(RED
PROBE)

tmr2012-004-007_a

1. Audio control connector (4-pin mini DIN)

Turn ignition key to ON position.
Check voltage as per the following table.

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Remove glove box.
Unplug the power/audio 16-pin connector.
Turn ignition key to ON position

ua

REQUIRED TOOL

CONTINUITY

Pin 13

Close to 6 M

Pin 15

Close to 0

AUDIO CONTROL
CONNECTOR
(AMPLIFIER SIDE)

Pin 1

Pin 4

VOLTAGE DC
Close to battery
voltage

If voltage is within specification, replace the radio
control.
If voltage is out of specification, check the amplifier and connections.

Radio Control Removal

Refer to BODY and remove the following parts:
– Upper console
– Glove box.
Unplug the audio control connector (4-pin mini
DIN) from the amplifier.

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If continuity is out of specification, repair or replace wiring harness and connectors.
If continuity is within specification, replace the
amplifier.

RADIO CONTROL

Radio Control Input Voltage Test
REQUIRED TOOL

FLUKE 115 MULTIMETER
(P/N 529 035 868)

The radio control receives its power through the
amplifier.
4

tmr2012-004-007_a

1. Audio control connector (4-pin mini DIN)

Cut or release all locking ties retaining the radio
control harness.
Unscrew radio control retaining ring.
tmr2011-004

tmr2012-004-008_a

1. Radio control retaining ring

Remove radio control from upper console. Check
cable routing for reinstallation.

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Radio Control Installation

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ls

Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

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The installation is the reverse of the removal procedure.

tmr2011-004

5

Subsection 01 (WIRING DIAGRAM INFORMATION)

WIRING DIAGRAM INFORMATION
GENERAL

Connector Housing Area
XX/XX-18

The wiring diagram is stored in the back cover
pocket.

4

5

-m
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2-BF-A

The first number in the connector/pin contact
number represents the area in the vehicle where
the connector is located.

Wire colors
Wire gauge
Connector housing area
Connector identification
Wire location in connector

Wire Colors

2

ua

3

XX/XX-18

V00G0FA

1.
2.
3.
4.
5.

2

2 -BF-A

V06G1HA

WIRING DIAGRAM CODES
1

ls

WIRING DIAGRAM LOCATION

3

5

1

2

4

It identifies the color of a wire. When a 2-color
scheme is used, the first color is the main color
while the second color is the tracer color.

tmr2011-041-001_a

XX/XX
XX/XX

-18

2-BF-A

en

V06G1FA

AREA LOCATION
1

Steering, dashboard and upper console area

2

Under dashboard and front bulkhead area

3

Front of vehicle

4

Engine, seat and lower console area

5

Rear of vehicle

THE SHADED PART INDICATES THE WIRE COLOR

Example: YL/BK is a YELLOW wire with a BLACK
stripe.

Connector Identification

The number after wire color indicates the gauge
of a wire.

The letters in the middle of the connector/pin contact number Indicates the connector's function. If
there are many connectors in the same area, this
helps to identify which wire is in which connector.

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Wire Gauge

18

XX/XX- 18

V06G1GA

XX/XX-18

2-BF-A

THE SHADED PART INDICATES THE WIRE GAUGE

Example: The number that follows the wire color
indicates the wire size used, in this case 18 gauge
wire.

tmr2012-007

V06G1JA

2- BF -A

BF

THE SHADED PART INDICATES A CONNECTOR

1

Subsection 01 (WIRING DIAGRAM INFORMATION)

ABBREVIATION
ACS

DESCRIPTION
Air Controlled Suspension

M1

DESCRIPTION
ACS compressor
Manifold air pressure and
temperature sensor

BA

Ignition coil

BAT

Battery

MD

2WD/4WD actuator

BD

2WD/4WD switch

OPS

Oil pressure switch

BN

Ground post

BP

Battery power

PDH

BV1

ACS solenoid valve

PDL

BV3

ACS release valve

PF1

CA

Magneto

PF2

Camshaft position sensor

PGH

CC

Ignition switch

PGL

CI

Multifunction gauge

PRD

RH tail light

CPS

Crankshaft position sensor

PRG

LH tail light

CTS

Coolant temperature sensor

RD

CV

Speed sensor

S1

ACS button

DB

Diagnostic connector

SB

Seat belt

DC

DC outlet

SD

2WD/4WD actuator switch

DC3/DC5
DC6/DC7

Accessories connector

SM

Starter motor

ECM

Engine control module

SPK1 and SPK2

ETA

Electric throttle actuator

SPSW

ETC

Electronic throttle control

SS

Fuel pump

en

FP

FRA
FT

ls

MAPTS

Override button

RH headlight (high beam)

ua

OV

RH headlight (low beam)

Fuse Holder (main)
Fuse Holder

LH headlight (high beam)

LH headlight (low beam)

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CAPS

Brake light switch

Cooling fan

Voltage regulator/rectifier

Spark plug

Sport switch
Starter solenoid

STSW

Start switch

SW

Winch relay

SWW

Winch switch
Temperature sensor (ACS
compressor)

GBPS

Gearbox position sensor

T1

HIBM

High beam (headlights)

TPS

Throttle position sensor

Harness interconnect
(engine/vehicle)

TAS

Throttle accelerator sensor

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HIC

INJ1 and INJ2

2

ABBREVIATION

Fuel injector

tmr2012-007

Subsection 01 (WIRING DIAGRAM INFORMATION)

Wire Location in Connector

XX/XX-18

A

THE SHADED PART INDICATES THE CONNECTOR LOCATION
IN HOUSING

B

B
A

B

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A

ua

A
2- BF- A

V06G1KA

B
A

ls

This is the wire position in the connector. The
number or letter given refers to the physical identification stamped or molded on the connector.

C

C

B
A

B

A

A

en

C

D
A

A00E4WB

C
B

C

D
A

C
B

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TYPICAL

tmr2012-007

3

1

2

3

4

COMMANDER 2012

1

3

GENERAL SYSTEM

J

5

ACCESSORY
CONNECTOR

5

4

2

6

7

DC3
DC5
DC6
DC7

8

9

TERMINAL IDENTIFICATION

GPS
TRUNK BOX
RADIO
LTD

NAME

ZONE #

ZONE-CONNECTOR NAME-TERMINAL #/A

CI

EX:

1 -

CI

-

EX:

CV

4 -

CV

EX:

ME

2 -

ME

10

15

-

A

COLOR CODE

WELDED JOINT

ZONE DESCRIPTION
STEERING AREA

2

MODULE AREA

WIRE BUS

3

FRONT OF VEHICLE

SIMPLE CONDUCTOR WIRE

4

ENGINE AREA

FEMALE TERMINAL

5

REAR OF VEHICLE

LT BU

LIGHT BLUE

CROSSED WIRE

MALE TERMINAL
STEEL LINK (FRAME )
TERMINAL

RD-6

BEIGE
BLACK
BLUE
BROWN
GREEN
GREY
ORANGE
RED
VIOLET
WHITE
YELLOW
PINK

SHRINKED JOINT

1

JT RD/GN

BE
BK
BU
BR
GN
GY
OR
RD
VI
WH
YL
PK

J

JT OR/BE

BD-4

1

RD/GN

OR/GN-16
RD/OR

OR/BE

BR/RD

OR/BE

BK-6

SWWRC-B

RD/GN
RD/YL

FAN
RELAY
(R1)

M

OR/BK

PF1-7C

JT OR/BK

J4

C3

B-

B-

3-

3-

3-

RD/OR

A3-

WH/OR

o - o

1-DC3-1

PGL-1

HI

GN-18

PDL-2

LO

PDH-1

RIGHT
TAIL
LIGHT

PDL-1

WH

RD

WH
PRD-2

B

PRG
LEFT
TAIL
LIGHT

PRG-2

HIC5-A

A

JT BK4
JT BK5
(30 SEPT. 2011 )

2

3

4

5

6

7

8

9

B

BK-16

LO

PDH-2

P

BK-16

HI
PGH-1

JT BK3

PGL-2

BK

PGH-2

B

PRD

BK

2

P

BK

JT
BU

THROTTLE ACCELERATOR SENSOR

1

JT GN

BU-18

1-DC1

DC4

OIL
PRESSURE
SWITCH

5-PRD-3 5-PRD-1 5-PRG-3 5-PRG-1

BK

TAS

OPS

5-HIC5-C

DC

GN-18

CRANKSHAFT
POSITION
SENSOR

P

5-HIC5-D

1-DC2

DC
OUTLET

CPS

OR/GN
OR/GN

GN

BU

RD/BR-16

BK-20

WH-20

GN

E3

E

C

4-OPS

PF1-12A

BK-16

F

PF1-11A

RD

A

PF1-11B

5-HIC5-B

DC
OPTION

TAS-F TAS-E

LT BU-18

B3-

1-DC3-2

DC3

-

MANIFOLD
AIR
PRESSURE /
TEMP
SENSOR

BRK RELAY
(R8)

PF1-12B

RD/BR-16

BU/GN
TAS-A

+ + -

GEAR - BOX
POSITION SENSOR

PF1

JT RD/BR

BU/PK

BU/RD
TAS-B

BU/VI

BU/OR
TAS-C

B

ENGINE
CONTROL
MODULE

A3

B3
B-

E1

BU/BK

BU/YL-18

YL/WH-18

TAS-D

C

HI-BEAM
SWITCH

D

ECM

1-HIBM-3
3-

B3-

B3-

3-

B-

K3

K1

J3
3-

B-

BK-18

BU-18

BK-18

K2
3-

A-

H1

4-CPS-1

P

MAPTS

G1
B-

C2
A3-

LOBM

HIBM

BK-16

OR/WH-18

3-FT-A

RD/OR

LIGHTS
RELAY
(R4)

E

BK-16

PF1

PF1-6C
1-DC5-A

4-HIC7-A

D

GBPS

F

COOLING
FAN

BC4

A-

OR/GY

WH/GY

BK-16

GY/BU-18

BK/OR

4-GBPS-1

3-PF1-3E

BU-16

FT

JT RD/OR

DC
OPTION

BU-18

t

PF1

BR/WH-16

OR/WH-18

RD/OR

OR/GN

3-PF1-1E

YL/BU

PF1-6D

3-

3G1
3-

3-

3-

A-

A-

F4

G4
A3-

A3-

PK/BU-18

BK/BR-18

WH/GY-18

RD-18

LT BU-18

YL/BK
SWWRC-A

SPSW-8

BD-10

BD-8

SWW-8

OVR-8

DPS4-8

HIBM-8

HIBM-10

BE/GN-18

WH/BE-18
C1
B-

M2
3B4

H2
3-

3-

A-

H3
A-

E1

RD/OR-18

WH-18

BK-18

PF1-11C

DC5

BK

A

ACC2
FUSE
(F14)
15A
JT RD/VI

4-HIC7-B

BK

JT BK2

4-GBPS-3
4-GBPS-2

3-PF1-1D

1-DC5-B

1-DC6-A

BK-16

BK-12

BK-6

BK-18

GN-18

1-DC6-B

DC
OPTION

BK-16

JT BK1
BK-12 BK-12 BK-12

BK-12

PF1-8E

ENGINE
CONTROL
MODULE

BD-7

5-BN1

4-MAPTS-4
4-MAPTS-3

G

PF1

HIBM

BD-9

5-BN3

DC OUTLETS
FUSE
(F12)
15A

ECM

SWW-7

5-BN2

PF1

1-HIBM-2

+

VEHICULE
SPEED
SENSOR

3-PF1-12D

PF1-10C

PF1-9E

PF1-7D

WH

OVR-7

OVERRIDE

COOLANT
TEMP
SENSOR

JT RD/YL

BD-5

JT WH/BE

2-SPSW-7

OVR

4-MAPTS-1
4-MAPTS-2

VSS

CTS

3-PF1-10D

RD/VI

DC6

2-HIBM-9

TPS

3-PF1-10E

WINCH
MOTOR

3-WM2

JT RD/BK

RD/BR

BE/GN-18

WH/BE-18
WH/BE-18

GN/BU-18

BK-16

SWW-2

2WD/4WD SWITCH

2-HIBM-7

ELECTRONIC THROTTLE

3-PF1-12E

OR/BK-18

WH/BU

12V
SWWB

WINCH
SWITCH

BD

BD-2

BK-18

ETA

WM

2WD

BK-18

MAGNETO
650 WATTS

OVER
RIDE

2,5k

2

YL/BK
WH/BU-18

WH-18

WH/BK-18

WH

SWW

BD-6

WINCH
2WD/4WD
FUSE
( F7 )
PF1-5A 5 A

IN

HIC-B

ENGINE
CONTROL
MODULE

OV-3

t

OR/GN

RD/GN

RD-6
BK-6

BU-18

BK-18

WH/BK

PF1

FREE

4-CV-A

HALL
- +

PF1
ACCESSORIES
RELAY
(R3)

H
PF1-4C

3-FT-B

HIBM-1

2,5k

4-CV-B

M

FRA-1

3-PF1-3D

PF1-6A

ECM

BK-16

OV-2

WH-18

BK/GN -18

BK-18

BK-18

BK-18

BK/BR-18

BE/OR-18

VI/OR-18

VI/GY

VI/YL

BE/GN

0V-1

FREE

BK-6

BK-12

5

BK-18

+

2

BK-18

-

6

4-CTS-1 4-CTS-2

BK-18

B

BE/GY

BE/WH

BE/YL

BE/RD

BE/BK

BK-6

YL-12

BK-12

1

3

4

M

CA

4-CV-C

1

P

4WD

4-CPS-2

CA-3

300

YL-14

CA-2

YL-14

YL-12

YL-12
YL-14

CA-1

PF1-7E

OUT

JT WH
BD-1

RD/YL

SWW-3

SWW-1

2-DB-1

A-

M1

BR/OR-16

HIC-A

HIC-C

OUT
SWWC

5-RD2-1 5-RD2-2 5-RD2-3 5-RD1-3

C

3-WM1

COOLING
FAN
FUSE
( F9 )
30 A

GN

A-

BK/BU-18

SPARK
PLUG
( FRONT )

SPARK
PLUG
( REAR )

RD/BR

BK-16

SPK1

SPK2

3-

3-

IN
SWWA

RD/BK

2-DB-6

2-SW5

BRAKE
LIGHT
SWITCH

PF1-5C

PF1

FRA

LIGHT
FUSE
(F11)
30A

BK

GN

ONEWAY
DIODE
(D4)

2-DB-2

BR/BK-16

FUEL
INJECTOR
( REAR )

3-

A3-

OR

BK/BE-18

BE/GN-18

BE/GN-18

OR/GN

RD/GY-16

BN/BK-16

BK

BK

4-INJ2-1

A-

D4

L1
3-

B-

M3
B3-

3-

3-

B-

A-

M2

J2

A1
A3-

B-

ONEWAY
DIODE
(D5)

M

BK-18

VI/GN-16
VI/BU-18

BN/OR-16

2-DB-4

ENGINE
CONTROL
MODULE

3-

3-

3-

2WD/4WD
ACTUATOR

2-SW3

2-SW2

2-SW1

BK-18

JT BE/GN

ECM

F3

B1
B-

D3
B-

K3
A3-

3-

A-

A2

F3
A3-

3-

A-

K4

L1

BK/BE-18

RD/BE-14
A-

B3-

3-

INJ2

J1

M4

M1
B-

H2
B3-

B2
B-

E4
B-

3-

3-

3-

B-

B3-

3-

3-

A2

D1

A1
B-

E3
B-

D4
3-

B3-

B-

L4

B4
B3-

4-INJ1-1

BK/RD-18

BE-18

BK/BU

OR/BU

OR/RD

YL/OR

YL/RD

OR/VI

YL/GY

BR/GN

OR/BR-18

GN/BE

BE/BU
A4
B3A3-

3-

A-

L2

W

2-DB-5

2-DB-3

ENGINE
CONTROL
MODULE

RECTIFIER

IGNITION
COIL

2-SW4

FRA-2

PF1

(YL)

(BU)

OUT

IN

SWWRC-C

RD/GY-16

OR/BE

OR/GN-14

5-FP-4

RD

4-BA-3

HIC-G

FUEL
INJECTOR
( FRONT )

MD

BD-3

DIAGNOSTIC
CONNECTOR

INJ1

1-CI-5

4-MD1-1 4-MD1-4 4-MD1-2

DB

M

FUEL
PUMP

DB2-2

JT OR/VI

BA

4-BA-1

4-INJ2-2

ECM

V

4-BA-2

JT VI/BU

K1

START

FP
(1/2)

1-CI-20

4-SD

2WD/4WD
ACTUATOR
SWITCH

VI/BU-18

BU/GY

LOCK

SB2

SB1

FUEL
LEVEL
SENSOR

5-FP-3

FREE

HI
BEAM

1-CI-8

SD

START SWITCH

FREE

2-BN4

HIBM-5

3-PF1-4B

A-

5-BAT2

BK-6

INJECTORS
IGNITION
FUSE
( F5 )
7.5 A

4-INJ1-2

5-RD1-1

U

PF1

STSW

1-STSW-2

DB2

FP (2/2)

HIC-E

HIC-D

OR/BR-18

M

BAT

D

5-FP-2

JT VI/BU

1-STSW-1

RD-6

RD-6

RD-12

3-PF1-4A

3-PF1-5D

VI/BU

3-

RD-6

JT BK/YL

ECM
FUSE
( F6 )
5A

SPSW-2

SPSW-3

DB2-1

PF1

FUEL
PUMP
( F15 )
5A

OR/VI

SEAT BELT

RD-12

PF1

1-CC-E

SPORT

4-SM

4-BN5

1-CC-C

SPORT SWITCH

STARTER
MOTOR

5-BN4

1-CC-D

VI/BU

1-CC-F

OR/BR-18

3-PF1-3A

1-CI-17

HIC-H

3-PF1-3B

BE-18

RD-6

3-PF1-4D

OR/BR-18

SM

RD/BE-14

ON

FREE

BK-6

RD/GY-14

W/LIGHT
WO/LIGHT

5-BP3

E

RD/GY-14

ON

5-SS2

5-BAT1

RD/BE

STARTER
SOLENOID

BATTERY
12 VDC
18 AH

5-FP-1

1-CI-19 1-CI-18 1-CI-7

1-CI-4

OFF

FREE
WEELING
DIODE
( D2 )

SS

F

1-CI-21

PF1-6E

WINCH RELAY

4-BN3

JT RD/BE

CC-A

4WD

ENGINE

5-SS1

5-BP2

G

FUEL

BU

2-DC7-A

3-PF1-7B

SW

(BK)

YL

YL

WH/BE-18

5-BP1

CC-B

RD

DC
OPTION

3-PF1-5B

3-PF1-2B

(RD)

P

DC7

2-BP4

2-HIBM-6

BR/PK-18

IGNITION KEY
( ON & DESS )

BK/YL

RELAY
DRIVER
FUSE
( F13 )
5A

2-DC7-B

VI/PK-18

CC

RD-10

JT
BE/WH

PF1

3-PF1-8B

OR/GN

SPEEDOMETER
& PILOT LAMPS

1-CI-16

RD/BE

1-HIBM-4

3-PF1-2A

3-PF1-6B

RELAY
SPEEDO
FUSE
( F4 )
10 A

MAIN
RELAY
(R2)

PF1-5E

JT OR/GN

RD/BE-14

PF2-1

PF1

PF1

KEY
SWITCH
FUSE
( F8 )
5A

PF1-8A

BK/YL

RD-6

MAIN FAN /
FUSE ACCES.
(F1) FUSE
30 A (F2)
50 A

PF1

CI

3-PF1-1A

RD/BE-14

HP ACC
F3
60 A

3-PF1-1B

OR/BU-18

( 3/3 )

PF1-4E

YL/BU

PF2

PF2 PF2
(1/3 )(2/3 )

H

PF1
CONTROL
EURO
F10
5A

PF2-C

PF2-B

BE/WH

PF1-7A

RD/GY

PF2-A

I

RD/PK

BE/WH

RD/GY-12

I

RD/GN-12

JT RD/GY

(RÉF. BOSCH 2.5)

10

710002625F1

P

N

2

1

3

4

5

6

COMMANDER

ACS SYSTEM

8

7

9

11

10

1

3

4

2

NAME

MAIN
HARNESS
SIDE

YL

BE/GN-18

1-CI-19

1-CI-18

BU
4WD

ENGINE

1-CI-4

BR/PK-18

YL

1-CI-7

START
ER
SOLEN
OID

BATTERY
12 VDC
18 AH

AIR
COMPRES
SOR

OR/BR-18

-

EX:

ME

2 -

ME

M

RD/WH

RD/BR

BE/GN-18

SM

JT BE/GN

STARTER
MOTOR

M1-2

TEMPERATURE
SENSOR

U

BK

4-T1-2

2-DB1-2

4-PCM-9

BK-6

WH/BE

2-DB2-1

BK/VI

4-PCM-6

BK/GY

4-PCM-7

4-PCM-27

SCM

SECTION OF MODULE

STEEL LINK (FRAME )

SLOTTED SCREW

TERMINAL

OPTIONAL

LT BU

LIGHT BLUE

N

M

L

BR/PK

BR/PK

BR/PK

RD/BR

4-BV1-1

4-BV1-3

( VALVE AVANT-GAUCHE )
4-BV1-2

BK/BE

4-PCM-22

+

E

( VALVE USER )
4-BV1-4

( VALVE ARRIERE )

D

4-PCM-14

1-S1-10

1-S1-8

4-BV1-9

P

U
P

BK

4-BV1-10

4-PCM-3

F

( VALVE AVANT-DROIT )

4-PCM-24

4-PCM-25

G

4-BV1-8

BR/YL

PK/BR

S1 (1/2)

FREE

J

4-BV1-5

4-BV1-6

( VALVE VENT )

4-PCM-23

4-PCM-10

CA

S1 (2/2)

PRESSURE
SENSOR

C

1-S1-7

1-S1-9

4-BV1-7

BK-6

BK-12

MALE TERMINAL

( VALVE POMPE VENT )

4-PCM-26

SUSPENSION
CONTROL
MODULE

PK/OR

BK-6

BK-12

YL-12

REAR OF VEHICLE

4-BV3-2

BK/GN

4-PCM-33

1-S1-1

UP

YL-14

YL-14

1-S1-3

BK

2-DB1-3

5-BN3

B

JT BK

JT BK1

BK-12

BK-12

5-BN1

BK-12
BK-12

2

2-DB2-3

JT BK2

BK-12

A
1

5

4-PCM-34

4-PCM-1

WH/BE

2-DB1-1

BE/GN-18

WH/BE-18

CAN HI

1-S1-2

4-BN5

COMPONENT CONNECTION

H

BK/YL

5-RD1-3

5-BN4

FEMALE TERMINAL

4-PCM-16

VI/PK

4-PCM-2

BE/GN

DOWN

BK-6

ENGINE AREA

BV3-1

4-PCM-36

C

B

4

4-PCM-35

4-PCM-18

OR/GN

2-DB2-4

BE/GN

BR/PK

4-PCM-13
BK

T

4-PCM-17

4-PCM-28

4-T1-1

CA-3

MAGNETO
650 WATTS

SPLICE CONNECTION

K

W

CA-2

SIMPLE CONDUCTOR WIRE

M

2-DB2-2

JT WH/BE

RD-12
YL-12

YL-12
YL-14

CA-1

FRONT OF VEHICLE

3

P

SEE MAIN HARNESS DIAGRAM
FOR DETAILS ON DB1 AND DC7

BK/BU

D

NUT CONNECTION

MODULE AREA

RD/BR

4-PCM-32

5-RD2-3

WIRE BUS

2

OR/PK

4-PCM-31

5-RD2-2

PHILLIPS SCREW

BEIGE
BLACK
BLUE
BROWN
GREEN
GREY
ORANGE
RED
VIOLET
WHITE
YELLOW
PINK

DB1 FROM MAIN HARNESS
DIAGNOSTIC CONNECTOR

RECTI
FIER

5-RD2-1

CROSSED WIRE

4-R5-88

2-DB1-4

OR/GN

RD
V

EGINE GROUND

STEERING AREA

BE
BK
BU
BR
GN
GY
OR
RD
VI
WH
YL
PK

JT BR/PK

BR/BE

5-RD1-1

U

A

COLOR CODE

SHRINKED JOINT

1

4-R5-85

2-DB2-5

5-BAT2

E

CV

1450 watts
930 watts
580 watts
365 watts
230 watts
145 watts
85 watts

28

FRAME GROUND

WELDED JOINT

ZONE DESCRIPTION

27

DC7 FROM MAIN HARNESS
HIGH POWER ACC

2-DB1-5

RD/GY

CAN LOW

F

CV

4 -

4-SM

BAT

G

EX:

15

125 amps
80 amps
50 amps
30 amps
20 amps
15 amps
7.5 amps

BR/PK

5-SS2

WH/BE-18
5-BAT1

-

M1-1

1-CI-5

RD/GY

RD-6

RD-6

RD-12

H

CI

100 amps
65 amps
40 amps
25 amps
16 amps
10 amps
6 amps
50°C MAX

ZONE #

MAX. WATT

BR/PK

5-SS1

5-BP3

1 -

RD/GN

4-R5-30

HI
BEAM

1-CI-20

BK-18

FUEL

VI/PK-18

RD-12

SS

J

CI

MAX. FUSE CURRENT

R5

OR/GN-18
5-BP1

# 6
# 8
# 10
# 12
# 14
# 16
# 18
* AT

MAX. CURRENT

26

25

24

RD/BR

4-R5-87

BU-18

RD

1-CI-21

5-BP2

AWG

23

22

21

2-DB2-6

SPEEDOM
ETER
& PILOT
LAMPS

1-CI-17

BK/BE-18

HP
ACCES.
FUSE
(F3)
60 A

K

EX:

20

19

ZONE-CONNECTOR NAME-TERMINAL #/A

2-DB1-6

CI

OR/GN-18

P

PF2
(3/3)

MAIN FAN /
FUSE ACCES.
(F1) FUSE
(F2)
30 A
50 A

ACS
HARNESS
SIDE

2-DC7-B

WH/BE-18

RD/GY-12

L

18

17

JT RD/BR

JT OR/GN

PF2 PF2
(1/3) (2/3)

16

15

5

RD/PK

M

14

TERMINAL IDENTIFICATION

JT RD/BR

JT RD/GY

13

12

3

2-DC7-A

JT BK3
JT BK4

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

30 SEPT. 2011

26

27

710002542F3
28

A

2

1
P

N

3

4

5

6

8

7

9

10

11

12

13

14

16

15

18

17

AWG

TERMINAL IDENTIFICATION

COMMANDER

1

3

RADIO SYSTEM

5

4

2

MAIN
HARNESS
SIDE

NAME

RADIO
SIDE

EX:

CI

1 -

CI

-

EX:

CV

4 -

CV

-

EX:

ME

2 -

ME

15
A

100 amps
65 amps
40 amps
25 amps
16 amps
10 amps
6 amps
50°C MAX

20
MAX. FUSE CURRENT
125 amps
80 amps
50 amps
30 amps
20 amps
15 amps
7.5 amps

22

21

ZONE #

MAX. WATT
1450 watts
930 watts
580 watts
365 watts
230 watts
145 watts
85 watts

23

26

25

24

27

SHRINKED JOINT

EGINE GROUND

CROSSED WIRE

PHILLIPS SCREW

WIRE BUS

NUT CONNECTION

FRONT OF VEHICLE

SIMPLE CONDUCTOR WIRE

SPLICE CONNECTION

4

ENGINE AREA

FEMALE TERMINAL

COMPONENT CONNECTION

5

REAR OF VEHICLE

MALE TERMINAL

SECTION OF MODULE

STEEL LINK (FRAME )

SLOTTED SCREW

TERMINAL

OPTIONAL

1

STEERING AREA

2

MODULE AREA

3

28
COLOR CODE

FRAME GROUND

WELDED JOINT

ZONE DESCRIPTION

RD/VI

BE
BK
BU
BR
GN
GY
OR
RD
VI
WH
YL
PK

BEIGE
BLACK
BLUE
BROWN
GREEN
GREY
ORANGE
RED
VIOLET
WHITE
YELLOW
PINK

LT BU

LIGHT BLUE

P

N

BK

SEE MAIN HARNESS

JT RD/GN

MAX. CURRENT

# 6
# 8
# 10
# 12
# 14
# 16
# 18
* AT

ZONE-CONNECTOR NAME-TERMINAL #/A

2-DC6-B

JT RD/VI

19

JT RD/GY
JT OR/GN

YL

1-CI-19 1-CI-18

1-CI-7

1-CI-5

K

RO1

OR/GN-18
5-BP2

5-SS1

5-BP1

SS

J

L

HI
BEAM

1-CI-20

BK-18

BK/BE-18

BR/PK-18

VI/PK-18

RD-12

K

WH/BE-18

1-CI-4

1-CI-21

AM/FM
ANTENNA

BU
4WD

ENGINE

BE/GN-18

FUEL

YL

DC6 ACCESSORY
POWER CONNECTOR

BU-18

RD

FAN /
ACCES.
FUSE
(F2)
40 A

MAIN
FUSE
(F1)
30 A

SPEEDOMETER
& PILOT LAMPS

1-CI-17

P

PF2 PF2
(1/2) (2/2)

L

M

CI

OR/GN-18

RD/GN-12

RD/GY-12

M

STARTER
SOLENOID

13

BK

15

RD/VI

J

15 A FUSE

5-SS2

5-BP3

RR

RD-6

H

RD-6

RD-12

OR/BR-18

4

VI

VI

RD

B

+

H
SPEAKER
REAR RIGHT

BK/VI

5-BAT1

BAT

G

8

BK/VI

A

BK

B

WH

4-SM

BATTERY
12 VDC
18 AH

M

RADIO

SM

3

GY

FR
GY

+

STARTER
MOTOR

G
SPEAKER
FRONT RIGHT

BK/GY

7

BK/GY

A

BK

B

RD

BK-6

5-BAT2

1

GN

GN

+

RD-12

F

RL

5-RD1-1

RD

E

BK/GN

5

BK/GN

WH

2

WH

A

BK

B

WH

FL

+

RECTIFIER

BK/WH

W

V

6

A

BK/WH

E

SPEAKER
FRONT LEFT

U

F

SPEAKER
REAR LEFT

BK

YL-14

YL-14

CA-1

BK-6

BK-12

YL-12
CA-2

D

CA-3

YL-14

YL-12

D

YL-12

5-RD2-1 5-RD2-2 5-RD2-3 5-RD1-3

DASH REMOTE

C

C

5-BN4

BK-6
4-BN5

5-BN3

BK-12

BK-12

JT BK1

BK-12 BK-12

2

GLOVE BOX
USB / AUX IN

JT BK2

A

1

B

2-DC6-A

SEE MAIN HARNESS

5-BN1

BK-12

B

IPOD
GLOVE BOX

BK-6

MAGNETO
650 WATTS

BK-12

CA

3

A

JT BK3

30 SEPT. 2011

JT BK4

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

710002553F4
27

28

Date :

October 13 2010

Subject : Service Tools

No

Year

Model

All

All

2011-5

BRP is proud to introduce its latest Service Tools
Bulletin. These special tools were designed to help
you efficiently service BRP vehicles.
Please always make sure to use special tools along
with the appropriate Shop Manual(s) and respect all
safety measures.

Mandatory Tools: These tools are absolutely
needed to perform certain service procedures.
They will be automatically shipped to dealerships.
They do not need to be ordered separately.

Recommended Tools: These tools will facilitate
the Technicians work. They will not be
automatically shipped to dealerships. They need to
be ordered separately.

Table of contents
Tools by System:
Engine .......................................................................................................................... P

2

Fuel .............................................................................................................................. P

4

Cooling ......................................................................................................................... P

4

Electrical ....................................................................................................................... P

4

Lubrication .................................................................................................................... P

5

Transmission / Propulsion ............................................................................................ P

5

Steering ........................................................................................................................ P

6

Suspension ................................................................................................................... P

6

Various ......................................................................................................................... P

7

Index of tools by Part Number:

.............................................................................. P

Printed in Canada (tbs2011-005)
©2010 Bombardier Recreational Products inc. and BRP US inc. All rights reserved.
®™ and the BRP logo are trademarks of Bombardier Recreational Products inc. or its affiliates.

8

1/8

Engine

Crankshaft locking bolt
P/N 529 035 617
Mandatory
Quest 500/610,
DS650/Outlander/Renegade

Valve spring compressor
P/N 529 035 724
Recommended
4-TEC engines
To be used with valve spring compressor
cup 529 035 764 and 529 036 073

Valve spring compressor cup
P/N 529 035 764
Recommended
330/400/490/660/810/1004
To be used with valve spring compressor
529 035 724.

Seal pusher
P/N 529 035 766
Recommended
All V-twin, 330/400, 610/500, 500 eng.
Use with 529 036 130

Suction pump
P/N 529 035 880

Recommended

Plain bearing remover/installer
P/N 529 035 917
Recommended
610, 500, 650, 800 engines

Piston ring compressor
P/N 529 035 919
V-800 engine

Recommended

Valve guide remover 5 mm
P/N 529 035 924
Recommended
400, 500, 650, 800 engines

Drive shaft oil seal installer
P/N 529 036 028
Recommended
V-490, V-660 and V-810 engines

Drive shaft oil seal protector
P/N 529 036 029
Recommended
V-490, V-660 and V-810 engines

Crankcase support MAG/PTO
P/N 529 036 031
Recommended
V-490, V-660 and V-810 engines

Plain bearing remover/installer
P/N 529 036 032
Recommended
V-490, V-660 and V-810 engines

Service

2011-5

2/8

Engine

PTO cover oil seal installer
P/N 529 036 033
Recommended
V-490, V-660 and V-810 engines

Crankshaft protector
P/N 529 036 034
Recommended
V-490, V-660 and V-810 engines

Puller/locking tool
P/N 529 036 098
Mandatory
610/500, 991, V-490, V-660, V-810

Rotary seal pusher plate
P/N 529 036 130
Recommended
V-490, V-660 and V-810 engines
Use with seal installer 529035766

Valve guide installer
P/N 529 036 140
Recommended
V-490, V-660 and V-810 engines
replace 529035853

Piston circlip installer
P/N 529 036 153
1203

Crankshaft TDC position tool
P/N 529 036 200
Mandatory
V1010

Camshaft timing tool
P/N 529 036 201
V1010

Service

2011-5

Recommended

Mandatory

3/8

Fuel

Pressure gauge
P/N 529 035 709
Mandatory
Injection type engines
Use with 529035652, 529035714 and
529036023

Disconnect tool
P/N 529 035 714
Mandatory
Injection models
Used also with gauge P/N 529 035 709,
529 035 652 and 529 036 023

Extractor adaptor
P/N 529 036 136
E-TEC, V-twin

Recommended

Back probe test wires
P/N 529 036 063
Recommended
All models
To back probe various connectors.

ECM adapter tool
P/N 529 036 166
RXT iS and GTX iS

Mandatory

Cooling

Oil seal pusher
P/N 529 035 757
Outlander 330/400

Recommended

Electrical

Magneto puller
P/N 529 035 748
All V-twin

Service

Mandatory

2011-5

4/8

Electrical

ECM terminal remover 3.36
P/N 529 036 174
Recommended
All models

ECM terminal remover 2.25
P/N 529 036 175
Recommended
All models

Lubrication

Adapter hose
P/N 529 035 652
4-stroke engines
Used with 529 035 709.

Mandatory

Transmission / Propulsion

Drive pulley holder (CVT)
P/N 529 006 400
Recommended

Service

Clutch puller
P/N 529 035 746
Mandatory
610/500, V-490, V-660, V-810 engines

2011-5

Oil seal installer (gearbox)
P/N 529 035 758
Recommended
V-490, V-660, V-810 engines
Use with handle 420 877 650

5/8

Transmission / Propulsion

Driven clutch holder
P/N 529 035 771
Recommended
330/400, 610/500, V-490, V-660, V-810

CV boot clamp plier
P/N 529 036 120
Recommended
All models
For stepless low profile clamps 192
Clamp pincer with special jaw form

Oil seal installer
P/N 529 036 204
All V-Twin

Spring compressor
P/N 529 036 184
Recommended
All models
To remove coil spring from shock.

Key ajustment suspension
P/N 529 036 192
Recommended
X package

Recommended

Steering

Steering alignment tool
P/N 529 036 059
All except DS 450

Recommended

Suspension

Ball joint remover support
P/N 529 036 121
Recommended
REV, RT, Outlander, roadsters

Service

2011-5

6/8

Various

Handle
P/N 420 877 650
Recommended
All models
Can be used with many types of pushers.

Service

Blind hole bearing puller set
P/N 529 036 117
Recommended
All models
Replaced by 529036056

2011-5

7/8

Index
Tool Part Numbers ... Page
420877650 ..............
529006400 ..............
529035617 ..............
529035652 ..............
529035709 ..............
529035714 ..............
529035724 ..............
529035746 ..............
529035748 ..............
529035757 ..............
529035758 ..............
529035764 ..............
529035766 ..............
529035771 ..............
529035880 ..............
529035917 ..............
529035919 ..............
529035924 ..............
529036028 ..............
529036029 ..............
529036031 ..............
529036032 ..............
529036033 ..............
529036034 ..............
529036059 ..............
529036063 ..............
529036098 ..............
529036117 ..............
529036120 ..............
529036121 ..............
529036130 ..............
529036136 ..............
529036140 ..............
529036153 ..............
529036166 ..............
529036174 ..............
529036175 ..............
529036184 ..............
529036192 ..............
529036200 ..............
529036201 ..............
529036204 ..............

Service

These tools are mandatory

7
5
2
5
4
4
2
5
4
4
5
2
2
6
2
2
2
2
2
2
2
2
3
3
6
4
3
7
6
6
3
4
3
3
4
5
5
6
6
3
3
6

2011-5

8/8

SIDE-BY-SIDE
VEHICLES
SERVICE
Bulletin

July 9, 2010

YEAR

2011

Subject: Can-Am High Altitude

MODEL NAME

MODEL NUMBER

Commander 1000

6ABA, 6ABC

Commander 1000 X

6EBA, 6EBC

Commander 1000 XT

6BBA, 6BBB, 6BBC
6BBD, 6BBE, 6BBF

No.

2011-4

SERIAL NUMBER

All

HIGH ALTITUDE
PARTS RETURN PROGRAM
Purchase from BRP the necessary parts for high altitude application. Anything other than a BRP part will
not be accepted.
Submit via BOSSWeb a Return Authorization Request and once approved by BRP, return the original UNUSED centrifugal levers (complete with bolts and nuts), with a copy of the Return Order Confirmation
form. Attach proof that replacement parts were purchased from BRP (invoice or packing slip).
NOTE: Centrifugal levers are sold by package with the required quantity to update a model to high altitude. The same quantity of levers must be returned for each specific model.
Credit for the original parts will be issued to dealer's account through the regular parts system, credited
at 100% of parts cost (current dealer cost), no handling.
Levers will be inspected when received and, if found used, will be returned to the dealer without credit.
Note that a 30$ handling fee plus freight charge could be applied to dealer account.
NOTE: Only centrifugal levers (complete with bolts and nuts) are allowed to be returned with this program; no other parts can be returned. No labor credit.
Be sure to match and ship all centrifugal levers with the same form.
Return to:

U.S. Dealers

Canadian Dealers

Bombardier Recreational Products Inc.,
c/o Affiliated,
60 Maple Street
Derby Line, VT
05830
ATTN: HIGH ALTITUDE PARTS RETURN

Bombardier Recreational Products Inc.,
75 J.-A.-Bombardier,
Sherbrooke, Qc
J1L 1W3
ATTN: HIGH ALTITUDE PARTS RETURN

International Dealers
All parts must be returned to the distributor or
BRP regional office. Contact them for complete
address and shipping information.

Printed in Canada. (tbs2011-001 en AP)
©2010 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

1/ 5

BOSSWEB RETURN AUTHORIZATION REQUEST
NOTICE In our continuing efforts to improve our return process, as we announced in our WHAT'S

NEWS Dealer Support Group journal July 2009, all authorization numbers have to be requested via
BOSSWeb to return the parts that were removed. To proceed, please follow these quick and easy
steps:
1. From the home page, choose the "Parts" menu, and select Return Entry.
2. For "Return Type", select Return Program.
3. For "Return Reason", select High Altitude exchange.
4. For "Your Return Number" write the unit serial number: <<________>>.
5. For "Product Line" select: Side-by-Side.
6. Click the blue forward arrow to go to next step.
7. Enter part number for the centrifugal lever kit that was removed from the unit; the return quantity
should always be 1 kit per return request.
8. Once you are sure that all information is correct, click the blue forward arrow to submit.
NOTE: Once your return request has been submitted via BOSSWeb, please allow 1 to 3 days to receive
the approval to return the items. The items can only be returned after having received the return authorization number via BOSSWeb (this number will appear in the return status screen on BOSSWeb).

HIGH ALTITUDE SPECIFICATIONS
In the tables throughout this document, the shaded column gives factory setting.

Commander™ 1000 EFI
No high altitude calibration settings have to be done through B.U.D.S. The calibration features an automatic electronic fuel injection compensation allowing fuel injection mapping to be optimized at all altitudes.
DRIVE PULLEY
Altitude

Sea Level

1 200 m (4,000 ft)

2 400 m (8,000 ft)

Qty

Centrifugal
Lever

420 248 495

715 500 351
(10.8 mm (.425 in))

715 500 352
(10 mm (.394 in))

1
(set of 6)

Drive pulley spring

420 238 617

420 238 617

420 238 610

1

Remove all 6 standard levers and replace them with 6 high altitude levers.

2/ 5

2011-4

SERVICE

WARNING
Failure to perform proper installation can cause damage to the vehicle and serious personal injuries to the rider.

SERVICE

2011-4

3/ 5

QUALITY
SIDE-BY-SIDE
VEHICLES
WARRANTY
Bulletin

NOTE: Repair only if described symptoms exist or are noticed.
Campaign no.: 2011–0001
October 15, 2010

Subject: Gearbox Clunking Noise at CVT
Engagement

2011-1

No.

YEAR

MODEL

MODEL NUMBER

SERIAL NUMBER

2011

Commander™ 1000 Series

6ABA, 6ABC
6BBA, 6BBC, 6BBE
6EBA

See list enclosed

PROBLEM
After making a gear selection, gearbox may have
a clunking noise (louder than expected).
This situation happened only on vehicles built before September. All vehicles produced since the
beginning of September have the new parts.

SOLUTION
Replace ramps and spring into drive pulley.
The combination of the new spring calibration and
new ramps profile, reduce the clunking noise to a
normal level and provide a smoother engagement.

REQUIRED PARTS
DESCRIPTION

PART NUMBER

QTY

Drive pulley
spring

(P/N 420 238 615)

1

Drive pulley
ramps

(P/N 420 248 496)

1
(pack of 6)

PROCEDURES
Refer to proper shop manual for complete removal and installation procedures.
2011 Shop manual:
Commander 800R/1000 (P/N 219 100 452)

If the shop manual is not available, an electronic
version of the required sections have been placed
on BOSSWeb, go to:
– www.bossweb.brp.com
– ComCenter = Document
– Document type = Shop Manual
– Product Line = Side-by-Side
– Document Year = 2011
Select the following documents:
– Continuously Variable Transmission (CVT)
– Body

WARRANTY
Submit a warranty claim using the following information:
CAMPAIGN NUMBER

2011-0001

Claim Type

Campaign claim

Action

Repair

Flat Rate Time

1.3 hour

Click in the REPAIR BOX while completing your
claim on BOSSWeb.
REPAIR

✔

For claiming procedure, refer to the DEALER/DIS-

TRIBUTOR WARRANTY GUIDE.

Printed in Canada. (tbg2011-001 en AP)
©2010 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

1/ 2

SERIAL NUMBERS LISTING OF INVOLVED VEHICLES
Model: 6ABA
From 000022 to 000032
From 000040 to 000046

Model: 6ABC
From 000011 to 000021
From 000033 to 000039

Model: 6BBA
From 000021 to 000069
From 000081 to 000128
From 000136 to 000188

Model: 6BBC
From 000070 to 000080
From 000129 to 000135

Model: 6BBE
000006

Model: 6EBA
From 000013 to 000014

2/ 2

2011-1

QUALITY

INTRODUCTION
This publication governs all warranty labor allowances for 2011 Can-Am SSV COMMANDER models.

1. HOW DOES IT WORK
We follow the procedures detailed in the Can-Am SSV Shop Manual. The flat rate time is the maximum time allowed
for a repair involving any given part. FLAT RATE TIME IS NOT CUMULATIVE. You must use the flat rate time given
for the longest lasting operation.
NOTE: The Flat Rate Time Schedule was prepared by skilled mechanics using the hand tool usually found in workshops and all the special tools mentioned in the Shop Manual.

2. COMPILATION
The Flat Rate Time Schedule is compiled as follows:
The actual required time to perform the repair plus (+) 30% correction factor up to 3.0 hours or (+) 15% over 3.0
hours time to take into account, among others:
– Vehicle handling
– Obtaining the parts
– Diagnosis
– Cleaning
– Special compensation (rusted bolts).

3. HOW TO USE IT
Refer to the system you need, locate part of series of parts replaced. List JOB CODE in the appropriate column on
claim.
SYSTEM
01 ENGINE SYSTEM
02 INTAKE AND FUEL SYSTEM
03 IGNITION SYSTEM
04 STARTER SYSTEM
05 TRANSMISSION AND LINKAGE SYSTEM
06 BRAKE SYSTEM

PAGE
4
16
20
22
23
29

SYSTEM
- FRONT DRIVE SYSTEM AND
07 STEERING
SUSPENSION
08 REAR DRIVE SYSTEM AND SUSPENSION
09 BODY AND ACCESSORIES
10 ELECTRICAL SYSTEM
11 CLAIM TYPE 02

PAGE
31
36
39
51
55

NOTE: Unless otherwise specified, dismantling order is: top to bottom, exterior to interior, front to rear.
All fractions of hours are in tenths:
0.1 = 6 minutes
0.2 = 12 minutes, and so on
LEGEND:
* REQUIRES PRIOR AUTHORIZATION BY DISTRIBUTOR.
** INDICATE LABOUR TIME ON LINE “LABOUR ONLY“ OF CLAIM.
*** INDICATE $$$ AMOUNT ON “SUB-CONTRACTED LABOUR“ OF CLAIM.

IMPORTANT: Always use the longuest flat rate time applicable to the repair performed.

4. JOB REQUIREMENTS
All the flat rate times mentioned in the following pages include the required operations such as: engine timing (piston
clearance/ring end gap measurement, crankshaft to crankcase measurement, cylinder honing, engine leak test.

5. ILLUSTRATIONS
The illustrations contained in this manual do not necessarily show every components of a given system as Parts
Catalog do. Their purpose is to facilitate recognition of parts related to a flat rate time. Item numbers on illustrations
correspond to the four or five digit Job Code.

6. SUGGESTION (FORM REQUEST)

Volume 1 - Can-Am

2011

TTF2011-001.FM

1

INTRODUCTION
Cette publication détermine le temps de MAIN-D’OEUVRE couvert par la garantie pour les VCC Can-Am 2011
modèle COMMANDER.

1. UTILISATION DU MANUEL
En procédant de la façon indiquée dans le Manuel de réparation Can-Am VCC, chaque temps donné représente le
maximum permis pour une réparation portant sur cette pièce. LES TEMPS NE SONT PAS CUMULATIFS. On doit
inscrire le temps donné pour l’opération qui prend le plus de temps.
REMARQUE: Le Barème de temps à taux fixe a été préparé par des mécaniciens compétents utilisant les outils
que l’on retrouve normalement dans les ateliers de réparation, en plus de tous les outils spéciaux mentionnés dans
le Manuel de réparation.

2. COMPILATION
Le Barème de temps à taux fixe a été établi en compilant le temps nécessaire pour faire la réparation plus (+) un
facteur de correction de 30% lorsqu’un travail dure 3.0 heures et moins, ou (+) 15% lorsqu’un travail dure plus de
3.0 heures. Cette compilation comprends, entre autres les étapes suivantes:
– Manutention du véhicule
– Nettoyage
– Aller chercher les pièces, essais physique
– Compensation spéciale (boulons rouillés)
– Diagnostic.

3. UTILISATION DU BARÈME
Se reporter à la section désirée, repérer la pièce ou l’ensemble de pièces remplacées et inscrire le CODE DE
TRAVAIL dans la colonne appropriée sur la formule de réclamation.
SYSTÈME
01 SYSTÈME MOTEUR
ET SYSTÈME D’ALIMENTATION
02 ADMISSION
D’ESSENCE
03 SYSTÈME D’ALLUMAGE
04 SYSTÈME DE DÉMARREUR
05 SYSTÈME DE TRANSMISSION ET DE TRINGLERIE
06 SYSTÈME DE FREIN

PAGE
4

SYSTÈME
PAGE
DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET
07 SUSPENSION
31
08 SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION 36
09 CARROSSERIE ET ACCESSOIRES
39
10 SYSTÈME ÉLECTRIQUE
51
11 RÉCLAMATION DE TYPE 02
55

16
20
22
23
29

REMARQUE: Sauf indication contraire, le démontage doit s’effectuer de haut en bas, de l’extérieur vers l’intérieur,
de l’avant vers l’arrière.
Toutes les fractions d’heures sont exprimées en dixièmes:
0.1 = 6 minutes
0.2 = 12 minutes, et ainsi de suite
LÉGENDE:
* AUTORISATION REQUISE AVANT LE REMPLACEMENT.
** INSCRIRE LE TEMPS À LA LIGNE «MAIN-D’OEUVRE SEULEMENT».
*** INSCRIRE LE MONTANT $$$ À LA LIGNE «OUVRAGE SOUS-CONTRACTÉE».

IMPORTANT: Toujours utiliser le temps donné à l’opération qui nécessite le plus de temps.

4. TRAVAUX REQUIS
Tous les temps mentionnés dans les pages suivantes incluent les opérations telles que: réglage du moteur (mesure
du jet des pistons/jeu en bout des segments, mesure de l’écart entre le vilebrequin et le carter, rectification du
cylindre, vérification de fuite du moteur.

5. ILLUSTRATIONS
Contrairement aux Catalogues de pièces, les illustrations de ce manuel ne montrent pas nécessairement chacune
des pièces qu’elles représentent, leur raison d’être étant plutôt de faciliter la reconnaissance des pièces reliées à
un barème de temps à taux fixe. Les numéros d’items sur les illustrations correspondent aux quatre ou cinq
derniers chiffres du code de travail.

6. SUGGESTION (FORMULAIRE)

2

2011

Can-Am - Volume 1

2011

SSV / VCC
TABLE

1

2

DESCRIPTION
COMMANDER 800R

MODEL/MODÈLE

CARBURETOR/
CARBURATEUR

COOLING SYSTEM/
SYSTÈME DE
REFROIDISSEMENT

800R CVT

BOSCH ETC
54 mm

Liquid cooled/
Refroidi par liquide

1000 CVT

BOSCH ETC
54 mm

Liquid cooled/
Refroidi par liquide

6CBA/6CBC

COMMANDER XT 800R

6DBA/6DBD

COMMANDER 1000

6ABA/6ABC

COMMANDER XT 1000

6BBA/6BBB
6BBC/6BBD
6BBE/6BBF

COMMANDER X 1000

6EBA/6EBC

Volume 1 - Can-Am

ENGINE TYPE/
TYPE DE MOTEUR

2011

3

01

COMMANDER
1000

2

0

0

5.5

5.5

0.4

0.4

0.5

0.5

01 18 CAPTEUR DE TEMPÉRATURE (MOTEUR)

0.4

0.4

THERMOSTAT
01 19 THERMOSTAT

1.0

1.0

1.0

1.0

01 37 BOYAU D’ENTRÉE DU RADIATEUR

0.6

0.6

WATER PUMP SHAFT (ALL PARTS)
01 38 ARBRE DE POMPE À L'EAU (TOUTES LES PIÈCES)

6.4

6.4

5.6

5.6

1.1

1.1

01 50 VILEBREQUIN ET/OU ROULEMENTS (AVANT/ARRIÈRE)

7.5

7.5

CRANKCASE COVER GASKET
01 56 JOINT DE COUVERCLE DE CARTER

2.0

2.0

2.0

2.0

01 58 GUIDE DE SOUPAPE D'ADMISSION OU D'ÉCHAPPEMENT (1)

3.1

3.1

INTAKE OR EXHAUST VALVE GUIDE (2)
01 59 GUIDE DE SOUPAPE D'ADMISSION OU D'ÉCHAPPEMENT (2)

3.2

3.2

0.3

0.3

01 71 COLLECTEUR D'ÉCHAPPEMENT

0.8

0.8

EXHAUST MANIFOLD (REAR)
01 73 CONNECTEUR D'ÉCHAPPEMENT (ARRIÈRE)

0.6

0.6

0.5

0.5

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

ENGINE SYSTEM
SYSTÈME MOTEUR

DESCRIPTION

NO LABOR INVOLVED
01 00 AUCUNE MAIN D’OEUVRE
01 01 REMOVE AND REPLACE ENGINE (ASS’Y)
REMPLACEMENT DU MOTEUR (COMPLET)
*
OIL PRESSURE SWITCH
01 03 INTERRUPTEUR DE PRESSION D’HUILE
FAN AND/OR FAN SUPPORT

01 08 VENTILATEUR ET/OU SUPPORT DE VENTILATEUR
SENDER TEMPERATURE (ENGINE)

COOLANT HOSE T-FITTING (ONE OR TWO)

01 21 BOYAU DE LIQUIDE DE REFROIDISSEMENT RACCORD EN T (1 OU 2)
RADIATOR INLET HOSE

ENGINE RUBBER MOUNT

01 45 TAMPONS D'ANCRAGE DU MOTEUR
RADIATOR AND/OR GROMMMET

01 46 RADIATEUR ET/OU PASSE-FILS

CRANKSHAFT AND/OR BEARINGS (FRONT/REAR)

PTO CRANKCASE COVER

01 57 COUVERCLE DE CARTER PDM
INTAKE OR EXHAUST VALVE GUIDE (1)

MUFFLER AND/OR EXHAUST GASKET AND/OR CLAMP

01 70 SILENCIEUX D’ÉCHAPPEMENT ET/OU JOINT D’ÉCHAPPEMENT ET/OU BRIDE DE SERRAGE
EXHAUST MANIFOLD

ANTI-VIBRATION RUBBER MOUNT (1 OR 2) (TOP)

01 77 TAMPON D’ANCRAGE ANTI-VIBRATION (1 OU 2) (HAUT)

4

2011

Can-Am - Volume 1

01
2

01 79 BOYAU DU SYSTÈME DE REFROIDISSEMENT (RÉSERVOIR AU RADIATEUR)

0.3

0.3

EXHAUST MANIFOLD (FRONT)
01 83 CONNECTEUR D'ÉCHAPPEMENT (AVANT)

0.7

0.7

0.3

0.3

0.4

0.4

7.5

7.5

0.4

0.4

0.6

0.6

01 101 PISTON, GOUPILLE, CIRCLIP, SEGMENTS (1)

3.1

3.1

PISTONS, PINS, CIRCLIPS, RINGS (2)
01 102 PISTONS, GOUPILLES, CIRCLIPS, SEGMENTS (2)

4.9

4.9

0.4

0.4

1.6

1.6

01 113 CULBUTEUR ET/OU TIGE POUSSOIR ET/OU ARBRE DE CULBUTEUR

1.7

1.7

CYLINDER HEAD AND/OR GASKET
01 114 CULASSE ET/OU JOINT D’ÉTANCHÉITÉ

3.8

3.8

3.0

3.0

01 117 CYLINDRE ET/OU JOINT D’ÉTANCHÉITÉ

3.0

3.0

WATER PUMP HOUSING AND/OR IMPELLER
01 119 CARTER DE LA POMPE À EAU ET/OU ROUE À AILETTES

0.7

0.7

2.1

2.1

01 133 TUYAU À L'HUILE

0.4

0.4

CAMSHAFT
01 134 ARBRE À CAME

2.6

2.6

2.1

2.1

CODE

1

SYSTEM
SYSTÈME

COMMANDER
1000

SYSTEM/SYSTÈME

COMMANDER
800

ENGINE SYSTEM
SYSTÈME MOTEUR

DESCRIPTION

COOLANT HOSE (RADIATOR TO TANK)

RUBBER MOUNT (MUFFLER)

01 88 TAMPON D'ANCRAGE (SILENCIEUX)
ENGINE OIL FILTER

01 90 FILTRE À HUILE DU MOTEUR
OIL SIEVE AND/OR O-RING AND/OR COLLECTOR AND/OR RUBBER RING AND/OR COVER

01 96 CRIBLE D’HUILE ET/OU JOINT TORIQUE ET/OU COLLECTEUR ET/OU ANNEAU DE CAOUTCHOUC
ET/OU COUVERCLE
COOLING RESERVOIR
01 98 RÉSERVOIR D’ANTIGEL
RADIATOR OUTLET HOSE

01 100 BOYAU DE SORTIE DU RADIATEUR
PISTON, PIN, CIRCLIP, RINGS (1)

VALVE COVER AND/OR GASKET

01 109 COUVERCLE DE SOUPAPE ET/OU JOINT D’ÉTANCHÉITÉ
TIMING GEAR

01 111 PIGNON DE DISTRIBUTION
ROCKER ARM AND/OR PUSH ROD AND/OR ROCKER ARM SHAFT

EXHAUST AND/OR INLET VALVE AND/OR SPRING AND/OR SEAL

01 116 VALVE ADMISSION ET/OU ÉCHAPPEMENT ET/OU RESSORT ET/OU ANNEAU D’ÉTANCHÉITÉ
CYLINDER AND/OR GASKET

OIL PUMP GEAR

01 132 ENGRENAGE DE LA POMPE À HUILE
OIL PIPE

OIL PUMP COVER AND/OR SHAFT AND/OR ROTOR

01 137 COUVERCLE DE LA POMPE À HUILE ET/OU ARBRE ET/OU ROTOR

Volume 1 - Can-Am

2011

5

01

COMMANDER
1000

2

01 138 RECELLEMENT DU CARTER ET/OU JOINT D’ÉTANCHÉITÉ

7.5

7.5

CRANKCASE REPLACEMENT
01 139 REMPLACEMENT DU CARTER

8.0

8.0

6.5

6.5

01 154 CHAÎNE D’ENGRENAGE

3.4

3.4

CHAIN GUIDE
01 179 GUIDE DE CHAÎNE

1.4

1.4

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

ENGINE SYSTEM
SYSTÈME MOTEUR

DESCRIPTION

CRANKCASE RESEAL OR GASKET

DRIVE SHAFT AND/OR BEARINGS AND/OR SEALS

01 152 ARBRE D’ENTRAÎNEMENT ET/OU ROULEMENT À BILLES ET/OU ANNEAUX D’ÉTANCHÉITÉ
TIMING CHAIN

OIL RADIATOR AND/OR O-RING

01 182 RADIATEUR D'HUILE ET/OU JOINT D'ÉTANCHÉITÉ
CHAIN TENSION GUIDE

2.0

01 191 GUIDE DE TENSION DE CHAÎNE

3.4

3.4

CHAIN TENSIONER (ASS’Y)
01 192 TENDEUR DE CHAÎNE (COMPLET)

0.4

0.4

2.1

2.1

01 201 VIS, RESSORT DE COMPRESSION, SOUPAPE DE RETENUE ET BILLE

2.0

2.0

REAR OUTPUT SHAFT SEAL
01 205 ANNEAU D’ÉTANCHÉITÉ DE L’ARBRE DE SORTIE ARRIÈRE

6.0

6.0

0.3

0.3

0.3

0.3

01 217 ATTACHE MOTEUR ET/OU TAMPON D'ANCRAGE

0.4

0.4

MAIN DRIVE GEAR AND/OR PIN
01 220 ROUAGE D'ENTRAÎNEMENT PRINCIPALE ET/OU GOUPILLE

2.1

2.1

2.1

2.1

01 223 ANNEAU ÉTANCHÉITÉ ARBRE SORTIE AVANT

6.0

6.0

OUTPUT CRANKSHAFT SEAL (PTO SIDE)
01 245 ANNEAU ÉTANCHÉITÉ SORTIE VILEBREQUIN (CÔTÉ PDM)

1.3

1.3

6.4

6.4

01 247 SOUPAPE À CLAPET ET/OU BUTOIR

2.1

2.1

BREATHER GEAR AND/OR V-RING
01 248 RENIFLARD ET/OU ANNEAU ÉTANCHÉITÉ EN «V»

2.1

2.1

WATER PUMP GEAR

01 200 ENGRENAGE DE LA POMPE À EAU
PLUG, COMPRESSION SPRING, PRESSURE RETAINER AND BALL

OIL DIPSTICK

01 215 JAUGE À HUILE
PRESSURE CAP

01 216 BOUCHON À PRESSION
ENGINE BRACKET AND/OR RUBBER MOUNT

INTERMEDIATE GEAR AND/OR PIN AND/OR THRUST WASHER

01 221 ROUAGE INTERMEDIAIRE ET/OU GOUPILLE ET/OU RONDELLE D'APPUI
FRONT OUTPUT SHAFT SEAL

WATER PUMP GEAR AND/OR SEAL

01 246 ARBRE POMPE À EAU ET/OU JOINT ÉTANCHÉITÉ
REED VALVE AND/OR STOPPER

6

2011

Can-Am - Volume 1

01
2

01 255 ÉCHAPPEMENT ET/OU VALVES ADMISSION ET/OU RESSORTS ET/OU ANNEAUX D’ÉTANCHÉITÉ (4)

3.6

3.6

EXHAUST AND/OR INLET VALVES AND/OR SPRINGS AND/OR SEALS (8)
01 256 ÉCHAPPEMENT ET/OU VALVES ADMISSION ET/OU RESSORTS ET/OU ANNEAUX D’ÉTANCHÉITÉ (8)

6.2

6.2

3.2

3.2

01 264 ENSEMBLE CARTER - CYLINDRE - CULASSE

7.4

7.4

WATER PUMP DYNAMIC SEAL AND/OR OIL SEAL
01 301 ANNEAU D’ÉTANCHÉITÉ DYNAMIQUE DE LA POMPE À EAU

2.5

2.5

5.5

5.5

01 304 GUIDE DE TENSION DE CHAÎNES (TOUS)

5.5

5.5

CHAINS GUIDE (ALL)
01 305 GUIDE DE CHAÎNES (TOUS)

2.1

2.1

0.7

0.7

01 308 JOINT D’ÉTANCHÉITÉ DE LA CULASSE (1)

2.0

2.0

CYLINDER HEAD GASKETS (2)
01 309 JOINTS D’ÉTANCHÉITÉ DE LA CULASSE (2)

2.7

2.7

0.3

0.3

CODE

1

SYSTEM
SYSTÈME

COMMANDER
1000

SYSTEM/SYSTÈME

COMMANDER
800

ENGINE SYSTEM
SYSTÈME MOTEUR

DESCRIPTION

EXHAUST AND/OR INLET VALVES AND/OR SPRINGS AND/OR SEALS (4)

TIMING CHAIN (MAG SIDE)

01 261 CHAÎNE D’ENGRENAGE (CÔTÉ MAG)
LONG BLOCK

TIMING CHAINS (ALL)

01 303 CHAÎNES D’ENGRENAGE (TOUTES)
CHAINS TENSION GUIDE (ALL)

VALVE COVERS AND/OR GASKETS (2)

01 307 COUVERCLES SOUPAPE ET/OU JOINTS D’ÉTANCHÉITÉ (2)
CYLINDER HEAD GASKET (1)

MUFFLER COVER

01 319 COUVRE SILENCIEUX

Volume 1 - Can-Am

2011

7

01

SYSTEM/SYSTÈME

ENGINE SYSTEM
SYSTÈME MOTEUR

800/1000
FRONT/REAR
AVANT/ARRIÈRE

01109
01307

01113
0119

01111
01192

01191
01305
01116
01255
01256

01154
01261
01303

01134

01179
01304
01249
0158
0159

01114
01113
01116
01255
01256

01116
01255
01256
01308
01309

V07C2RV

8

2011

Can-Am - Volume 1

ENGINE SYSTEM
SYSTÈME MOTEUR

01

SYSTEM/SYSTÈME

800/1000
01117

01101
01102

01101
01102

01117

0150

V07C2SS

Volume 1 - Can-Am

2011

9

01

SYSTEM/SYSTÈME

ENGINE SYSTEM
SYSTÈME MOTEUR

800/1000

01247

0156

0157
01139
01245

V07C2TS

10

2011

Can-Am - Volume 1

ENGINE SYSTEM
SYSTÈME MOTEUR

01

SYSTEM/SYSTÈME

800

01119
01301
01246

0138

01246

01200

V07C2VT

Volume 1 - Can-Am

2011

11

01

ENGINE SYSTEM
SYSTÈME MOTEUR

SYSTEM/SYSTÈME

1000
01215

01133

0103
01221

0190

01248
0196

01182

01248
01132
01137

ttf2011-001-001_a

12

2011

Can-Am - Volume 1

01

SYSTEM/SYSTÈME

Engine /
Moteur

0119

0121

0121

0179

01216

0198

0146

0108

0137

01100

ENGINE SYSTEM
SYSTÈME MOTEUR

ttf2011-001-002_a

Volume 1 - Can-Am

2011

13

01

01319

0170

0171

0173

0183

SYSTEM/SYSTÈME

ENGINE SYSTEM
SYSTÈME MOTEUR

ttf2011-001-003_a

14

2011

Can-Am - Volume 1

ENGINE SYSTEM
SYSTÈME MOTEUR

01

SYSTEM/SYSTÈME

800/1000
01205

01152

01223
vtf2009-001-001_a

Volume 1 - Can-Am

2011

15

02

COMMANDER
1000

2

0

0

02 01 SILENCIEUX D’ADMISSION D’AIR (COMPLET)

1.1

1.1

INTAKE ADAPTOR
02 16 ADAPTATEUR D’ADMISSION

0.7

0.7

0.4

0.4

02 23 TUYAU D’ADMISSION D’AIR ARRIÈRE ET/OU DOUILLE

0.7

0.7

AIR TEMPERATURE SENSOR
02 46 CAPTEUR DE TEMPÉRATURE D’AIR

0.6

0.6

0.9

0.9

02 58 RÉSERVOIR D’ESSENCE

1.1

1.1

INTAKE COVER AND/OR SEAL
02 59 COUVERCLE D’ADMISSION ET/OU JOINT D’ÉTANCHÉITÉ

0.3

0.3

0.3

0.3

02 69 FILTRE À AIR

0.3

0.3

INTAKE MANIFOLD
02 72 CONNECTEUR D’ADMISSION

1.1

1.1

02 79 RAMPE D’ESSENCE (1 OU 2)

1.0

1.0

INJECTOR (ALL)
02 80 INJECTEUR (TOUS)

1.0

1.0

1.1

1.1

02 89 MODULE POMPE À ESSENCE

0.9

0.9

FEMALE QUICK FITTING
02 94 CONNECTEUR RAPIDE FEMELLE

0.4

0.4

0.8

0.8

02 112 SUPPORT DU SILENCIEUX D'ADMISSION

0.7

0.7

PLENUM
02 115 CHAMBRE D’AIR

1.1

1.1

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

INTAKE AND FUEL SYSTEM
ADMISSION ET SYSTÈME D’ALIMENTATION D’ESSENCE

DESCRIPTION

NO LABOR INVOLVED

02 00 AUCUNE MAIN D’OEUVRE
AIR INTAKE SILENCER (ASS’Y)

AIR INTAKE TUBE

02 19 TUYAU D’ADMISSION D’AIR
REAR AIR INTAKE TUBE AND/OR SLEEVE

FUEL FILTER

02 57 FILTRE À ESSENCE
FUEL TANK

FUEL CAP

02 60 BOUCHON DU RÉSERVOIR À ESSENCE
AIR FILTER

FUEL RAIL (1 OR 2)

THROTTLE BODY (ASS’Y)

02 81 CARTER ACCÉLÉRATEUR (COMPLET)
FUEL PUMP MODULE

FUEL INJECTION HOSE (ASS’Y)

02 99 BOYAU À INJECTION D’ESSENCE (COMPLET)
AIR SILENCER SUPPORT

16

2011

Can-Am - Volume 1

INTAKE AND FUEL SYSTEM
ADMISSION ET SYSTÈME D’ALIMENTATION D’ESSENCE

02

SYSTEM/SYSTÈME

0269
0201

0223

0219

Throttle Body /
Carter de Papillon

Crankcase Housing /
Carter de Vilebrequin
TTF2011-001-004_a

Volume 1 - Can-Am

2011

17

02

SYSTEM/SYSTÈME

INTAKE AND FUEL SYSTEM
ADMISSION ET SYSTÈME D’ALIMENTATION D’ESSENCE

Engine/
Moteur
0294
Engine/
Moteur

0294
0289
0299

0289
0257

0258

0260
ttf2011-001-005_a

18

2011

Can-Am - Volume 1

INTAKE AND FUEL SYSTEM
ADMISSION ET SYSTÈME D’ALIMENTATION D’ESSENCE

02

SYSTEM/SYSTÈME

1000

0216

0246

02115

02112
0281

0272
ttf2011-001-006_a

Volume 1 - Can-Am

2011

19

03

COMMANDER
1000

2

0

0

2.3

2.3

03 08 BOBINE D’ALLUMAGE (CHAQUE)

0.5

0.5

IGNITION CABLE
03 10 CÂBLE D’ALLUMAGE

0.4

0.4

2.1

2.1

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

IGNITION SYSTEM
SYSTÈME D’ALLUMAGE

DESCRIPTION

NO LABOR INVOLVED
03 00 AUCUNE MAIN D’OEUVRE
MAGNETO (ASS’Y)

03 02 MAGNÉTO (COMPLET)
IGNITION COIL (EACH)

STATOR (ASS’Y)

03 27 STATOR (COMPLET)

20

2011

Can-Am - Volume 1

IGNITION SYSTEM
SYSTÈME D’ALLUMAGE

03

SYSTEM/SYSTÈME

800/1000

0327

0302

V07G29S

Volume 1 - Can-Am

2011

21

04

COMMANDER
1000

2

0

0

0.6

0.6

04 03 SOLÉNOÏDE DE DÉMARRAGE

0.3

0.3

STARTER DRIVE
04 19 LANCEUR DÉMARREUR

2.3

2.3

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

STARTER SYSTEM
SYSTÈME DE DÉMARREUR

DESCRIPTION

NO LABOUR INVOLVED
04 00 AUCUNE MAIN-D’OEUVRE
ELECTRIC STARTER (ASS’Y)

04 02 DÉMARREUR (COMPLET)
STARTER RELAY

22

2011

Can-Am - Volume 1

05

TRANSMISSION AND LINKAGE SYSTEM
SYSTÈME DE TRANSMISSION ET DE TRINGLERIE

COMMANDER
1000

2

0

0

PULLEY SLIDING HALF
05 12 DRIVEN
DEMI-POULIE MENÉE COULISSANTE

1.3

1.3

05 19 BELT
COURROIE

1.2

1.2

BUTTON
05 55 LEVER
BOUTON DE LEVIER

0.3

0.3

(ASS’Y) AND/OR LEVER SPRING
05 56 LEVER
LEVIER (COMPLET) ET/OU RESSORT DE LEVIER

0.6

0.6

SENSOR
05 59 SPEED
CAPTEUR DE VITESSE

0.4

0.4

LEVER
05 66 GEARSHIFT
LEVIER D'EMBRAYAGE

0.5

0.5

COVER
05 78 CVT
COUVERCLE CVC

1.1

1.1

05 79 GASKET
JOINT D’ÉTANCHÉITÉ

1.1

1.1

CUP
05 80 GOVERNOR
COUPOLE RÉGULATEUR

1.4

1.4

WAY CLUTCH, FLANGE, RING, SPRING
05 81 ONE
EMBRAYAGE À ROUE LIBRE, FLASQUE, ANNEAU, RESSORT

1.4

1.4

PULLEY (ASS’Y)
05 82 DRIVE
POULIE MOTRICE (COMPLET)

1.5

1.5

PULLEY FIXED HALF
05 83 DRIVE
POULIE MOTRICE FIXE

1.5

1.5

PULLEY OUTER CAM AND/OR SPRING
05 84 DRIVEN
CAME DE POULIE MENÉE EXTERNE ET/OU RESSORT

1.3

1.3

LEVER
05 85 CENTRIFUGAL
LEVIER CENTRIFUGE

1.6

1.6

SHOES
05 86 SLIDER
GLISSIÈRES

1.4

1.4

AND REPLACE TRANSMISSION ASS'Y
05 89 REMOVE
REMPLACEMENT DE LA TRANSMISSION (COMPLET)

5.9

5.9

SHAFT (ASS'Y)
05 91 MAIN
ARBRE DE RENVOI (COMPLET)

6.5

6.5

05 95 ENTRÉE D'AIR (CVC)

0.5

0.5

AIR OUTLET (CVT)
05 96 SORTIE D'AIR (CVC)

0.5

0.5

0.5

0.5

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

DESCRIPTION

LABOR INVOLVED
05 00 NO
AUCUNE MAIN-D’OEUVRE IMPLIQUÉE

AIR INTAKE (CVT)

FLEXIBLE ADAPTOR

05 97 ADAPTATEUR FLEXIBLE
Volume 1 - Can-Am

2011

23

05

COMMANDER
1000

2

05 98 CAME, PLAQUE, ARBRE POULIE MENÉE, RESSORT

1.3

1.3

OUTPUT SHAFT
05 99 ARBRE DE SORTIE

6.4

6.4

6.2

6.2

05 101 BOÎTE D'ENGRENAGE (COMPLET)/ARBRE PRINCIPAL

6.7

6.7

SHIFT SHAFT (ASS'Y )
05 102 ARBRE D'EMBRAYAGE (COMPLET)

6.7

6.7

6.7

6.7

05 105 JOINT D'ÉTANCHÉITÉ DE L'ARBRE PRINCIPAL

1.9

1.9

SPACER AND/OR O-RING
05 107 ENTRETOISE ET/OU JOINT TORIQUE

0.8

0.8

0.8

0.8

05 109 FOURCHETTE ET/OU GOUPILLE

1.2

1.2

CENTER HOUSING GEAR AND/OR BEARING
05 110 LOGEMENT DE TRANSMISSION CENTRE ET/OU ROULEMENT

6.7

6.7

6.6

6.6

0.6

0.6

05 115 GUIDE D'AÉRATION ET/OU JOINT D'ÉTANCHÉITÉ

1.6

1.6

GEARBOX POSITION SENSOR
05 120 CAPTEUR DE POSITION D'ENGRENAGE

0.4

0.4

0.3

0.3

05 160 FILTRE

0.3

0.3

SHIFTING CABLE
05 161 CÂBLE D'EMBRAYAGE

1.1

1.1

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

TRANSMISSION AND LINKAGE SYSTEM
SYSTÈME DE TRANSMISSION ET DE TRINGLERIE

DESCRIPTION

CAM, PLATE, DRIVEN SHAFT, SPRING

REAR OUTPUT SHAFT SEALS

05 100 ANNEAUX ÉTANCHÉITÉ DE L’ARBRE DE SORTIE ARRIÈRE
GEARS BOX (ASS'Y)/MAIN SHAFT

INDEX LEVER (ASS'Y)

05 104 LEVIER D'INDEXATION (COMPLET)
MAIN SHAFT SEAL

ACTUATOR AND/OR FORK AND/OR SEAL

05 108 ACTUATEUR ET/OU FOURCHETTE ET/OU JOINT D'ÉTANCHÉITÉ
FORK AND/OR PIN

RH HOUSING GEAR AND/OR BEARING

05 111 LOGEMENT DE TRANSMISSION DROIT ET/OU ROULEMENT
SHIFTING SWITCH

05 113 INTERRUPTEUR D'EMBRAYAGE
CVT AIR GUIDE AND/OR O-RINGS

PRIMARY INLET AND/OR ADAPTER

05 159 ENTRÉE PRIMAIRE ET/OU ADAPTATEUR
FILTER

24

2011

Can-Am - Volume 1

TRANSMISSION AND LINKAGE SYSTEM
SYSTÈME DE TRANSMISSION ET DE TRINGLERIE

05

SYSTEM/SYSTÈME

05115

0598
0512

0584

0583

0581

0585
0586

0578

0579

ttf2011-001-007_a

Volume 1 - Can-Am

2011

25

05

SYSTEM/SYSTÈME

TRANSMISSION AND LINKAGE SYSTEM
SYSTÈME DE TRANSMISSION ET DE TRINGLERIE
05120

0559

05111

05113

0599
05103

05100

05110
05111

05102

05108

05104

05109
0591
0599

05110

05101

0589

ttf2011-001-008_a

26

2011

Can-Am - Volume 1

TRANSMISSION AND LINKAGE SYSTEM
SYSTÈME DE TRANSMISSION ET DE TRINGLERIE

05

SYSTEM/SYSTÈME

05104

05110

05101

05101

05107

05105
ttf2011-001-009_a

Volume 1 - Can-Am

2011

27

05

0566

05161

0556

0555

0597

0596

0597

0595

0597

05159

05160

SYSTEM/SYSTÈME

TRANSMISSION AND LINKAGE SYSTEM
SYSTÈME DE TRANSMISSION ET DE TRINGLERIE

ttf2011-001-010_a

28

2011

Can-Am - Volume 1

06

BRAKE SYSTEM
SYSTÈME DE FREIN

COMMANDER
1000

2

0

0

1.0

1.0

06 09 ÉTRIER AVANT (DROIT OU GAUCHE)

0.5

0.5

FRONT BRAKE PAD (RH OR LH)
06 10 PLAQUETTE DE FREIN AVANT (DROIT OU GAUCHE)

0.3

0.3

0.7

0.7

06 12 BOYAU FLEXIBLE DE FREIN AVANT

0.8

0.8

BRAKE SWITCH
06 19 INTERRUPTEUR DE FREIN

0.3

0.3

1.3

1.3

06 26 ÉTRIER ARRIÈRE

0.5

0.5

REAR BRAKE PAD
06 27 PLAQUETTE DE FREIN ARRIÈRE

0.3

0.3

0.7

0.7

0.5

0.5

06 35 PÉDALE DE FREIN

0.5

0.5

MASTER CYLINDER ROD
06 44 TIGE DU MAÎTRE-CYLINDRE

0.4

0.4

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

DESCRIPTION

NO LABOR INVOLVED
06 00 AUCUNE MAIN-D’OEUVRE
MASTER CYLINDER

06 06 MAÎTRE-CYLINDRE

FRONT CALIPER (RH OR LH)

FRONT BRAKE DISC (RH OR LH)

06 11 DISQUE DE FREIN AVANT (DROIT OU GAUCHE)
FRONT FLEXIBLE BRAKE HOSE

REAR BRAKE HOSE

06 25 BOYAU DE FREIN ARRIÈRE
REAR CALIPER

REAR BRAKE DISC

06 28 DISQUE DE FREIN ARRIÈRE
MASTER CYLINDER RESERVOIR

06 34 RÉSERVOIR DU MAÎTRE-CYLINDRE
BRAKE PEDAL

Volume 1 - Can-Am

2011

29

06

SYSTEM/SYSTÈME

BRAKE SYSTEM
SYSTÈME DE FREIN

0611
0634
0606
0619

0611

0612

0612
0609

0635
0610

0625

0609

0628

0610

0626

0627

ttf2011-001-011_a

30

2011

Can-Am - Volume 1

07

00

07

04

07

13

07

24

07

27

07

32

07

33

07

37

07

40

07

42

07

45

07

46

07

47

07

50

07

64

07

72

07

80

07

85

07

88

07

89

07

90

NO LABOR INVOLVED
AUCUNE MAIN-D’OEUVRE
ARM PROTECTOR (RH OR LH)
PROTECTEUR DE BRAS (DROIT OU GAUCHE)
EXTERNAL BALL JOINT (RH OR LH)
JOINT À ROTULE EXTERNE (DROIT OU GAUCHE)
MAIN TUBE
TUBE PRINCIPAL
STEERING COVER
COUVRE-GUIDON
LOWER ARM AND/OR BALL JOINT (RH OR LH)
BRAS INFÉRIEUR ET/OU JOINT À ROTULE (DROIT OU GAUCHE)
UPPER ARM (RH OR LH)
BRAS DE SUSPENSION SUPÉRIEUR (DROIT OU GAUCHE)
FRONT SHOCK AND/OR SPRING AND/OR STOPPER AND/OR PROTECTOR AND/OR SEAT (RH OR LH)
AMORTISSEUR AVANT ET/OU RESSORT ET/OU BUTÉE ET/OU SIÈGE ET/OU PROTECTEUR
(DROIT OU GAUCHE)
FRONT DIFFERENTIEL (ASS’Y)
DIFFÉRENTIEL AVANT (COMPLET)
FRONT PROPELLER SHAFT (ASS’Y)
ARBRE DE PROPULSION AVANT (COMPLET)
CV JOINT (RH OR LH)
JOINT HOMOCINÉTIQUE (DROIT OU GAUCHE)
FRONT WHEEL HUB (SEAL AND/OR BEARING) (RH OR LH)
MOYEU DE ROUE AVANT (JOINT ET/OU ROULEMENT) (DROIT OU GAUCHE)
KNUCKLE (RH OR LH)
PORTE-FUSÉE (DROIT OU GAUCHE)
FRONT RIM AND/OR TIRE
JANTE AVANT ET/OU PNEU
DOUBLE BALL JOINT
JOINT À ROTULE DOUBLE
INTERNAL BUSHING AND/OR CUSHION (LOWER AND/OR UPPER ARM) (RH OR LH)
DOUILLE INTERNE ET/OU COUSSIN (BRAS INFÉRIEUR ET/OU SUPÉRIEUR) (DROIT OU GAUCHE)
FRONT RIM
JANTE AVANT
RING GEAR AND/OR CARRIER AND/OR SHIM
COURONNE DE LANCEMENT ET/OU SUPPORT ET/OU CALE
RING GEAR DRIVE GEAR AND/OR BEARING AND/OR SHIM
PIGNON DE COMMANDE DE LA COURONNE ET/OU ROULEMENT À BILLE ET/OU CALE
COVER AND/OR PINION COVER AND/OR SEAL AND/OR BEARING
COUVERCLE ET/OU COUVERCLE DE PIGNON ET/OU JOINT D’ÉTANCHÉITÉ ET/OU ROULEMENT
À BILLE
BOOT WHEEL KIT AND/OR CV JOINT (RH OR LH)
ENSEMBLE DE SOUFFLET DE ROUE ET/OU JOINT CV (DROIT OU GAUCHE)

Volume 1 - Can-Am

2011

COMMANDER
1000

07

DESCRIPTION

SYSTEM/SYSTÈME

COMMANDER
800

CODE

SYSTEM
SYSTÈME

STEERING - FRONT DRIVE SYSTEM AND SUSPENSION
DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION

1

2

0

0

0.3

0.3

0.8

0.8

1.1

1.1

0.3

0.3

0.7

0.7

0.7

0.7

0.4

0.4

2.8

2.8

2.0

2.0

0.7

0.7

0.3

0.3

0.7

0.7

0.4

0.4
0.3

0.4

0.4

0.4

0.4

3.3

3.3

3.3

3.3

3.6

3.6

0.8

0.8

31

07

91

07

92

07

103

07

104

07

106

07

115

07

116

07

117

07

118

07

120

32

DESCRIPTION

BOOT DIFFERENTIAL KIT AND/OR PLUNGING JOINT (RH OR LH)
ENSEMBLE DE SOUFFLET DE DIFFÉRENTIEL ET/OU JOINT PLONGEANT (DROIT OU GAUCHE)
SLEEVE AND/OR WEARRING
MANCHON ET/OU BAGUE D'USURE
DIFFERENTIAL SEAL (1)
JOINT D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (1)
DIFFERENTIAL SEALS (2)
JOINTS D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (2)
STEERING COLUMN SUPPORT AND/OR BUSHINGS
SUPPORT DE COLONNE DE DIRECTION ET/OU COUSSINETS
RACK AND PINION STEERING
DIRECTION À CRÉMAILLÈRE
STEERING SHAFT
ARBRE DU VOLANT
ADJUSTMENT CYLINDER
CYLINDRE D'AJUSTEMENT
STEERING WHEEL
VOLANT
DIFFERENTIAL OIL SEAL
ANNEAU D’ÉTANCHÉITÉ DU DIFFÉRENTIEL

2011

COMMANDER
1000

CODE

SYSTEM
SYSTÈME

SYSTEM/SYSTÈME

STEERING - FRONT DRIVE SYSTEM AND SUSPENSION
DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION
COMMANDER
800

07

1

2

0.8

0.8

3.1

3.1

0.7

0.7

1.4

1.4

0.8

0.8

2.0

2.0

0.9

0.9

0.3

0.3

0.3

0.3

3.0

3.0

Can-Am - Volume 1

STEERING - FRONT DRIVE SYSTEM AND SUSPENSION
DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION

07

SYSTEM/SYSTÈME

0737

0733

0737
0732

0733

0772

0704

0732
0764

0739

0704

X model/
modèle X

0764

ttf2011-001-012_ a

Volume 1 - Can-Am

2011

33

07

SYSTEM/SYSTÈME

STEERING - FRONT DRIVE SYSTEM AND SUSPENSION
DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION
X, XT

STD

07118

07118

0727

07116

0724
07106

07117
07115

0713

ttf2011-001-013_a

34

2011

Can-Am - Volume 1

STEERING - FRONT DRIVE SYSTEM AND SUSPENSION
DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION

07

SYSTEM/SYSTÈME

07103
07104

0746
0789
0789
0785

0788
0790
07103
07104
07120
0747
0745
0745

0745

0791

0790
0792

0745
0791
0742
0750

0747

0746

ttf2011-001-014_a

Volume 1 - Can-Am

2011

35

08

COMMANDER
1000

2

0

0

0.3

0.3

1.6

1.6

1.8

1.8

08 62 BRAS OSCILLANT

1.2

1.2

LH PROTECTOR
08 101 PROTECTEUR GAUCHE

0.3

0.3

RH PROTECTOR
08 102 PROTECTEUR DROIT

0.3

0.3

0.3

0.3

0.3

0.3

0.4

0.4

08 120 JOINT HOMOCINÉTIQUE (DROIT OU GAUCHE)

0.7

0.7

STABILIZER BAR
08 121 BARRE STABILISATRICE

0.4

0.4

RING GEAR AND/OR SHIM
08 122 COURONNE DE LANCEMENT ET/OU CALE

2.8

2.8

RING GEAR DRIVE GEAR AND/OR BEARING AND/OR SHIM
08 123 PIGNON DE COMMANDE DE LA COURONNE ET/OU ROULEMENT À BILLE ET/OU CALE

2.8

2.8

08 124 COUVERCLE ET/OU COUVERCLE DE PIGNON ET/OU JOINT D’ÉTANCHÉITÉ ET/OU ROULEMENT À BILLE 2.9

2.9

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

REAR DRIVE SYSTEM AND SUSPENSION
SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION

DESCRIPTION

NO LABOR INVOLVED

08 00 AUCUNE MAIN D’OEUVRE
REAR WHEEL HUB (RH)

08 05 MOYEU DE ROUE ARRIÈRE (DROIT)
REAR DIFFERENTIAL (ASS’Y)

08 07 DIFFÉRENTIEL ARRIÈRE (COMPLET)
REAR PROPELLER SHAFT (ASS’Y)

08 26 ARBRE DE PROPULSION ARRIÈRE (COMPLET)
SWING ARM

REAR WHEEL HUB (LH)

08 109 MOYEU DE ROUE ARRIÈRE (GAUCHE)
REAR SHOCK (RH OR LH)

08 111 AMORTISSEUR ARRIÈRE (DROIT OU GAUCHE)
REAR RIM AND/OR TIRE

08 114 JANTE ARRIÈRE ET/OU PNEU
CV JOINT (RH OR LH)

COVER AND/OR PINION COVER AND/OR SEAL AND/OR BEARING
BOOT WHEEL KIT AND/OR CV JOINT (RH OR LH)

08 125 ENSEMBLE DE SOUFFLET DE ROUE ET/OU JOINT CV (DROIT OU GAUCHE)

0.8

0.8

0.8

0.8

08 127 ROULEMENTS À BILLE RADIALES

0.9

0.9

DIFFERENTIAL SEAL (1)
08 134 JOINT D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (1)

0.5

0.5

DIFFERENTIAL SEALS (2)
08 135 JOINTS D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (2)

1.0

1.0

0.9

0.9

2.5

2.5

BOOT DIFFERENTIAL KIT AND/OR PLUNGING JOINT (RH OR LH)

08 126 ENSEMBLE DE SOUFFLET DE DIFFÉRENTIEL ET/OU JOINT PLONGENT (DROIT OU GAUCHE)
RADIAL BALL BEARINGS

PIVOTS BUSHINGS, SEALS AND BEARINGS

08 146 DOUILLES DE PIVOTS, JOINTS D’ÉTANCHÉITÉ ET ROULEMENTS À BILLE
DIFFERENTIAL OIL SEAL

08 148 ANNEAU D’ÉTANCHÉITÉ DU DIFFÉRENTIEL

36

2011

Can-Am - Volume 1

08

08146

SYSTEM/SYSTÈME

08102

08146

0862

08146

08121

08102

08146

08111

0862

REAR DRIVE SYSTEM AND SUSPENSION
SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION

ttf2011-001-015_a

Volume 1 - Can-Am

2011

37

08

SYSTEM/SYSTÈME

REAR DRIVE SYSTEM AND SUSPENSION
SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION

08114
08134
08135

08124
08122

08127
0805

08124

08125

08123
08134
08135

08120

08148

08125

08126

08120
08125

0826

08126

08125
08127

08109

ttf2011-001-016_a

38

2011

Can-Am - Volume 1

09

BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES

COMMANDER
1000

2

0

0

3.0

3.0

09 25 BASE DE LOQUET ET/OU LEVIER ET/OU RESSORT

0.3

0.3

FRONT BUMPER
09 26 PARE-CHOCS AVANT

0.6

0.6

0.3

0.3

09 28 FASCIA AVANT

0.5

0.5

HITCH SUPPORT
09 35 SUPPORT D'ATTELAGE

0.4

0.4

0.7

0.7

09 57 AILE AVANT ET/OU SUPPORT (DROIT OU GAUCHE)

1.5

1.5

FUEL TANK COVER
09 71 COUVRE RÉSERVOIR D'ESSENCE

0.5

0.5

0.3

0.3

0.3

0.3

09 82 CÂBLE DE RETENUE

0.3

0.3

PROTECTION PLATE
09 93 PLAQUE DE PROTECTION

0.4

0.4

0.3

0.3

09 97 AMORTISSEUR (BOÎTE DE RANGEMENT)

0.3

0.3

PIVOT SUPPORT
09 102 SUPPORT DE PIVOT

0.3

0.3

0.3

0.3

09 111 BASE DE SIÈGE COMPLET (CONDUCTEUR OU COPILOTE)

0.3

0.3

FRONT LIGHT FASCIA
09 120 FASCIA DE LUMIÈRE AVANT

0.4

0.4

0.6

0.6

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

DESCRIPTION

NO LABOR INVOLVED
09 00 AUCUNE MAIN D’OEUVRE IMPLIQUÉE
HOOD

09 01 CAPOT
LATCH BASE AND/OR LEVER AND/OR SPRING

WINCH LATCH

09 27 ATTACHE DE TREUIL
FRONT FASCIA

FRONT OR REAR MUDGUARD KIT (RH OR LH)

09 39 ENSEMBLE DE GARDE-BOUE AVANT OU ARRIÈRE (DROIT OU GAUCHE)
FRONT FENDER AND/OR SUPPORT (RH OR LH)

FRONT GRILLS

09 80 GRILLES AVANT
SIDE GRILL (RIGHT AND/OR LEFT)

09 81 GRILLE LATÉRALE (DROITE ET/OU GAUCHE)
CABLE RETAINER

EACH DECAL (1)

09 95 CHAQUE AUTOCOLLANT (1)
SHOCK GAZ (REAR CARGO BOX)

SEAT AND/OR BACKREST (DRIVER OR CO-PILOT)

09 110 SIÈGE ET/OU DOSSIER (CONDUCTEUR OU COPILOTE)
SEAT BASE ASS'Y (DRIVER OR CO-PILOT)

CARGO BOX LEVER AND/OR RINGS AND/OR CLAMP

09 134 LEVIER BENNE ET/OU BAGUES ET/OU BRIDE
Volume 1 - Can-Am

2011

39

09

COMMANDER
1000

2

09 157 CONSOLE SUPÉRIEURE

0.5

0.5

FRONT BUMPER (XT)
09 162 PARE-CHOC AVANT (XT)

0.3

0.3

0.3

0.3

09 219 LOQUET DE PORTE

0.3

0.3

LOWER CONSOLE
09 226 CONSOLE INFÉRIEURE

0.4

0.4

0.3

0.3

09 231 PANNEAU ARRIÈRE (GAUCHE OU DROIT)

0.9

0.9

MIDDLE SIDE PANEL (LEFT OR RIGHT)
09 239 PANNEAU LATÉRAL CENTRAL (GAUCHE OU DROIT)

0.6

0.6

0.3

0.3

09 284 PORTE DE COFFRE

0.3

0.3

GLOVES BOX
09 289 BOÎTE À GANTS

0.3

0.3

0.4

0.4

0.5

0.5

09 304 SUPPORT ARRIÈRE

0.8

0.8

REAR SIDE PANEL (RIGHT OR LEFT)
09 306 PANNEAU LATÉRAL ARRIÈRE (DROIT OU GAUCHE)

0.3

0.3

0.6

0.6

09 334 FASCIA SUPÉRIEUR

0.3

0.3

FLASHER COVER (RIGHT OR LEFT)
09 335 COUVRE CLIGNOTANT (DROIT OU GAUCHE)

0.3

0.3

0.3

0.3

09 337 PLAQUE DE PROTECTION ARRIÈRE

0.3

0.3

AIR INLET COVER
09 338 COUVERCLE D'ADMISSION D'AIR

0.3

0.3

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES

DESCRIPTION

UPPER CONSOLE

FRONT GRILL

09 168 GRILLE FRONTALE
DOOR LATCH

SERVICE COVER

09 227 COUVERCLE DE SERVICE
REAR PANEL (LEFT OR RIGHT)

LATCH AND/OR BASE (RIGHT OR LEFT)

09 282 LOQUET ET/OU BASE (DROIT OU GAUCHE)
BOX DOOR

DASHBOARD

09 290 TABLEAU DE BORD
SIDE STORAGE COMPARTMENT (RIGHT OR LEFT)

09 294 COMPARTIMENT DE RANGEMENT LATÉRAL (DROIT OU GAUCHE)
REAR SUPPORT

BOTTOM FRONT SIDE PANEL (RH OR LH)

09 308 PANNEAU LATÉRAL AVANT BAS (DROIT OU GAUCHE)
UPPER FASCIA

CENTRAL SKID PLATE

09 336 PLAQUE DE PROTECTION CENTRALE
REAR SKID PLATE

40

2011

Can-Am - Volume 1

09

BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES

COMMANDER
1000

2

09 339 PANNEAU DE PLANCHER (GAUCHE)

3.0

3.0

FLOOR PANEL (RIGHT)
09 340 PANNEAU DE PLANCHER (DROIT)

2.1

2.1

2.6

2.6

09 342 CLOISON AVANT (DROITE)

2.0

2.0

REAR BULKHEAD (LEFT)
09 343 CLOISON ARRIÈRE (GAUCHE)

1.3

1.3

1.3

1.3

09 345 PANNEAU LATÉRAL DE CONSOLE (GAUCHE)

0.3

0.3

LATERAL CONSOLE PANEL (RIGHT)
09 346 PANNEAU LATÉRAL DE CONSOLE (DROIT)

0.3

0.3

0.8

0.8

09 348 PANNEAU FIXE DE CONSOLE (DROIT)

0.8

0.8

LEVER INDICATOR
09 349 INDICATEUR DE VITESSE

0.5

0.5

4.6

4.6

3.7

3.7

09 352 BENNE (DROITE)

3.7

3.7

REMOVABLE FLOOR
09 353 PLATEAU AMOVIBLE

0.3

0.3

0.3

0.3

09 355 ENJOLIVEUR DE FEU ARRIÈRE (GAUCHE OU DROIT)

0.3

0.3

CARGO BOX RAIL AND/OR COVER
09 356 RAIL DE BENNE ET/OU COUVERCLE

0.3

0.3

0.5

0.5

09 358 CHÂSSIS DE LA BENNE

1.6

1.6

CARGO BOX PIVOTS (ALL PARTS)
09 359 PIVOTS DE LA BENNE (TOUTES LES PIÈCES)

0.7

0.7

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

DESCRIPTION

FLOOR PANEL (LEFT)

FRONT BULKHEAD (LEFT)

09 341 CLOISON AVANT (GAUCHE)
FRONT BULKHEAD (RIGHT)

REAR BULKHEAD (RIGHT)

09 344 CLOISON ARRIÈRE (DROITE)
LATERAL CONSOLE PANEL (LEFT)

FIXE CONSOLE PANEL (LEFT)

09 347 PANNEAU FIXE DE CONSOLE (GAUCHE)
FIXE CONSOLE PANEL (RIGHT)

CARGO BOX (LEFT AND RIGHT)

09 350 BENNE (GAUCHE ET DROITE)
CARGO BOX (LEFT)

09 351 BENNE (GAUCHE)

CARGO BOX (RIGHT)

FRONT REINFORCEMENT

09 354 RENFORT AVANT

TAILLIGHT TRIM (LEFT OR RIGHT)

CARGO BOX RETAINER AND/OR SPRING (LEFT OR RIGHT)

09 357 ANCRAGE DE BENNE ET/OU RESSORT (GAUCHE OU DROIT)
CARGO BOX FRAME

Volume 1 - Can-Am

2011

41

09

COMMANDER
1000

2

09 360 PANNEAU DU HAYON SUPÉRIEUR

0.3

0.3

LOWER TAIL GATE PANEL
09 361 PANNEAU DU HAYON INFÉRIEUR

0.3

0.3

0.4

0.4

09 363 HAYON INFÉRIEUR

0.6

0.6

HEAD REST
09 364 APPUI-TÊTE

0.3

0.3

0.3

0.3

09 366 VERROU CEINTURE

0.3

0.3

LOCK
09 367 VERROU

0.3

0.3

0.3

0.3

09 369 CAGE (AVANT)

0.5

0.5

CAGE (REAR)
09 370 CAGE (ARRIÈRE)

0.9

0.9

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES

DESCRIPTION

UPPER TAIL GATE PANEL

UPPER TAIL GATE

09 362 HAYON SUPÉRIEUR
LOWER TAIL GATE

SAFETY BELT

09 365 CEINTURE DE SÉCURITÉ
BUCKLE BELT

HANDHOLD (LEFT)

09 368 POIGNÉE DE MAINTIEN (GAUCHE)
CAGE (FRONT)

ROCK SLIDER (LEFT OR RIGHT)

09 371 GLISSIÈRE DE PROTECTION (GAUCHE OU DROITE)

0.5

SHOULDER GUARD (LEFT AND/OR RIGHT)

09 372 PROTECTEUR D'ÉPAULE (GAUCHE ET/OU DROIT)

0.3

0.3

09 373 POIGNÉE DE MAINTIEN (AVANT)

0.3

0.3

LATERAL NET (LEFT OR RIGHT)
09 374 FILET LATÉRAL (GAUCHE OU DROIT)

0.5

0.5

0.4

0.4

HANDHOLD (FRONT)

HANDHOLD BAR (LEFT)

09 375 BARRE DE POIGNÉE DE MAINTIEN (GAUCHE)

42

2011

Can-Am - Volume 1

BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES

09

SYSTEM/SYSTÈME

09227

0901

09334

09335

0981

0980
0928
ttf2011-001-017_a

Volume 1 - Can-Am

2011

43

09

SYSTEM/SYSTÈME

BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES

09306

0939

0957

09308

09239
09120
09337
0993

09336

09338
09306

0957
09239
09308
09120
ttf2011-001-018_a

44

2011

Can-Am - Volume 1

BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES

09

SYSTEM/SYSTÈME

09341

09339

09342
09294

09340

09343

0971

09344
ttf2011-001-019_a

Volume 1 - Can-Am

2011

45

09

SYSTEM/SYSTÈME

BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES

09289

09290
09157

09284
09345
09368
09226

09284

09348
09349
09346

09367
ttf2011-001-020_a

46

2011

Can-Am - Volume 1

09

SYSTEM/SYSTÈME

0982

0982

0982

09282

09282

09219

09219

09361

09360

09363

09282

09362

0982

09282

09358

09359

0997

BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES

ttf2011-001-021_a

Volume 1 - Can-Am

2011

47

09

09356

09353
09355

09102
09356

09356

09355

09102

09351

09231

09357

09357

09354

09350

09352

09231

09134

09357

09357

SYSTEM/SYSTÈME

BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES

ttf2011-001-022_a

48

2011

Can-Am - Volume 1

BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES

09

SYSTEM/SYSTÈME

09365

09366

09364

09365

09110

09364

09111

09110

0925
0925
09111
ttf2011-001-023_a

Volume 1 - Can-Am

2011

49

09

SYSTEM/SYSTÈME

BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES

09369

09372
09372

09374
09375

0926

09370

For Lateral Net See Cab Interior System/
Pour Filet Latéral Voir Système Cabine Intérieur

09373
09304

X, XT

09162

0935

09371

XT

09371
X

ttf2011-001-024_a

50

2011

Can-Am - Volume 1

10

ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE

COMMANDER
1000

2

0

0

0.3

0.3

10 04 INTERRUPTEUR DE PHARE

0.3

0.3

HEADLAMP AND/OR HEADLAMP SUPPORT (ASS’Y) (RH OR LH)
10 09 PHARE AVANT ET/OU SUPPORT (COMPLET) (DROIT OU GAUCHE)

0.5

0.5

0.3

0.3

10 13 BATTERIE

0.3

0.3

FUSE BOX
10 14 BOÎTE-FUSIBLE

0.4

0.4

0.3

0.3

10 31 PRISE D’ACCESSOIRE DC

0.3

0.3

ELECTRONIC MODULE
10 34 MODULE ÉLECTRONIQUE

0.3

0.3

0.6

0.6

0.5

0.5

10 47 INTERRUPTEUR DE TREUIL (XT)

0.3

0.3

MULTIFUNCTION GAUGE
10 49 CADRAN MULTIFONCTION

0.3

0.3

3.0

3.0

10 52 RELAIS DE DÉMARRAGE

0.4

0.4

FRONT FLASHERS 1 OR 2 (CE ONLY)
10 61 CLIGNOTANTS AVANT 1 OU 2 (CE SEULEMENT)

0.3

0.3

0.3

0.3

10 63 COMMUTATEUR D’URGENCE (CE SEULEMENT)

0.3

0.3

DIRECTION INDICATOR SWITCH (CE ONLY)
10 64 INTERRUPTEUR CLIGNOTANTS (CE SEULEMENT)

0.3

0.3

0.3

0.3

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

DESCRIPTION

NO LABOR INVOLVED
10 00 AUCUNE MAIN-D’OEUVRE
IGNITION SWITCH

10 01 INTERRUPTEUR D’ALLUMAGE
HEADLIGHT SWITCH

VOLTAGE REGULATOR

10 10 RÉGULATEUR DE TENSION
BATTERY

TAIL LAMP HOUSING (ASS’Y)

10 29 BOÎTIER DE FEU ARRIÈRE (COMPLET)
DC OUTLET PLUG

WINCH (ASS’Y) (XT)

10 45 TREUIL (COMPLET) (XT)
WINCH SOLENOID (XT)

10 46 SOLÉNOÏDE DE TREUIL (XT)
WINCH SWITCH (XT)

MAIN WIRE HARNESS

10 51 CÂBLAGE PRINCIPAL
STARTING RELAY

REAR FLASHERS 1 OR 2 (CE ONLY)

10 62 CLIGNOTANTS ARRIÈRE 1 OU 2 (CE SEULEMENT)
HAZARD WARNING BUTTON (CE ONLY)

12 VOLT RELAY (CE ONLY)

10 65 RELAIS 12 VOLT (CE SEULEMENT)
Volume 1 - Can-Am

2011

51

10

COMMANDER
1000

2

10 66 AVERTISSEUR

0.3

0.3

RELAY
10 67 RELAIS

0.3

0.3

0.4

0.4

10 71 LUMIÈRE D'IMMATRICULATION (COMPLET)

0.3

0.3

START BUTTON
10 111 BOUTON DE DÉMARRAGE

0.3

0.3

0.3

0.3

10 113 COMMANDE À DISTANCE

0.3

0.3

WINCH CONNECTOR
10 114 CONNECTEUR DE TREUIL

0.3

0.3

CODE

1

SYSTEM
SYSTÈME

COMMANDER
800

SYSTEM/SYSTÈME

ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE

DESCRIPTION

HORN

ANY BULBS

10 68 TOUTES LES AMPOULES
LICENSE LIGHT (ASS'Y)

OVERRIDE SWITCH

10 112 INTERRUPTEUR DE NEUTRALISATION
REMOTE CONTROL

52

2011

Can-Am - Volume 1

ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE
XT

STD, X

10

SYSTEM/SYSTÈME

0949
1052

0949
Europe

1014

1064
1014

1065
1013

1004
Europe

Engine/
Moteur

Europe

1010

C/U, Inter

Europe

C/U, Inter

1063
XT

1001
STD, X

XT

10111
1047
Frame/
Chassis

Starter/
Démarreur

1031

10112
10114

1029
1062
1062
Europe

ttf2011-001-025_a

Volume 1 - Can-Am

Europe

Europe

1029

1071

2011

53

10

SYSTEM/SYSTÈME

ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE

Europe

Europe

1061
1066
1068

1009

1061
Europe

XT

1045

XT

1046

10113

ttf2011-001-026_a

54

2011

Can-Am - Volume 1

11

NO LABOR INVOLVED
AUCUNE MAIN-D’OEUVRE
SCHEDULED MAINTENANCE TRACKING

11 MT1 SUIVI DES ENTRETIENS PLANIFIÉS

Volume 1 - Can-Am

2011

COMMANDER
1000

00

DESCRIPTION

SYSTEM/SYSTÈME

COMMANDER
800

11

CODE

SYSTEM
SYSTÈME

CLAIM TYPE 02
RÉCLAMATION DE TYPE 02

1

2

0

0

0

0

55

SIDE-BY-SIDE
VEHICLES
SERVICE
Bulletin

June 10, 2010

Subject: Spring Chart

No.

2011-3

YEAR

MODEL

MODEL NUMBER

SERIAL NUMBER

2011

Commander Series

All

All

The information in this bulletin supersedes all information previously published.

SPRING INFORMATION
NOTE: Read color codes when spring is upright

and stripes are down.

Identification
Spring identification is done by color code stripes
or part number. Part number is printed on the
spring within first 1-1/4 coils.

1

Spring Types
All call-outs below each following illustrations refer to:
1. Color code stripes or part number,
2. Wire diameter,
3. Free length.
NOTE: Read color codes when spring is upright
and stripes are down.
Spring type
Type T and V
(barrel shape at
both ends)

Single
Rate
Spring

Type 2 and 6
(barrel shape at
both ends)

Dual Rate
Spring

Type 8
(barrel shape
at both ends)

Dual Rate
Spring

2

1

3

mbs2009-002-001_a

1. Part number ink marked within first 1-1/4 coils

Color Code Legend
COLOR CODE
BL
BK
GD
GN
OR

—
—
—
—
—

BLUE
BLACK
GOLD
GREEN
ORANGE

PI
RD
SI
WH
YL

—
—
—
—
—

PINK
RED
SILVER
WHITE
YELLOW

Printed in Canada. (tbs2011-002 en AP)
©2010 Bombardier Recreational Products Inc. and BRP US Inc. All rights reserved.
®™ and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates.

1/2

SPRING APPLICATIONS
SPRING APPLICATIONS
SPRING P/N

MODEL
YEAR

MODEL
NUMBER

FRONT

REAR

2011

6CBA, 6CBC

706 200 859

706 000 667

2011

6DBA

706 200 860

706 000 667

2011

6DBD

706 201 369

706 001 045

STD

2011

6ABA, 6ABC

706 200 859

706 000 667

X

2011

6EBA, 6EBC

706 201 124

706 000 821

2011

6BBA, 6BBB,
6BBC

706 200 860

706 000 667

2011

6BBD

706 201 367

706 001 043

2011

6BBE, 6BBF

706 201 369

706 001 045

MODEL
STD
Commander
800R

XT

Commander
1000
XT

SPRING SPECIFICATIONS
COIL SPRINGS SPECIFICATIONS (REAR SHOCK ABSORBER)
P/N

TYPE

SPRING RATE
(LB/IN) ± 10
_________
(RATE 1 / RATE 2)

706 000 667

6

200 / 251.3

358

11.5

Yellow

706 000 821

2

158.2 / 259.2

373

11.5

Yellow

706 001 043

6

200 / 251.3

358

11.5

Viper Red

706 001 045

6

200 / 251.3

358

11.5

Deep Black

FREE LENGTH
(MM) ± 3

WIRE DIAMETER
(MM) ± .05

COLOR OF
SPRING

COIL SPRINGS SPECIFICATIONS (FRONT SHOCK ABSORBER)
P/N

TYPE

SPRING RATE
(LB/IN) ± 10
_________
(RATE 1 / RATE 2)

706 200 859

V

150 ± 5

355.6

10.31

Yellow

706 200 860

6

137 ± 5 / 162.7 ± 5

363

10.6

Yellow

706 201 124

T

150 ± 5

350

10.6

Yellow

706 201 367

6

137 ± 5 / 162.7 ± 5

363

10.6

Viper Red

706 201 369

6

137 ± 5 / 162.7 ± 5

363

10.6

Deep Black

2/2

FREE LENGTH
(MM) ± 3

WIRE DIAMETER
(MM) ± .05

COLOR OF
SPRING

2011-3

SERVICE

2011

PARTS, ACCESSORIES & RIDING GEAR

2

PARTS & ACCESSORIES
COMMANDERTM SIDE-BY-SIDE VEHICLE
MAKE IT YOUR OWN
4
UNDERBELLY PROTECTION
6
BUMPERS
7
WINDSHIELDS
9
ROOF ACCESSORIES
10
LIGHTS ACCESSORIES
11
WHEELS & PLOW
12
HITCHES & WINCHES
14
MULTI-FIT
15

OFF-ROAD RIDING GEAR
RACE
LADIES’ RACE
ADVENTURE
RECREATIONAL
SPORTSWEAR
BAGS & GOOGLES
HELMETS & ACCESSORIES
XP-2 / XC-1
XP-R
ST-1 / ST-3
VISION 180°
BV2S
MODULAR 2
BALACLAVAS
SIZING CHART

16
20
22
26
28
32
33
34
35
36
37
38
39
40
40

MAKE IT YOUR OWN PARTSS & ACCESSORIES
MAKE
ACCE
ACCE
C SSO
SSORRIE
IESS

3

MAKE IT YOUR OWN

4

PARTS
PAR
PAR
PA
PART
ARTS
TS & ACCESSORIES
ACC
AC
CCCE
CCEESSO
ESSORIE
SSSSOORIES
SSO
RIIE
RRIE
IES M
MAK
MAKE
AKE IT
AK
AKE
IT YOUR
YOUR
OUURR OW
OU
OOWN
WN

SPORT
ACCES SORIES
UTILITY
ACCES SORIES
WINTER
ACCES SORIES

MAAK
M
MAK
MAKE
AKE
KE IT
IT YOUR
YOOU
YO
OUR
UR OWN
UR
OWN PARTS
OW
PPAAR
PAR
ARTS
TS & ACCESSORIES
ACCCE
AC
CCCCEESSS
SSO
SSO
ORIE
RIES
RI
IES
IE

5

A-ARM PROTECTORS P. 6 / TRAILING ARM PROTECTORS P. 6 / LATERAL SKID PLATES P. 6 /
FRONT SKID PLATE P. 6 / CENTRAL SKID PLATE P. 6 / REAR SKID PLATE P. 6 /
FOX† PERFORMANCE FRONT SHOCKS P. 6 / FOX PERFORMANCE REAR SHOCKS P. 6 / FRONT XT BUMPER P. 7 /
HALF WINDSHIELD P. 9 / SPORT VISOR P. 10 / ROOF MIDDLE SECTION P. 10 /
LIGHT RACK FOR SPORT VISOR P. 11 / HALOGEN OR HID LIGHTS P. 11 / XT SPORT STEERING WHEEL P. 15 /
ROCK SLIDER P. 15 /

A-ARM PROTECTORS P. 6 / TRAILING ARM PROTECTORS P. 6 / LATERAL SKID PLATES P. 6 /
FRONT SKID PLATE P. 6 / CENTRAL SKID PLATE P. 6 / REAR SKID PLATE P. 6 / FRONT XT BUMPER P. 7 /
OFF-ROAD XTREME FRONT-BUMPER P. 7 / FRONT LIGHT PROTECTION P. 7 / FRONT RACK P. 7 /
REAR BUMPER P. 8 / LOWER TAILGATE PROTECTOR P. 8 / XT FENDER FLARES P. 8 / FULL WINDSHIELD P. 9 /
SPORT VISOR P. 10 / ROOF MIDDLE SECTION P. 10 / LIGHT RACK FOR SPORT VISOR P. 11 /
HALOGEN OR HID LIGHTS P. 11 / MULTIMOUNT WINCH KIT P. 13 / FRONT 2” RECEIVER HITCH P. 13 /
RT40 WARN† WINCH KIT P. 14

A-ARM PROTECTORS P. 6 / TRAILING ARM PROTECTORS P. 6 / LATERAL SKID PLATES P. 6 / FRONT SKID PLATE P. 6 /
CENTRAL SKID PLATE P. 6 / REAR SKID PLATE P. 6 / FRONT XT BUMPER P. 7 / OFF-ROAD XTREME FRONT-BUMPER P. 7 /
FRONT RACK P. 7 / REAR BUMPER P. 8 / FULL WINDSHIELD P. 9 / SPORT VISOR P. 10 /
ROOF MIDDLE SECTION P. 10 / LIGHT RACK FOR SPORT VISOR P. 11 / HALOGEN OR HID LIGHTS P. 11 /
SUPER DUTY PLOW P. 12 / MULTIMOUNT WINCH KIT P. 13

6

PARTS
PAARTTSS & ACCESSORIES
ACCCE
AC
CCCCEESSO
SSSSO
SORIE
RIE
RI
IES UND
UUN
UNDERBELLY
NNDDEER
ERB
RB
RBEL
EELL
LLLY PPROTECTION
ROOOTTEECT
RROT
ECCCTTIO
IOONN
ION

UNDERBELLY PROTECTION
FRONT SKID PLATE
Draw-formed 5052-H32 aluminum front skid plate provides
essential protection. 3/16” thick for durability and strength.
Commander, Commander X, Commander XT - 715000692

$159.99

A-ARM PROTECTORS
5052-H32 aluminum A-arm plates and plastic deflectors
provide essential protection and aggressive look.
Engraved Can-Am logo. 3/16” thick for durability
and strength. Sold in pairs.
Commander, Commander X, Commander XT - 715000660

$164.99

LATERAL SKID PLATES
Draw-formed 5052-H32 aluminum lateral skid plates provide
essential protection. 3/16” thick for durability and strength.
Engraved Can-Am logo. Sold in pairs.
Commander, Commander X, Commander XT - 715000950

$229.99

CENTRAL SKID PLATE
5052-H32 aluminum, 3/16” thick. Pre-cut holes for fluid
and mud drainage, and servicing access. Engraved Can-Am logo.
Direct replacement of factory installed plastic skid.
Commander, Commander X, Commander XT - 715000693

$314.99

REAR SKID PLATE
5052-H32 aluminum, 3/16” thick. Provides additional
protection to rear end of vehicle. Engraved Can-Am logo.
Direct replacement of factory installed plastic skid.
Commander, Commander X, Commander XT - 715000694

$114.99

TRAILING ARM PROTECTORS
5052-H32 aluminum trailing arm plates and plastic deflectors
provide essential protection. Engraved Can-Am logo.
3 16
/ ” thick for durability and strength. Sold in pairs.
Commander, Commander X, Commander XT - 715000661

$149.99

FOX PERFORMANCE
FRONT SHOCKS

FOX PERFORMANCE
REAR SHOCKS

Fox Piggyback racing shocks.
Includes rebound and high/low
speed compression adjustments.
Sold in pairs.
715001022

Fox 2.0 Position Sensitive
racing shocks. Includes rebound
and high/low speed compression
adjustments. Sold in pairs.
715001023

$999.99

$1,111.99

AIR INTAKE PRE-FILTER
Add extra protection to your engine in harsh
riding conditions. Filter blocks particles
larger than 0.005”.
715000953

$39.99

BUMPERS PARTS & ACCESSORIES

7

BUMPERS
OFF-ROAD XTREME
FRONT BUMPER
Delivers additional heavy duty protection
that works with or without the front XT
bumper. Textured black electrocoated
for durability and rugged style.
Can-Am logo tag.
Commander, Commander X, Commander XT
715000951

$299.99

FRONT XT BUMPER

FRONT RACK

FRONT LIGHT PROTECTION

Made of heavy gauge steel for additional
protection. XT styled for matching
appearance. Textured black electrocoated
for durability and rugged style.
Effortless mounting.
Commander
715000958

Durable finish for scratch resistant
performance. Equipped with genuine
Can-Am casted clamps for easy
mounting on required XT bumper
(sold separately). Does not limit
access to air filter or cooling.
75 lbs load capacity.
715000985

Works in conjuction with XT bumper,
offering protection to front headlights
and sporting aggressive look. Textured
black electrocoated for durability
and rugged style. Integrated Can-Am
fastening system provides efficient
mounting vs traditional P-clamps.
Commander, Commander X, Commander XT
715000656

$219.99

$299.99

$159.99

RADIATOR PROTECTOR
Black epoxy electrocoated metal shield that mounts over
radiator face to provide protection from stones and branches.
Commander, Commander X, Commander XT
715001126

$64.99

8

PARTS & ACCESSORIES BUMPERS

BUMPERS
LOWER TAILGATE PROTECTOR
Aluminum body plating covering lower tailgate
provides additional protection and aggressive look.
Commander, Commander X, Commander XT except CE version
715001097

$89.99

XT FENDER FLARES
Deliver aggressive look while providing added protection
from dirt and debris. Standard on XT models. Includes front
and rear extensions and all mounting hardware.
715001013

$199.99

REAR BUMPER
Integrated tubular system provides
sporty look while protecting vehicle’s
bodywork. Flips with cargo box
and lower tailgate.
Commander, Commander X, Commander XT
715000657
ALLOWS
ALL
OWS TO OPEN LOWER TAILGATE
TAILGA
GATE
TE

$249.99

XT BOX RAILS
Add integrated tie down area to your cargo box
while enhancing the look. Textured black finish.
715000957

$99.99

WINDSHIELDS PARTS & ACCESSORIES

9

HALF WINDSHIELD
Designed for protection from wind
and debris as well as optical clarity.
This rugged, durable polycarbonate
construction offers better impact resistance
than acrylic windshields. Features reverse
angle lip to deflect air flow. Non yellowing,
non crazing, non cracking and UV resistant
properties. Quick-attach brackets procure
fast, easy and tool-less installation
and removal.
Commander, Commander X, Commander XT
715000954

$229.99

WINDSHIELDS

FULL WINDSHIELD
- HARDCOATED
Combines the utmost in protection
from the elements with optical clarity
while riding. Hardcoated (both sides)
polycarbonate material offers excellent
impact and abrasion resistance, as well
as prolonged protection against
wear-and-tear for longer “like new” look
than acrylic windshields. Non yellowing,
non crazing, non cracking and UV
resistant properties. Quick-attach
brackets procure fast, easy
and tool-less installation.
Commander, Commander X, Commander XT
715001177

$529.99

FULL WINDSHIELD
Designed for optical clarity and better
impact resistance than acrylic windshields
thanks to durable polycarbonate
construction. Non yellowing, non crazing,
non cracking and UV resistant properties.
Quick-attach brackets procure fast, easy
and tool-less installation and removal.
Commander, Commander X, Commander XT
715000664

$369.99

10 PARTS
10
PAAAR
PPAR
RTS
TS & ACCESSORIES
ACC
AC
CCCE
CCEESS
SSSO
SO
SORIE
RIE
IES ROO
RROOF
RO
OOOF AACCESSORIES
CCE
CC
CCEESS
SSSO
SORIES
SO
IEESS

ROOF ACCESSORIES
ROOF MIDDLE SECTION
Ultimate in protection, style and integration.
Twinsheet HDPE manufacturing delivers
premium look, and complete coverage when
combined with Sport Visor. Quick-attach
bracket procures fast, easy and tool-less
installation and removal.
Commander, Commander X, Commander XT
715001176 Yellow
715000655 Black

$499.99

SPORT VISOR
Aggressive designed, twinsheet HDPE
sport visor complete with integrated driver
and passenger inner storage pockets.
Required for installation of Can-Am light
rack system. Complete with integrated light
switch knock outs. Creates full roof for
maximum element protection when combined
with the roof middle section. Easy installation
and removal. Can be used in conjunction
with any windshield.
Commander, Commander X, Commander XT
715000762

$299.99

PANORAMIC CENTER MIRROR
Convex mirror for wide angle visibility. Can be used
with or without roof and windshields. Light switches
not included. Sport Visor sold seperately.
715000956

$74.99

LIGHTS ACCESSORIES PARTS & ACCESSORIES 11

LIGHTS ACCESSORIES

HID LIGHTS
Incomparable and powerful HID long range illumination plug-and-play system
converts night usage into virtually daytime riding. Integrated ballast unit with
3.25” clear glass lens and swivel mounting heavy-duty bracket provides
compact design. Water and dust proof IP67 and IP6K9K. Highest electromagnetic
compatibility rating, i.e. EMC Class 5 according to CISPR 25, for total
disturbance-free electronic operation. Peak light performance with just 35W.
Luminous flux is 2.5 times higher than conventional halogen bulb with 35% less
energy consumption. High vibration resistance with 5 times longer lifetime than
halogen bulb. Constant light intensity even under unsteady power supply
voltage. Includes basic wiring and switch. Works in conjunction with halogen
and/or HID lights separately or in combination without overloading your
charging system. Must be used with Light Rack for Sport Visor (715000910)
and Sport Visor (715000762). Roof Accessories and Light Wiring Kit
(715000987) is required to install the HID lights. Sold in packs of 2.
Commander, Commander X, Commander XT - 715000836

$899.99

HALOGEN LIGHTS
Delivers long range illumination. Integrated ballast unit with 3.25” clear glass
lens and swivel mounting heavy duty bracket provides compact design.
Includes basic wiring and switch. Works in conjunction with halogen and/or HID
lights separately or in combination without overloading your charging system.
Must be used with Light Rack for Sport Visor (715000910) and Sport Visor
(715000762). Roof Accessories and Light Wiring Kit (715000987)
is required to install the halogen lights. Sold in packs of 2.
Commander, Commander X, Commander XT - 715000909

$169.99

LED LIGHT BAR
Plug-and-play 21 LED x 5w 6300 lm system for premium long and close
range illumination. Water and dust proof IP67. Heavy-duty, with 50,000 hrs
durability. Includes basic wiring and switch. Must be used with Light Rack
for Sport Visor (715000910) and Sport Visor (715000762). Roof Accessories
and Light Wiring Kit (715000987) is required to install the LED Light Bar.
Commander, Commander X, Commander XT - 715000976

$849.99

LIGHT RACK FOR SPORT VISOR
Provides Commander side-by-side vehicle with a custom look. Made of rugged aluminum with
a light anodized finish. Essential protection for your accessory lighting systems. Works in
conjunction with LED Light Bar, or halogen and/or HID lights separately or in combination without
overloading your charging system. Fully integrated. Sport Visor (715000762) is required for
installation of the light rack. Lights sold seperately.
Commander, Commander X, Commander XT - 715000910

$149.99

ROOF ACCESSORIES AND LIGHT WIRING KIT
All the necessary hardware, wires, fuses and relay to power your roof lighting
for a clean well routed look. Includes additional output for future roof accessories.
Commander, Commander X, Commander XT - 715000987

$79.99

12 PARTS
12
PAR
PA
ARTTSS & ACCESSORIES
AR
ACCE
CCCCEESSO
SSSOORRIE
SS
RIIES WHE
W
WHEELS
HEEELS
ELSS & PPLOW
LOOW
W

WHEELS
XT 14” WHEELS (SILVER)
Premium cast aluminum rim.
Standard on XT models. Sold individually.
705400632 Front

$124.99
705500965 Rear

$139.99

XT 14” WHEELS (BLACK)
Premium cast aluminum rim with durable
black finish. Standard on XT Camo models.
Sold individually.
705400919 Front

$124.99
705501261 Rear

$139.99

PLOW
SUPER DUTY PLOW
Heavy-duty 12 gauge steel blade
with integrated reinforcement
for maximum durability. Complete plow
system with manual lifting and angling.
Heavy-duty push tubes withstand
the roughest uses. Requires winch
for raising and lowering. Easy install.
Quick disconnect system for fast
installation and removal. Front mount
system provides a minimum of 11”
of lift. Front mount included.
715001140

$999.99
NOTE: Picture shows plow extensions
and drift cutters that are not included
with the plow.

Front mount

Front mount does not reduce clearance and
can be installed with or without front skid plate.

HITCHES & WINCHES PARTS & ACCESSORIES 13

WINCH & HITCH SUPPORT PLATE

FRONT 2” RECEIVER HITCH

MULTIMOUNT TOW

Mounting plate for RT40 Warn winch kit (715000658)
and front 2” receiver hitch (715000663).
Standard on XT models.
715000704

Can be used with a standard 2” draw bar. Complete with integrated
quick locking/release pin for easy installation and removal of draw bar.
Allows for front-mount pulling/pushing or additional accessory
attachments, such as a plow. Winch & hitch support plate (715000704)
is required for installation.
715000663

1.5” bar system, no ball.
Requires multimount
winch kit (715000659).
715001142

$89.99

$44.99

$89.99

MULTIMOUNT WINCH KIT
Enhances vehicle performance
and control during hard cornering.
715001125

For use with RT40 Warn winch kit (715000658). Versatile system that can be easily mounted
at the front or rear of the Can-Am Commander side-by-side vehicle. Complete with Can-Am plug-and-play
front and rear wire harness. Ergonomic branded handle makes it easy to carry from front to rear.
Front 2” receiver hitch (715000663) is required for installation. Integrated receiver allows for use
with multimount tow (715001142), not included.
715000659

$479.99

$299.99

FRONT SWAY BAR

HITCHES & WINCHES

14 PARTS
14
PPAART
PAR
ARTS & ACCESSORIES
ACCCE
CE
CESS
SSO
SSO
SORRIE
IES HIT
IE
HHITCHES
ITTCHES
E & WINCHES
WIN
INNCCH
CHES
ES

HITCHES & WINCHES
SYNTHETIC
WINCH CABLE
50 feet of 7/32” synthetic cable
for RT40 Warn winch kit.
NOTE: Replacing a wire rope
with synthetic cable also requires
changing the fairlead to avoid
damage and wear to the new
synthetic cable from the rough
surface of the old fairlead.
715001118

$119.99

SYNTHETIC
CABLE EXTENSION
Lightweight 1/4” diameter,
easy to handle and won’t rattle
in cargo box. Easily attaches
to winch cable to provide
additional 50’ of distance.
4,000 lbs single line capacity.
715001120

$129.99

WIRE ROPE REPLACEMENT
55 feet of 7/32” wire rope
for RT40 Warn winch kit.
715001117

$64.99

ROLLER FAIRLEAD
Heavy-duty replacement fairlead
for RT40 Warn winch kit.
715001119

$119.99

RT40 WARN WINCH KIT

WIRELESS REMOTE CONTROL

Fully-sealed, capable of 4,000 lbs pulling strength. Includes 1.5hp
motor, 55 feet of 7/32” wire rope, ergonomically designed clutch knob,
mechanical brake, hand-held remote and integrated dash switch,
waterproof contactor and roller fairlead. CE certified.
715000658

The system is quick and easy to install, thanks to a wiring harness
with an integrated antenna, and all necessary mounting hardware.
The system allows you to operate your winch from anywhere within
a 50’ (15 m) radius, increasing your recovery options. All components
are weatherproof.
715000544

$669.99

$164.99

MUL
MU
M
MULTI-FIT
UULLTI
TTIII--FFI
FIT
IITT PARTS
PAAARRTTSS & AACCESSORIES
PPAR
CCCE
CC
CESSSO
CE
SSSSOORIE
RIEES 15
15

MULTI-FIT

XT SPORT STEERING WHEEL
Polyurethane soft-touch black grip highlighted
with silver spokes. Standard on XT and X models.
715001134

$149.99

TRAILERING AND STORAGE COVER
Can-Am branded 300-denier solution-dyed, water repellent polyester construction.
Fits with or without roof, light rack, front rack, light protector, rear bumper, extreme
bumper, side mirrors. Has trap for fuel, access to cargo box and passenger area.
Heavy duty cord around bottom for secure fit. Features soft material in the windshield
area to prevent scratches while trailering.
715001025

$279.99

REAR WIND SCREEN
Full rear mesh coverage reduces backdraft when windshield is installed.
Mounts to roll bar. White Can-Am logo on black mesh.
715001193

$69.99

LOCKABLE GAS CAP
Protects your fuel. Meets latest
EPA requirements.
715001124

$44.99

LOCK FOR TAILGATE
Device locks lower tailgate. Includes key.
715001127

$29.99

WORK KEY
(Not illustrated)
Key limits vehicle speed to
25 mph for use on construction
sites
715001201

$44.99

ROCK SLIDER
Protects vehicle’s sides and undercarriage against large obstacles.
Textured black electrocoated for durability. Standard equipment
on Commander X model.
Commander, Commander XT - 715001014

$259.99

16 RIDING GEAR

RACE

RACE

Yellow (10)

Green (70)

White (01)

X RACE JERSEY
Very light, quick-dry, antibacterial, moisture-wicking fabric. Mesh panels
at front, back and armholes for maximum breathability. Extended back
for coverage while riding. Non-fading sublimated graphics.
100% Polyester — Sizes: M, L, XL, 2XL
286193 - White (01), Yellow (10), Green (70)

FOR RACE INSPIRED RIDERS
WHO WANT TO RIDE LIKE
PROS. HIGH PERFORMANCE,
MULTIFUNCTIONAL GEAR
FEATURING THE BOLD TEAM
LOOK THAT HAS PODIUM-FINISH
RIDE WRITTEN ALL OVER IT.

$59.99
Back

Yellow (10)

Green (70)

Black (90)

X RACE PANTS
Lightweight and extremely breathable pants for riders seeking peak
performance, toughness and a competitive edge. Strong nylon outer shell.
Overall water-repelling Teflon® treatment, and light colors Teflon
HT-treated for water and stain resistance. 3/4 length mesh lining.
Can-Am sublimated stretch panel on sides. Double- and triple-stitched
construction for enhanced durability. Inner knee debossed fullgrain leather
for heat and abrasion resistance. Stretch panel at crotch, knee, back and
lower back leg for ease of movement. Rubberized elastic waist to hold
jersey in place. Ratchet-style waist closure for better adjustment. Straight
hem at leg opening for better in-boot comfort.
Shell: 54% Nylon, 41% Polyester, 5% Genuine Leather — Sizes: 30, 32, 34, 36, 38, 40
286194 - Yellow (10), Green (70), Black (90)

$159.99

White (01)

Charcoal Grey (07)

X RACE CAP
Fitted stretch twill cap with all-over pattern. X-Team rubber patch at front.
98% Cotton, 2% Spandex — Sizes: S/M, L/XL
286196 - White (01), Charcoal Grey (07)

$19.99

RAC
RACE
CE

RIDIN
RID
RIDING
ING GEAR
GEEAR 177

MATCHING
PRODUCT
X RACE GLOVES

White (01)

Designed for coverage and flexibility.
Hook-and-loop wrist closure system.
Pre-curved design for improved fit.
Air mesh panels for ventilation and
mobility. Perforated palm for
ventilation. Direct injection details
on backhand. Silicone fingertip for
added grip and control. Double
Clarino layer at palm and thumb for
extra durability and comfort. Knuckle
gussets for better mobility.
Shell: Air Mesh, Spandex, Clarino†
Sizes: S, M, L, XL, 2XL
286195 - White (01), Yellow (10), Black (90)
Yellow (10)

Black (90)

$37.99

CAN-AM ATV XP-2 X RACE HELMET

SEE P.34

188 RIDING
RID
IDDIN
IING
NNGG GGE
GEAR
EAR

RACE
RAC
RA
RAC
ACE

TEAM JERSEY
Quick-dry, antibacterial,
Microbox moisture-wicking
fabric. Mesh at underarms.
Non-fading sublimated
graphics that match
perfectly with Team Riding
pants. Drop-tail.
100% Polyester
Sizes: S, M, L, XL, 2XL
286216 - Black (90),
Matte Black (93)

$49.99

Matte Black (93)

Black (90)

TEAM RIDING PANTS
Ultimate-ride design.
Lightweight and durable.
Breathable, waterproof nylon
shell. 500 denier nylon
at seat for extra durability.
Double- and triple-stitched
construction for added
toughness. Sealed critical
seams. Zipper ventilation on
thigh. 3/4 length mesh lining.
Stretch panel at lower back
for ease of movement.
Water-resistant stretch panel
at crotch. Binding hem
for reinforcement. Two hip
pockets. Quick-release front
closure buckle adjustment.
Connector attaching pants
to Can-Am Riding jacket to
prevent jacket from riding up.
Shell: 100% Nylon
Sizes: 30, 32, 34, 36, 38, 40
286138 - Charcoal Grey (07),
Black (90)

$139.99

RACE

Charcoal Grey (07)

Black (90)

MATCHING
PRODUCT
TEAM RIDING GLOVES
Hook-and-loop wrist closure system.
Spandex construction for good
mobility. Pre-curved design for
improved fit. Direct-injection patches
on back hand. Chamude palm.
Shell: Spandex, Chamude
Sizes: S, M, L, XL, 2XL
286139 - Charcoal Grey (07), Black (90)

$26.99

Charcoal Grey (07)

Black (90)

CAN-AM ATV XC
XC-11 HOLESHOT HELMET

SEE P34
P.34

RRAC
RACE
AAC
CE

RID
RI
RID
RIDING
IDING
INNG
NG GEAR
GGEEAR 19
19

RACE

Brown (04)

Yellow (10)

Black (90)

CAN-AM RIDING JACKET
Highly resistant, Teflon HP-treated nylon with RPM waterproof, breathable technology.
Double stitch construction throughout. Mesh lining. Sealed critical seams. Shaped sleeves.
Double front flap and adjustable wrist, hem and collar. Removable panel at underarm plus
additional ventilation at back for maximum airflow. Interior zippered pocket. Two 3-D
pockets at chest plus two hip pockets. Can-Am sonic-injection logo at chest; yellow version
features X-Team logo. Reflective Can-Am logo at center back. Connector attaching jacket
to Team Riding or Can-Am Cross pants to prevent jacket from riding up.
Shell: 100% Nylon — Sizes: XS, S, M, L, XL, 2XL
286143 - Brown (04), Yellow (10), Black (90)

$159.99

TEAM CAP
X-Team rubber patch with rubber details
on peak. BRP metal adjuster at back.
100% Cotton — One size
286142 - Charcoal Grey (07), Black (90)

$19.99
Charcoal Grey (07)

Back

MUD JACKET
100% waterproof
translucent PVC.
Electronically-welded
seams. Underarm
and rear vent panels.
Drawstring hood and
hem. Elastic cuffs.
Two hand pockets.
Sizes: S, M, L, XL, 2XL
286127 - Clear (00)

$28.99

MUD PANTS
Oversized pants made of 100% waterproof
translucent PVC. Electronically-welded seams.
Strategic ventilation. Side openings at bottom leg.
Sizes: S, M, L, XL, 2XL
286128 - Clear (00)

$12.99

20 RIDING GEAR

RACE

White (01)

Turquoise (Aqua) (76)

LADIES’ TEAM JERSEY
Specific fit and design for ladies. Stretch, quick-dry, antibacterial,
moisture-wicking fabric for maximum comfort. Fitted cut with
non-fading sublimated graphics. Small cuff. V-neck.
94% Polyester, 6% Spandex — Sizes: S, M, L, XL, 2XL
286222 - White (01), Turquoise (Aqua) (76)
Back

$49.99

White (01)

Charcoal Grey (07)

LADIES’ TEAM PANTS
High-tech femine design fit for hard-riding. Lightweight and durable. Breathable,
waterproof nylon shell. 500 denier nylon at seat for extra durability. Double- and
triple-stitched construction for added toughness. Sealed critical seams. Side leg
zipper ventilation. 3/4 length mesh lining. Water-resistant stretch panel at crotch.
Reinforced binding hem with zipper to facilitate exit and entry. 2 hip pockets.
Padded, shaped knees.
Shell: 100% Nylon — Sizes: 5-6, 7-8, 9-10, 11-12, 13-14
286148 - White (01), Charcoal Grey (07)

$139.99

White (01)

Turquoise (Aqua) (76)

LADIES’ STRIPES CAP
Herringbone twill cap. Rubber Can-Am logo with contrasting appliqué
stripes. Metal adjuster with BRP logo.
100% Cotton — One size
286150 - White (01), Turquoise (Aqua) (76)

$19.99

RACE

RIDING GEAR
RIDING
GE R 21
21

RACE

MATCHING
PRODUCT
LADIES’ TEAM GLOVES
Pre-curved design for an
improved fit. Air mesh panel
for maximum ventilation and
mobility. Hook-and-loop wrist
closure system. Direct
injection details on back
hand. Silicone fingertips for
added grip and control.
Double Clarino layer at palm
and thumb for extra durability
and comfort.
Shell: Air Mesh, Spandex, Clarino
Sizes: S, M, L, XL
286149 - White (01),
Turquoise (Aqua) (76)
White (01)

Turquoise (Aqua) (76)

$32.99

PRO CROSS XP-R CARBON LIGHT HELMET

SEE P.35

22 RIDING GEAR

ADVENTURE

Brown (04)

Yellow (10)

Black (90)

CAN-AM RIDING JACKET

Back

Highly resistant, Teflon HP-treated nylon with RPM waterproof, breathable
technology. 500 denier nylon at hem and double stitch construction
throughout. Mesh lining. Sealed critical seams. Shaped sleeves. Double front
flap and adjustable wrist, hem and collar. Removable panel at underarm plus
additional ventilation at back for maximum airflow. Interior zippered pocket.
Two 3-D pockets at chest plus two hip pockets. Can-Am sonic-injection logo
at chest. Reflective Can-Am logo at center back. Connector attaching jacket
to Team Riding or Can-Am Cross pants to prevent jacket from riding up.
Shell: 100% Nylon — Sizes: XS, S, M, L, XL, 2XL
286143 - Brown (04), Yellow (10), Black (90)

$159.99

CAN-AM CROSS PANTS
Lightweight durable pants Teflon HP-Treated with
RPM waterproof and breathable technology.
500 denier waterproof nylon at crotch and seat
plus triple seams at crotch. Sealed critical seams.
Side leg zipper ventilation. Perfectly-positioned
flaps to protect all openings from infiltration. Mesh
lining. Binding hem at cuff for reinforcement
with zipper to facilitate exit and entry. 2 practical
cargo pockets with folded flaps. Cell phone pocket
inside right cargo pocket. Belt loops. Connector
attaching pants to Can-Am Riding Jacket to prevent
jacket from riding up.
Shell: 100% Nylon — Sizes: 30, 32, 34, 36, 38, 40
286126 - Black (90)

$139.99

MATCHINGG
PRODUCTT
TEAM RIDING GLOVES

TRAIL GLOVES

SEE P.26

Hook-and-loop wrist closure system. Spandex
construction for good mobility. Pre-curved design
for improved fit. Direct-injection patches on back
hand. Chamude palm.
Shell: Spandex, Chamude† — Sizes: S, M, L, XL, 2XL
286139 - Charcoal Grey (07)

$26.99

AADDV
ADV
ADVENTURE
DVEN
ENT
NTURE
TUURE
RE
RE

RIDING
RIIDDING
RID
DING
INNG
NG GEAR
GGEEAR 233

ADVENTURE

DESTINATION RIDERS
LOOK FOR ULTIMATE
COMFORT FOR DRIVER
AND PASSENGER.
WEATHERPROOF
AND RUGGED TO
ENHANCE THE RIDE
TO YOUR FAVOURITE
SPOT OR SPORT.

LADIES’ CAN-AM
CROSS PANTS

Back

LADIES’ CAN-AM RIDING JACKET
Highly resistant, Teflon HP-treated nylon with RPM
waterproof, breathable technology. 500 denier
nylon at hem and double stitch construction
throughout. Mesh lining. Sealed critical seams.
Shaped sleeves. Double front flap and adjustable
wrist, hem and collar. Long ventilation at side and
underarm, plus additional ventilation at back for
maximum airflow. Interior zippered pocket.
Can-Am sonic-injection logo at chest and reflective
tribal print. Reflective Can-Am logo at center back.
Connector attaching jacket to Team Riding
or Can-Am Cross pants to prevent jacket from
riding up. Gusset at back armhole for comfort.
Brushed polyester at inner collar, pocket and
wrist for extra comfort.
Shell: 100% Nylon — Sizes: XS, S, M, L, XL, 2XL
286201 - Black (90)

$159.99

Lightweight durable pants,
Teflon HP-treated nylon
with RPM waterproof and
breathable technology.
500 denier waterproof
nylon at crotch and seat.
Sealed critical seams.
Side leg zipper ventilation.
3 4
/ length mesh lining.
Binding hem at cuff for
reinforcement with zipper
to facilitate exit and entry.
Two zippered hip pockets
with flaps. Connector
attaching pants to Can-Am
Riding Jacket to prevent
jacket from riding up.
Shell: 100% Nylon
Sizes: 5-6, 7-8, 9-10, 11-12, 13-14
286267 - Black (90)

$139.99

24 RIDING
24
RIDDING
DINNG GE
GGEAR
EAR

ADVENTURE
AD ENT
AD
ADV
NNTTURE
RE
RE

ADVENTURE

TEAM JERSEY

Back

RAIN JACKET
Teflon HP-treated nylon.
Sealed critical seams.
Double front flap to
protect against water
and air infiltration.
Underarm ventilation.
Adjustable wrists
and hem. Two exterior
and one interior zippered
pockets. Reflective logos.
Shell: 100% Waterproof
Ripstop Nylon
Sizes: S, M, L, XL, 2XL
440416 - Black (90)

$84.99

Quick-dry, antibacterial, Microbox
moisture-wicking fabric. Mesh at
underarms. Non-fading sublimated
graphics that match perfectly
with Team Riding pants. Droptail.
100% Polyester — Sizes: S, M, L, XL, 2XL
286216 - Matte Black (93)

$49.99

TEAM RIDING PANTS
Teflon HP-treated
nylon. Sealed critical
seams. Two zippered
hip pockets. Short
zipper at calf to
facilitate exit and entry.
Belt loops. Reflective
logos and details.
Shell: 100% Waterproof
Ripstop Nylon
Sizes: S, M, L, XL, 2XL
441416 - Black (90)

Ultimate-ride design. Lightweight and durable.
Breathable, waterproof nylon shell. 500 denier
nylon at seat for extra durability. Double- and
triple-stitched construction for added toughness.
Sealed critical seams. Zipper ventilation on
thigh. 3/4 length mesh lining. Stretch panel at
lower back for ease of movement. Water-resistant
stretch panel at crotch. Soft inner waist for
increased comfort. Binding hem for reinforcement.
2 hip pockets. Quick-release front closure buckle
adjustment. Connector attaching pants to Can-Am
Riding jacket to prevent jacket from riding up.
Shell: 100% Nylon
Sizes: 30, 32, 34, 36, 38, 40
286138 - Charcoal Grey (07)

$74.99

$139.99

RAIN PANTS

ADVENTURE

RIDING GEAR 25

ADVENTURE

Back

QUADRUPLE FRONT FLAP

WINTER JACKET
Modern angular design. Robust textured fabric featuring RPM MAX
waterproof, windproof and breathable technology. All seams and logos sealed
for added protection from water. Quadruple front flap uniquely designed for
windproofness while riding. Vents at underarm and back to enhance moisture
evacuation during rigorous riding or mild temps. Adjustable fleece-lined
chin-cushioned collar, wrists and sides. Soft micro-fleece inner cuffs. Shaped
sleeves for unencumbered movement. Powder skirt to keep wind, cold and
snow from riding up. MP3, cell phone, cap inner pockets. Easy-access
Napoleon pocket. Reflective details.
Shell: Nylon — Insulation: PRIMALOFT CRESTA
Sizes: S, M, MT, L, LT, XL, XLT, 2XL
286253 - Black (90)

$299.99

WINTER HIGHPANTS
RPM MAX waterproof, windproof and breathable technology. All seams
and logos sealed for added protection from water. Intelligent combination
of materials specifically adapted to warmth, weatherproofing and comfort
standards required for off-road winter riding. Lightweight and versatile. Composite
insulation for extra warmth at seat and knees. 600 denier nylon seat, knees
and inner legs. Pads at knees for durability. Accordion knees and pre-shaped
legs for unencumbered movement. Bib style pants with high back and front
to keep wind and snow out. Storm gaiter. Reinforced topstitch at back rise.
Full-length side zip. Easy-access thigh pocket. Reflective ankle detail.
Shell: 100% Nylon — Insulation: Primaloft Cresta — Sizes: S, M, MT, L, LT, XL, XLT, 2XL
286254 - Black (90)

$249.99

CAN-AM WINTER
RIDING GLOVES

CAN-AM WINTER
RIDING MITTS

Extra warm nylon, leather palm.
Adjustable insulation with
removable antibacterial, stay-dry
moisture management lining.
Visor-wiping cotton terry left thumb
for clearing water, snow or fog
(also effective on goggles and face).
Large gauntlet with adjustable
wrist. Reflective details.
Shell: Nylon, Leather
Insulation: Primaloft One
Sizes: S, M, L, XL, 2XL
286204 - Black (90)

Extra warm nylon mitts with leather
palm. Adjustable insulation with
removable lining. Antibacterial,
stay-dry moisture management lining.
Reinforced non-slip palm. Visor
wiper. 5.5” (14 cm) gauntlet with
adjustable wrist. Reflective details.
Shell: 100% Nylon
Insulation: Primaloft One
Sizes: S, M, L, XL, 2XL
286257 - Black (90)

$84.99

$74.99

26 RIDING GEAR

RECREATIONAL

PANTS-IN-POUCH

BAYOU PANTS
Waterproof DWR-treated nylon
fabric. Double layer and triple
topstitch at seat for durability.
Sealed critical seams.
Pre-shaped leg. Adjustable
suspenders. Storm gaiters at
bottom opening. Adjustable
waist. Two cargo pockets
with flap and gusset at front
opening to prevent water
intrusion. Gusset at crotch
to facilitate movement.
Can-Am print at left leg.
Elastic at bottom leg
to prevent pants from riding
up. Pants-in-pouch folds into
inner pocket for easy traveling.
Shell: 100% Nylon
Sizes: S, M, L, XL, 2XL
286265 - Charcoal Grey (07)

BAYOU JACKET

Back

Waterproof DWR-treated nylon fabric.
Wide reflective stripes on shoulder for better
visibility. Back ventilation for moisture
evacuation. Sealed critical seams. Pre-shaped
sleeves. Bellows pocket at left chest.
Two Velcro† waist pockets with flap to prevent
water intrusion. Jacket-in-pouch folds into
a back pocket for easy traveling. Cozy collar.
Water deflecting double layer storm flaps.
Adjustable wrists and hem. Inner pocket.
Can-Am print at front and back.
Shell: 100% Nylon — Sizes: S, M, L, XL, 2XL
286264 - Charcoal Grey (07)

$99.99

$119.99
JACKET-IN-POUCH

TRAIL GLOVES
Comfortable and flexible gloves.
Leather reinforcements at
fingers, palm and backhand for
extra durability. Hipora insert at
backhand to add water resistance
without compromising grip
at palm. Pre-curved design
for improved fit. Clarino† at palm
and thumb. Inverted seams
at fingers for better comfort.
Shell: Air Mesh, Spandex, Clarino†
Sizes: S, M, L, XL, 2XL
286268 - Black (90)

$37.99

CAN-AM CANVAS PANTS
Durable 12 oz polyester-cotton blend canvas. Fabric treated with water
repellent, stone-washed for softness and comfort. Durable triple needle
stitching and bar tacks at stress points. Double layer at knee. Gusset
at crotch to facilitate movement. Higher back waist and shaped legs
for better riding comfort. Velcro cargo and back pockets. Can-Am
embroidery on back pocket. Belt loops.
65% Polyester, 35% Cotton — Sizes: 30, 32, 34, 36, 38, 40
286266 - Warm Grey (15)

$59.99

MATCHING
PRODUCT

CAN-AM ST-3 HELMET

SEE P.36

RECREATIONAL

RIDING GEAR 27

RECREATIONAL

APPAREL FOR WORK
AND PLAY RIDING
THAT DELIVERS
GOOD VALUE FOR
THE MONEY AND
COVERS ALL THE
BASICS. RUGGED
AND RELIABLE
FOR BIG PLAIN FUN!

Back

MUD JACKET

MUD PANTS

New matte black opaque version.
100% waterproof PVC. Electronically-welded
seams. Underarm and rear vent panels.
Drawstring hood and hem. Elastic cuffs.
Two hand pockets. Can-Am logo at front left
chest and upper back vent.
Sizes: S, M, L, XL, 2XL
286127 - Matte Black (93)

New matte black opaque version.
Oversized pants made of 100%
waterproof PVC. Electronicallywelded seams. Strategic
ventilation. Side openings
and Can-Am logo at bottom legs.
Sizes: S, M, L, XL, 2XL
286128 - Matte Black (93)

$28.99

$12.99

28 RIDING
28
RI ING
RID
NGG GEA
GGEAR
EAR

SPORTSWEAR
SPO
SP
POORT
RTSWE
WEA
EAAR
EAR

CAN-AM X RACE POLO
Quick-dry, antibacterial,
moisture-wicking fabric.
3-button front placket.
Sublimated non-faded Can-Am
and sponsor logos. Side slits.
100% Polyester — Sizes: S, M, L, XL, 2XL
286206 - White (01), Black (90)

CAN-AM ZIPPED HOODY
Full-zip hooded sweatshirt. Ribbed waistband and cuffs.
Embossed Can-Am logos on yellow stripe.
80% Cotton, 20% Polyester — Sizes: S, M, L, XL, 2XL
286209 - Black (90)

Black (90)

Back

$54.99

$59.99

Navy (89)

Black (90)

CAN-AM AUTHENTIC CREWNECK

CAN-AM TECHNICIAN SHIRT

Crewneck sweatshirt. Ribbed collar, waistband
and cuffs. Vintage crackled logo print.
80% Cotton, 20% Polyester
Sizes: S, M, L, XL, 2XL, 3XL
286208 - Charcoal Grey (07)

Cotton twill shirt. Chest pockets. X-Team rubber patch
at front. Large X-Team embroidery at back. Snap
placket. Embroidered sponsor logos on sleeves.
100% Cotton — Sizes: S, M, L, XL, 2XL, 3XL
286205 - Navy (89), Black (90)

$49.99

Back

$59.99

SPORTSWEAR

RIDING GEAR 29

RENEGADE TEE

CAN-AM BELT

Discharged print at front with
Can-Am logo on right sleeve.
100% Cotton — Sizes: M, L, XL, 2XL
286189 - Black (90)

Leather belt with vintage inspired
metal Can-Am buckle.
100% Leather — Sizes: M, L, XL
286153 - Black (90)

$24.99

$42.99

White (01)

Charcoal Grey (07)

Black (90)

DS TEE
Printed logo at front, X-Team logo on left sleeve
and “critter” at back bottom.
100% Cotton — Sizes: M, L, XL, 2XL
286188 - White (01), Charcoal Grey (07), Black (90)

$24.99

Ice (38)

CAN-AM X-TEAM TEE

Green (70)

Black (90)

Black (90)

CAN-AM AUTHENTIC TEE

Can-Am X-Team graffiti print at center front.
100% Cotton — Sizes: M, L, XL, 2XL
286191 - Green (70), Blue (80), Black (90)

Cool Can-Am vintage crackled logo on chest. Garment
enzyme washed for soft and vintage handfeel.
100% Cotton — Sizes: M, L, XL, 2XL
286190 - Ice (38), Black (90)

$24.99

$19.99

30 RIDING
30
RID
DING
G GE
GEAR
EAR

SPORTSWEAR
SPPPOORTS
SSPO
RTSWEA
WEA
WE
EAR

CAN-AM CLASSIC CAP

Charcoal Grey (07)

Black (90)

Light ultra-comfortable stretch fabric.
3-D Can-Am embroidery at front.
Metal adjuster with BRP logo.
72% Polyester, 23% Rayon, 5% Spandex
One size
286210 - Charcoal Grey (07), Black (90)

$19.99

Green (70)

Black (90)

CAN-AM TRACK CAP
Stretch cotton brushed twill hat. Can-Am
logo embossed on right front panel. Can-Am
rubber logo. 2 contrast stripes on brim.
98% Cotton, 2% Spandex
Sizes: S/M, L/XL
286212 - White (01), Green (70), Black (90)

$19.99

Grey (09)

Black (90)

CAN-AM AUTHENTIC CAP
Adjustable canvas hat. Vintage logo
embroidered at front. Metal adjuster
with BRP logo.
100% Cotton — One size
286211 - Fire Red (06), Grey (09), Black (90)

$19.99

CAN-AM COOLMAX
TECHNICAL SOCKS
Below-knee length with varied thicknesses
for comfort. Ribbed top. Moisture-wicking
Coolmax† at foot to keep riders cool and
dry. Spandex and nylon for comfort and
durability. Elasticized ankle and foot arch
for secure comfort and fit.
40% Coolmax, 27% Acrylic, 25% Cotton,
5% Nylon, 3% Lycra — Sizes: S/M, L/XL
286154 - Black (90)

CAN-AM SUMMER BEANIE
Lightweight, texturized knitted beanie
with “X” integrated logo and woven
Can-Am label appliqué.
95% Cotton, 5% Spandex — One size
286156 - Black (90)

$14.99

$24.99

TEEN & KIDS

TEEN RACE JERSEY

TEEN TEAM RIDING GLOVES

Made from quick-dry, antibacterial, moisture-wicking fabric.
Extended back for riding position. Sublimated print.
100% Polyester — Sizes: 7-8, 10-12, 14-16
286202 - Yellow (10)

Hook-and-loop wrist closure system. Spandex construction
for good mobility. Pre-curved design for improved fit.
Direct-injection patches on back hand. Chamude palm.
Shell: Spandex, Chamude — Sizes: 6-8, 10-12, 14-16
286203 - Black (90)

$44.99

$26.99

KIDS’ CAN-AM TEE
Can-Am ATV cartoon print at front.
100% Cotton — Sizes: 2, 3-4, 5-6
286260 - Blue (80)

$19.99

SPOORTS
SPO
SPORTSWEAR
RTS
T W
WEEAR
WEA
AR

RRID
RIDING
IDING
ID
INNNG
G GEAR
G AR 31
GE

LADIES’ AUTHENTIC T-SHIRT
Fitted t-shirt. V-neck with vintage crackled print at front.
95% Cotton, 5% Spandex — Sizes: S, M, L, XL
286263 - White (01), Black (90)

$19.99
White (01)

LADIES’ X-TEAM T-SHIRT
Fitted feminine t-shirt. X-Team logo at chest.
95% Cotton, 5% Spandex — Sizes: S, M, L, XL
286262 - White (01), Charcoal Grey (07)

$24.99

Charcoal Grey (07)

LADIES’ X-TEAM POLO

Back

LADIES’ CAN-AM MICRO-FLEECE HOODIE

Semi-fitted polo with contrasting placket. X-Team logo
printed at chest. Can-Am outline embroidery at back.
95% Cotton, 5% Spandex — Sizes: S, M, L, XL
286261 - Charcoal Grey (07)

Asymmetrical neck opening on a hooded feminine-fit micro-fleece.
Contrast cord, hood lining, pocket flaps and logo. Can-Am logo
appliqué on left sleeve. Two pockets.
100% Polyester — Sizes: S, M, L, XL, 2XL
286200 - Charcoal Grey (07)

$34.99

$59.99

32 RIDING GEAR

BAGS & GOGGLES

CAN-AM PRO GEAR BAG
FULL FACE HELMET CASE
Water-resistant shell biofoam construction. Self-healing nylon
zippers. Quick-access spare faceshield storage. External legs for
vertical storage. Interior scratch-proof inner surface. Ergonomic
soft-touch rubber carrying handle.
One size
445856 - Black (90)

Designed and built for consummate riding. Protective helmet
compartment, water-tight drained boot compartment, dry-mat
and cavernous center compartment, tool compartment. Inline
wheels and pull-handle for maximum portability.
One size
286214 - Black (90)

$189.99

$46.99

CROSS HELMET CASE

CAN-AM WEEKENDER DUFFLE BAG

Water-resistant EXO shell biofoam construction. Self-healing nylon
zippers. Quick-access spare faceshield storage. External legs for
vertical storage. Interior scratch-proof inner surface. Ergonomic
soft-touch rubber carrying handle.
One size
445857 - Black (90)

Designed for day trips or extended outings.
One size
286213 - Black (90)

$44.99

$46.99

CAN-AM X-TEAM GOGGLES BY SMITH†
Hinged strap for excellent fit. Comes with mirrored and clear
lenses. Includes tear-off posts. Large flexible frame. Fast
absorption technology 3-layer hypoallergenic face foam.
Double wide silicone-backed strap. Mask positioning system.
One size
447310 - White (01), Orange (12)

$94.99

PRO CAN-AM GOGGLES WITH
QUICK-STRAP BY SMITH

PRO CAN-AM GOGGLES BY SMITH

Same features as Pro Can-Am goggles plus
quick-strap.
One size
445874 - Black (90)

Flexible frame. 2-layer hypoallergenic face
foam. Double wide silicone-backed strap.
Clear Lexan† lens. Optional mask available.
One size
445873 - Yellow (10), Black (90)

$64.99

$53.99

HELLMETSS
HE
HELMETS

RRIDING
IDIN
ING GE
GEA
GEAR
AR 333

HELMETS

34 RIDING GEAR

HELMETS

XP-2 / XC-1

Red (30)

Yellow (10)

Green (70)

CAN-AM ATV XP-2 X RACE HELMET

CAN-AM ATV XC-1 HOLESHOT HELMET

Fiberglass/Kevlar matrix shell: high-tech, lightweight and tough. Fully-adjustable,
aero-tuned visor that reduces lift at high speeds. Ventilation system. Moisture-wicking
and breathable chin strap, liner and cheek pads. Easily removable and washable liner
and cheek pads. Provides maximum visibility, fits all goggles. Strap grip keeps goggle
strap in place. Clear coated bold waterslide graphics. Snell M2005 and D.O.T. certified.
Shell: Lightweight Fiberglass/Kevlar† — Sizes: XS, S, M, L, XL, 2XL
447407 - Grey (09), Yellow (10)

Advanced Polycarbonate Composite shell: lightweight and tough. Fully-adjustable,
aero-tuned visor that reduces lift at high speeds. Ventilation system. Moisture-wicking
and breathable chin strap, liner and cheek pads. Easily removable and washable liner
and cheek pads. Provides maximum visibility, fits all goggles. Strap grip keeps goggle
strap in place. Clear coated bold waterslide graphics. Snell M2005 and D.O.T.
certified. Two Can-Am stickers included.
Shell: Polycarbonate Composite — Sizes: XS, S, M, L, XL, 2XL
447406 - Yellow (10), Red (30), Green (70)

$199.99

$139.99

REPLACEMENT PEAKS
(Not illustrated)
One size

CROSS HELMET (2008)

CROSS CRITTER HELMET

445909 - Black with graphics (94)

447297 - Black with graphics (94)

$21.99

$21.99

PRO CROSS HELMET (2008)
445914 - Black with graphics (94)

X RACE PRO CROSS
XP-2 HELMET

$21.99

447408 - Grey (09), Yellow (10)

CAN-AM ATV CROSS HELMET

$21.99

445933 - Black (90)

CAN-AM ATV XC-1 HELMET
Advanced Polycarbonate Composite Shell: lightweight and tough. Fully-adjustable, aero-tuned
visor that reduces lift at high speeds. Ventilation system. Moisture-wicking and breathable
chin strap, liner and cheek pads. Easily removable and washable liner and cheek pads.
Provides maximum visibility, fits all goggles. Strap grip keeps goggle strap in place.
Snell M2005 and D.O.T. certified.
Shell: Polycarbonate Composite — Sizes: XS, S, M, L, XL, 2XL
445960 - Black (90)

$129.99

$19.99

MECHANITUNE
PRO CROSS HELMET

HOLESHOT CROSS
XC-1 HELMET
447409 - Yellow (10), Red (30), Green (70)

$21.99

$21.99

PRO CROSS XP-R
CARBON LIGHT HELMET

TEAM CROSS HELMET

447434 - Black (90)

447295 - Silver (08)

447296 - Yellow (10), Pink (36)

$21.99

$29.99

XP-R

HEELLMET
HEL
HE
HELMETS
ES

RRID
RIDING
IDDIN
ING
NG
G GE
GGEAR
GEA
EAR 35
35

25% LIGHTER

THAN ALL OTHER HELMETS
IN ITS CATEGORY
PRO CROSS XP-R
CARBON LIGHT HELMET

Our best-of-the-best M.D.C.F.
(Multi Directional Carbon Fiber)
lightweight helmet with carbon
and aramid fiber reinforced shell
(weight: +/- 1275g for “L” size).
EPS foam upper insert between inner
fabric and outer shell for optimized
user protection.
Integrated rear fin for added stability
and aerodynamic performance.
Tool-less multi adjustable wide angle
front peak with anti-reflecting sticker
just below to deflect glare.
Large flexible nose protector for better
protection.
Double D racing buckle, anti-slip goggle strap,
pocket for sweat absorbent front pad.
Removable and washable cheek
and head pads.
Morpho System Plus - Ergonomic 3D
cheek pads available in your size.
Surround comfort sanitized treated interior
with Coolmax moisture wicking action.
F.A.S. (Full Air System) with 10 ventilation
points and double rear extractor.
Aluminum screws, protective coated parts.

CARBON FIBER TEXTURE

Ergonomic helmet bag.
D.O.T. and ECE 22.05 certified.
Shell: 100% Carbon Fiber Composite — Sizes: XS, S, M, L, XL
447412 - Black (90)

$449.99

SWEAT ABSORBENT PADS

PRO CROSS XP-R MORPHO KIT CHEEK PADS

One size
447435 - White (01)

Left and right cheek pads included.
Sizes: M, L, XL, 2XL, 3XL
447436 - Clear (00)

$7.99

$14.99

36 RIDING
36
RIIIDDIIN
RRID
ING
NG GEA
GGE
GEAR
EAR

HELMETS
HEELLME
MET
M
ETS
ET

ST-1 / ST-3

CAN-AM ST-1 HYBRID HELMET
Multiple functionalities when fitted with optional one-of-a-kind jaws.
Outer shell ventilation features include two ventilation tab kits
with anti-fog spray kit. Anti-scratch and retractable sun visor. Moisturewicking and breathable removable liner and cheek pads. D.O.T. and
ECE 22.05 certified.
Shell: Polycarbonate Composite — Sizes: XS, S, S/M, M/L, L, XL
447427 - Silver (08), Blue (80), Black (90)
Silver (08)

Blue (80)

$299.99

CAN-AM ST-1 HYBRID FULL FACE JAW

CAN-AM ST-1 HYBRID VENTED JAW

Transforms the ST-1 Hybrid Helmet into a standard
full face helmet for extra wind protection.
One size
447428 - Silver (08), Blue (80), Black (90)

Transforms the ST-1 Hybrid Helmet into a jet
ventilated full face helmet for enhanced protection
with ventilation comfort.
One size
447429 - Silver (08), Blue (80), Black (90)

$69.99

$69.99

CAN-AM ST-3 HELMET
Open face helmet. Vent system on top. Double density inner shell.
Non-allergenic and breathable internal lining. Clear visor with
anti-scratch treatment. D.O.T. approved.
Shell: Polycarbonate Composite — Sizes: XS, S, M, L, XL, 2XL
447464 - Silver (08), Black (90)

$89.99

Silver (08)

CAN-AM ST-1
HYBRID
PANE VISOR
Optically-correct
shield with hardcoated
anti-scratch
technology.
One size
Short - 447431 - Clear (00)

$49.99

Black (90)

CAN-AM ST-1
HARDWARE KIT
FOR TOP VENT
Hardware Kit for Top vent
replacement.
One size
447432 - Clear (00)

$24.99

CAN-AM ST-1
HARDWARE KIT
FOR VISOR AND JAW
Hardware Kit for Visor
and Jaw.
One size
447433 - Clear (00)

$24.99

VISION 180°

HELM
HEL
HELMETS
ELLME
MEETTS
MET

RRID
RIDING
IDDING
INNG
IN
G GE
GGEAR
AR 37
37

COMPLETELY REDESIGNED NEW GENERATION
OF FULL FACE HELMET INSPIRED BY ORIGINAL MODULAR 2 HELMET

SPACIOUS DESIGN ALLOWS ROOM FOR EYEGLASSES. D.O.T. APPROVED. THE BEST QUALITY / PRICE RATIO ON THE MARKET.

VISION 180°
FULL FACE HELMET
Adjustable sunshield
at the touch of a button
Integrated sunshield
for reduced glare
Clear Vision Technology with
optically-correct dual lens visor for
increased 180° peripheral vision
Exhaust vent for control
breathing airflow
Breath deflector system
Double D ring chin strap
Shell: Polycarbonate Composite
Sizes: XS, S, M, L, XL, 2XL, 3XL
447445 - Grey (09), Red (30), Black (90)

$169.99

Red (30)

ELECTRIC VISOR

REPLACEMENT VISOR

Sun visor not included.
One size
445968 - Clear (00)

Sun visor not included.
One size
445967 - Clear (00)

$169.99

$99.99

Black (90)

VISION 180° ELECTRIC
FULL FACE HELMET
Shell: Polycarbonate Composite
Sizes: XS, S, M, L, XL, 2XL, 3XL
447446 - Grey (09), Red (30), Black (90)

$229.99

ABSORBENT MASK

SUN VISOR

One size
447473 - White (01)

One size
445971 - Yellow (10), Smoke (57)

$7.99

$59.99

38 RIDING GEAR

HELMETS

BV2S
BV2S fog-resistant mask system with unparalleled adjustment capabilities to adapt to all faces.
Integrated backlight. Dual lens visor featuring enhanced 180° peripheral vision. Adjustable sunshield.
Front push-button release. Detachable breathing mask. Quick-release chin strap. Washable interior.
D.O.T. approved. Backlight batteries included.

LIMITED TIME OFFER*

FLASHLIGHT KIT
INCLUDED
BV2S PROMO
Includes powerful led flashlight and quick
attach kit. Improves visibility at night.
Easily removable. Batteries not included
Retail value of $50.
At participating dealers only.
*While supplies last

White (01)

Red (30)

BV2S HELMET PROMO

BV2S ELECTRIC SE HELMET PROMO

Shell: Polycarbonate Composite — Sizes: S, M, L, XL, 2XL, 3XL
447460 - White (01), Yellow (10), Red (30), Black (90)

(Not illustrated)
447477 - Black (90)

SPECIAL PROMOTION PRICE $449.99

SPECIAL PROMOTION PRICE $529.99

Black (90)

White (01)

Yellow (10)

Black (90)

BV2S HELMET
Polycarbonate Composite — Sizes: S, M, L, XL, 2XL, 3XL
447404 - White (01), Yellow (10), Red (30), Black (90)

$449.99

BV2S SE HELMET
Polycarbonate Composite — Sizes: S, M, L, XL, 2XL, 3XL
447468 - Black (90)

$529.99

SUNSHIELD VISOR

HELMET LIGHTING
SYSTEM KIT

ELECTRIC VISOR

REPLACEMENT
VISOR

One size
447374 - Clear (00)

One size
445795 - Clear (00)

One size
445720 - Yellow (10), Orange (12),
Smoke (57)

Batteries are not included.
One size
447465 - Black (90)

$179.99

$109.99

$59.99

$39.99

BREATHING MASK

ABSORBENT MASK

One size
444695 - Yellow (10)

One size
447282 - White (01)

$49.99

$7.99

MODULAR 2

HELMETS
HHEL
HE
EELLMET
ETS

RRIDING
RID
IDIN
IING
NG GE
NG
GGEAR
EAR 3399

MODULAR 2 HELMET
Built-in Clear Vision Technology with
optically-correct dual lens visor for
increased peripheral vision and
integrated sunshield for reduced glare.
Adjustable sunshield lowers or raises
at the touch of a button.
Front push-button release integrated
into jaw section facilitates
manipulation when wearing gloves.
BREATH EVAC fog-resistant mask
system and increased vent diameter
control breathing airflow.
Quick-release chin strap.
Spacious design allows room for
eyeglasses.
Graphics applied with ink transfer
process for high quality finish and
increased scratch resistance.
D.O.T. approved.
Shell: Polycarbonate Composite — Sizes: S, M, L, XL, 2XL, 3XL
445935 - White (01), Grey (09), Yellow (10), Red (30), Black (90)

$324.99

Grey (09)

REPLACEMENT VISOR

ELECTRIC VISOR

Sun visor not included.
One size
445967 - Clear (00)

Sun visor not included.
One size
445968 - Clear (00)

$99.99

$169.99

Yellow (10)

Red (30)

MODULAR 2 SE HELMET
Shell: Polycarbonate Composite
Sizes: S, M, L, XL, 2XL, 3XL
447469 - Black (90)

$399.99

SUN VISOR

ABSORBENT MASK

One size
445971 - Yellow (10), Smoke (57)

One size
445953 - White (01)

$59.99

$7.99

Black (90)

40 RIDING GEAR

BALACLAVAS

BASIC BALACLAVA

MICRO-FLEECE
BALACLAVA

No-nonsense balaclava
designed for warmth, dryness
and comfort. Flatlocked
seams prevent skin chafing.
80% Nylon, 20% Spandex
One size
447449 - Black (90)

Stretchable, antibacterial
warming fleece fabric with
brushed inner surface.
Flatlocked seams prevent
skin chafing.
92% Polyester, 8% Spandex
One size
445952 - Black (90)

$9.99

$21.99

MASK SYSTEM
BALACLAVA

MOUNTAIN BALACLAVA

Mask system helmet-matching
balaclava. Seals around mouth
and nose, while keeping head
and face warm and dry.
60% Polyester, 30% Nylon, 10% Spandex
Sizes: S/M, L/XL
447450 - Black (90)

Stretchable, quick-dry fabric with
brushed inner surface. Neoprene face
guard for effective moisture exchange
to promote breathing in extreme cold.
Flatlocked seams prevent skin chafing.
80% Nylon, 15% Spandex, 5% Synthetic Rubber
One size
445951 - Black (90)

$25.99

$26.99

TECHNICAL BALACLAVA
Strategically placed mesh for
breathability, micro-fleece for warmth.
Windproof neck bib. Higher at back of
neck for increased motion range.
Flatlocked seams prevent skin chafing.
92% Polyester, 8% Spandex — One size
445950 - Black (90)

$26.99

USA – 716000724

2011

PARTS, ACCESSORIES & RIDING GEAR

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PARTS & ACCESSORIES
OUTLANDER
RENEGADE
DS 450
DS 250
TRACK SYSTEM
PLOW ACCESSORIES
WINCHES
COVERS
BAGS
MULTI-FIT
PRIME TLC FOR YOUR ATV
MAINTENANCE
DECALS
LICENSED PRODUCTS
SIZING CHART

4
12
18
23
24
27
30
32
33
34
35
36
38
39
40

Read the Side-by-Side vehicle (SSV) and All Terrain Vehicle (ATV) Operator’s Guide and watch the Safety DVD before driving. For your safety: wear a helmet, eye protection and other protective gear. In your SSV,
fasten lateral net and seat belt at all times. Operator must be at least 16 years old. Users should, however, respect any applicable law establishing a higher minimum age for riding an ATV or SSV. BRP urges you to
“TREAD LIGHTLY” on public and private lands. Preserve your future riding opportunities by showing respect for the environment, local laws and the rights of others when you ride. Always ride responsibly and safely.
BRP highly recommends that all ATV and SSV drivers take a training course. For safety and training information, see your authorized Can-Am dealer or, in the U.S.A., call the ATV Safety Institute at 1-800-887-2887.
In Canada, call the Canadian Safety Council at 1-613-739-1535 ext. 227. ATVs and SSVs can be hazardous to operate. Always remember that riding and alcohol/drugs don’t mix. SSVs and ATVs are for off-road use
only. Never ride on paved surfaces or public roads. Never engage in stunt driving. Avoid excessive speeds and be particularly careful on difficult terrain. Racing scenes in this brochure were photographed during an
organized race involving highly skilled operators under controlled conditions. Do not attempt. Can-Am Outlander MAX ATVs: these ATVs are recommended for drivers aged 16 and older, and passengers aged 12 and
older only. Make sure that all laws, regulations, and BRP’s warnings/recommendations for ATV and SSV passengers are respected. Never carry passengers on any ATV not specifically designed for such use. Never
carry a passenger under the age of 12. A passenger must be able to hold handgrips and to comfortably place both feet flat on the floorboard while seated upright. BRP reserves the right, at any time, to discontinue or
change specifications, prices, designs, features, models or equipment without incurring obligation. Some models depicted herein may include optional equipment. Prices are based on Manufacturer Suggested Retail
Prices. Dealers may sell for a different price. Taxes are not included. In the U.S.A., products are distributed by BRP US Inc. In Canada, products are distributed by BRP US Inc. In Canada, products are distributed
by Bombardier Recreational Products Inc. ™ ® and the BRP logo are trademarks of Bombardier Recreational Products Inc. or its affiliates. UNI is a trademark of UNIFILTER Inc. TWIN AIR is a trademark of Twin Air
USA. KYB is a registered trademark of Kayaba. WARN is a trademark of Warn Industries Inc. YUASA is a registered trademark of YUASA Batteries Inc. NGK is a registered trademark of NGK Spark Plugs, Ltd. Smith
is a registered trademark of Smith Sport Optics, Inc. Chamude is a registered trademark of Kolon Industries, Inc. Clarino is a trademark of Kuraray Co. Ltd. Teflon HT, Teflon HP and Kevlar are trademarks of E.I.
DuPont de Nemours & Co. Lexan is a trademark of General Electric (GE). Primaloft One and Primaloft Cresta are registered trademarks of Albany International Corp. Windows is a trademark of Microsoft group
of companies and is used under license from Microsoft. CARLISLE is a trademark of Carlisle Companies. FOX is a trademark of FOX Racing Canada. All other trademarks are the property of their respective owners.
© 2010 Bombardier Recreational Products Inc (BRP). All rights reserved. Printed in Canada.

4

PARTS & ACCESSORIES OUTLANDER

OUTLANDER

XT FRONT BUMPER KIT
REAR TRUNK BOX
PASSENGER WIND DEFLECTORS
FRONT RACK EXTENSIONS
MUDGUARD KIT
FRONT SHOCK PROTECTORS
FRONT BAG
MIRROR

P.6
P.7
P.7
P.8
P.8
P.15
P.33
P.34

OUTLANDER PARTS & ACCESSORIES

5

A-ARM PROTECTORS
Made with high strength aluminum for more
protection to the CV joint and rubber boots.
Drain hole to release water, mud and debris.
Unique design with embossed Outlander name.
Easy to install. Sold in pairs.
703500524

$139.99

FRONT ALUMINUM SKID PLATE
Stamped aluminum. Protection for the front
portion of the frame. Use in conjunction with
the central chassis skid plate (715000636)
for full frame protection.
715000548

$109.99

CENTRAL CHASSIS SKID PLATE
Protect your frame from the unexpected –
a must-have for rugged terrain. Stamped 1/8” (3 mm)
aluminum construction. Recessed bolt holes.
Cannot be installed with Plow Mounting Kit.
Renegade & Outlander 500, 650, 800 & Outlander MAX
715000636

$99.99

FOOTWELL PROTECTOR PLATES
Bump up the impact protection to the footwells.
1 8
/ ” (3 mm) aluminum construction.
Use in conjunction with the central skid plate
(703500570 or 715000636). Sold in pairs.
715000547

$169.99

TRAILING ARM PROTECTORS
1 8

/ ” (3 mm) aluminum construction.
Replace stock plastic protectors. Sold in pairs.
Renegade & Outlander - 715000311

$139.99

REAR DIFFERENTIAL PROTECTOR
1 8

/ ” (3 mm) aluminum construction.
Replaces stock plastic protector.
Renegade & Outlander - 715000285

$129.99

REAR SKID PLATE
1 8

/ ” (3 mm) aluminum plate provides additional
protection for your frame. A must when riding
on extremely rugged terrain.
Renegade & Outlander 500, 650, 800 - 715000609

$59.99
Outlander MAX 500, 650, 800 - 715000610

$74.99
Must be installed with the Central and Front Skid Plate
(703500570). Outlander MAX 400 only - 703500381

$79.99
Outlander 400 only - 703500382

$64.99

CENTRAL AND
FRONT SKID PLATE
Two-piece 3/16" (5 mm) aluminum
full-body skid plate designed to
protect frame and engine case from
rough terrain conditions.
Outlander 400 only - 703500570

$104.99

6

PARTS & ACCESSORIES OUTLANDER

REAR CARGO BOX
LOWER BUMPER EXTENSION
Adds protection to lower front plastic fascia. Easy to install.
No drilling required. Removable for Apache Track Kit installation.
Must be installed with XT Front Bumper Kit (715000670).
715000635 Black

Convert your Outlander MAX into a very versatile vehicle in only 30 seconds. Designed exclusively
for the Outlander MAX, this latest-generation rear cargo box is built tough and made of high-resistance
polyethylene plastic. Featuring a removable rear tailgate that also conveniently installs in the
center of the box. Since it can handle a maximum payload of 260 lbs (118 kg), you’ll really
hit paydirt with this cargo box. Dimensions: 35" (88 cm) W X 21" (54 cm) D X 7" (17 cm) H.
Outlander MAX 2006-2011 - 715000734 Black

$439.99

$79.99

XT REAR BUMPER KIT
Adds on to stock bumper to convert your Outlander into an XT model.
Large tube construction with textured black finish.
2009 800R only & 2010-2011 - 715000671 Black

$144.99
2006-2009, except 800R - 703500550 Black

$149.99
2004-2005 - 703500349 Black

$159.99

XT FRONT BUMPER KIT
Adds on to stock bumper to convert your Outlander into an XT model.
Large tube construction with textured black finish.
2009 800R only & 2010-2011 - 715000670 Black
2006-2009, except 800R - 703500551 Black

$159.99
2004-2005 - 703500348 Black

$169.99

FOOTPEG KIT

FOOTPEG EXTENSIONS

Made of aluminum, the Footpeg Kit
provides maximum integrated grip. Larger
than stock model, it gives more stability
during vigorous riding. Kick-up end
generates added grip during hard cornering.
Sold in pairs.
715000916

Made of aluminum, the Footpeg Extensions
provide grip in all weather and riding
conditions. Use in conjunction with
footpeg kit (715000916). Sold in pairs.
715000996

$34.99

$69.99

OUTLANDER PARTS & ACCESSORIES

7

HIGH WINDSHIELD KIT
These top of the line Windshield Kits
provide excellent wind protection.
Can be used on standard, XT and LTD
models. Easy to install and remove.
Can-Am branded.
Outlander 500, 650 & 800
715001015 Yellow
715001016 Red
715001017 Tinted Black

$189.99

ULTRA HIGH WINDSHIELD KIT
Provides superior wind protection.
4” (10 cm) higher windshield. Added
substructure to control vibration.
Can-Am branded and color matched.
Can be used on standard, XT and LTD
models. Easy to install and remove.
Outlander 500, 650 & 800
715001018 Yellow
715001019 Red
715001020 Tinted Black

$219.99

WINDSHIELD KIT
Can be used with or without handlebar
protectors. Includes steering cover.
Easy to install and remove.
Outlander 400 - 703500444

$154.99

REAR TRUNK BOX
PASSENGER HEATED GRIPS
Heat control can be set to High or Low.
Ideal for replacing stock passenger handles.
Added passenger comfort. Easily removable
when summer comes. Easy to install.
Outlander MAX 2006-2011 - 715000634

$159.99

Perfect fit with vehicle. Made of impact resistant polyethylene. Fully sealed
lid. Tray quick-hooks to box. Equipped with lid key lock. The molded handle
makes lifting and moving the box easy. Robust double wall lid. Improved
trunk latch and attachment system on rack. Easy-install quick attach
system (715000273) available as an option. Fits any ATV on the market.
Cannot be used with Rear Rack Extensions (703500537 & 703500538).
2006-2011 - 715000626 Black

$279.99

QUICK ATTACH/DETACH SYSTEM FOR REAR TRUNK BOX
(Not illustrated)
2006-2011 - 715000273

$79.99

PASSENGER WIND DEFLECTORS
These wind deflectors fit snugly around the passenger handles and provide
total comfort while riding. Easy to install and remove.
Outlander MAX 2006-2011 - 715000233
Outlander MAX 2004-2005 - 715000231

$59.99

8

PARTS & ACCESSORIES OUTLANDER

MUDGUARD KIT
Offers more protection from dirt and debris. Extra flair for that ruggedly cool
look. Kit includes front and rear extensions and all mounting hardware.
Outlander 500, 650, 800 - 715000533 Black
Outlander 400 2006-2011 - 715000297 Black
Outlander 400 2004-2005 - 715000296 Black

$129.99

FRONT RACK EXTENSIONS
Offers 4" (100 mm) or 7" (178 mm) of clearance with the existing racks.
Secure bulky loads with its sturdy tube construction. Textured black finish.
Medium Profile 4" (100 mm)
High Profile 7” (178 mm)
(Not illustrated)
2006-2011 - 703500535 Black
2006-2011 - 703500536 Black
$89.99

$89.99

REAR RACK EXTENSIONS
Offers 4" (100 mm) or 7" (178 mm) of clearance with the existing racks.
Secure bulky loads with its sturdy tube construction. Textured black finish.
High Profile 7” (178 mm)
Medium Profile 4" (100 mm)
2006-2011 - 703500537 Black
(Not illustrated)
2006-2011 - 703500538 Black
$109.99

$89.99

FRONT HITCH
Provide extra fender protection when you’re in tight situations.
1" (25 mm) diameter steel construction with textured black finish.
Outlander 2006-2011 - 703500544 Black
Outlander MAX 2006-2011 - 703500546 Black

Front hitch for Outlander with or without a winch.
This hitch offers 750 lbs (340 kg) of towing
capacity. Needs to be installed with the winch
fairlead bracket (715000696) for all Outlander
models equipped with a winch.
2006-2011 - 703500421 Black

$109.99

$79.99

FENDER PROTECTORS

OUTLANDER PARTS & ACCESSORIES

9

FRONT HPG SHOCK KIT
High pressure gas (HPG) shocks. Provides enhanced
Outlander ride, handling and control. Razor sharp
calibration for even the most demanding riders.
Fade-free performance. Sold in pairs.
Outlander 650, 800 Standard models - 715000303

$221.99

FRONT HPG SHOCK KIT WITH SPRINGS
Outlander 650, 800 XT models - 715000304

$259.99

REAR HPG SHOCK KIT WITH SPRINGS
(Not illustrated)
Outlander 650, 800 Standard and XT models - 715000305

$259.99

XT HANDLEBAR PROTECTOR KIT
Add handlebar protection with our XT-style kit.
Outlander 500, 650, 800 - 703500553 Black

$59.99

Outlander 400 2005-2011 - 715000271 Black
Outlander 400 2004 - 715000272 Grey

$99.99

715000961

NEW GPS PROTECTOR

GPS ADAPTOR
FOR OUTLANDER LTD WINDSHIELD

Provides extra protection from mud and dust.
Covers GPS support when GPS is removed.
Outlander LTD 2010-2011
715001210 - Black

Kit needed to install your GPS from LTD model
when using a Can-Am windshield.
Outlander 2009 and prior - 715000309
Outlander LTD 2010-2011 - 715000961

$19.99

$24.99

FRONT SPRING KIT
Front heavy-duty springs. Stiffer than factory installed
front springs for more precise front suspension
behavior. Ideal for snow plowing or heavy load
transportation applications. Sold in pairs.
Outlander 650, 800 Standard and XT models - 715000306

$74.99

10 PARTS & ACCESSORIES OUTLANDER

NEW SNORKEL KIT

NEW OUTLANDER X XC FRONT PRE-RUNNER BUMPER

The only way to tackle extreme muddy conditions. Snorkel kit comes complete with redesigned
air-box with extended air intake and a new extended CVT exhaust outlet conveniently
integrated into the upper gauge pod, maximizing muddy condition performance. Standard
equipment on X mr model.
Outlander 650 & 800R 2010-2011
715001136

Lightweight yet sturdy aluminum bumper provides maximum frontal protection.
Incorporated front skid plate, reinforced tubing and still works with a winch.
Outlander 800R 2009 & Outlander 2010-2011
715001123 Aluminum

$269.49

$259.99

NEW X MR
TRACTION PLATES
NEW RADIATOR
RELOCATOR KIT
Relocates radiator to top mount
position to prevent mud packing.
For use in extreme muddy conditions,
providing maximum performance.
Includes all brackets, hardware
and hoses (radiator not included).
Outlander 650 & 800R 2010-2011
715001178 Black

$249.99

NEW OUTLANDER X XC
WINCH MOUNTING KIT
Required for winch installation on
models equipped with the X xc bumper.
Must be used in conjonction with
winch mounting kit (703500547)
and roller fairlead (715000011)
(Winch not included)
Outlander X xc 2011
(or Outlander with X xc bumper)
715001121 Black

$39.99

RECEIVER HITCH
Powder-coated finish. Does not affect
ground clearance. Trailer ball not
included. Rear hitch plate
(715000286) is required for
Renegade and Outlander X xc 2011.
Renegade & Outlander with hitch plate kit 715000325

$97.99

Provide extra foot grip
for driver when riding
in extreme muddy
conditions. Help driver
maintain ideal riding
position to maximize
vehicle traction. Not
meant for a passenger.
Outlander Max
715001137 Aluminum

$149.99

OUTLANDER PARTS & ACCESSORIES 11

GUN-BOOT

GUN-BOOT SUPPORT

The best way to transport your rifle or shotgun. This
high-impact case securely holds your rifle while providing
a padded dust-proof and water-resistant protection.
Outlander & Rally - 715000028 Black

(Not illustrated)
Used in conjunction with the gun-boot.
Attaches to the rear rack.
Outlander & Rally - 715000029 Black

$69.99

$89.99

NONSKID LUGGAGE RACK STRIPS

RADIATOR PROTECTOR

Rubber strips you can apply to your front and rear luggage
racks to maintain your cargo in position. Helps keep your
luggage rack scratch free. Easy to install. Sold in packs of 4.
Outlander 2006-2011 - 703500569 Black

$15.99

FLASHER AND HORN KIT
Complete flasher and horn kit. Integrates to vehicle.
Easy to install. Not for road use.
Outlander 800R 2009-2011 - 715000695

$249.99

Metal shield which mounts over radiator face
providing protection from stones and branches.
Outlander 2006-2011 - 703500543 Black
Outlander & Rally 2004-2005 - 703500427 Black

$59.99

REWIND STARTER KIT
Complete manual rewind assembly.
Outlander 400 EFI 2010-2011 - 715001034

$154.99

12 PARTS & ACCESSORIES RENEGADE

RENEGADE

CENTER CONSOLE DAY LIGHT
REAR ALUMINUM RACK
FRONT SHOCK PROTECTORS
HANDLEBAR WIND DEFLECTORS
FULL WRAP ALUMINUM
MOUNTING KIT
MIRRORS

P.14
P.14
P.15
P.17
P.17
P.34

RENEGADE PARTS & ACCESSORIES 13

A-ARM PROTECTORS
Add protection to your Renegade lower A-arm with
this high-strength aluminum protector with drain
hole to release water, mud and debris. 1/8" (3 mm)
aluminum construction. Easy to install. Replaces
stock plastic protectors. Engraved Can-Am logo.
Sold in pairs.
715000287

$139.99

CENTRAL CHASSIS SKID PLATE
Protect your frame from the unexpected –
a must-have for rugged terrain. Stamped 1/8”
(3 mm) aluminum construction. Recessed bolt
holes. Cannot be installed with Plow Mounting Kit.
Renegade & Outlander 500, 650, 800 & Outlander MAX
715000636

$99.99

FOOTWELL PROTECTOR PLATES
Bump up the impact protection to the footwells
and structure. 1/8” (3 mm) aluminum construction.
Use in conjuction with a central chassis
skid plate (715000636). Sold in pairs.
715000686

$169.99

REAR DIFFERENTIAL PROTECTOR
1 8

/ ” (3 mm) aluminum construction.
Replaces stock plastic protector.
Renegade & Outlander - 715000285

$129.99

TRAILING ARM PROTECTORS
1 8

/ ” (3 mm) aluminum construction. Replace
stock plastic protectors. Sold in pairs.
Renegade & Outlander - 715000311

$139.99

REAR SKID PLATE
1 8

/ ” (3 mm) aluminum plate provides additional
protection for your frame. A must when riding
on extremely rugged terrain.
Renegade & Outlander 500, 650, 800 - 715000609

$59.99

14 PARTS & ACCESSORIES RENEGADE

X PACKAGE REAR SHOCK & SPRING KIT
Rebound and dual speed compression adjustable gas
shocks. Kit includes matching springs and hardware.
Sold in pairs.
2008-2011 - 715000538

$979.99

NEW MUD GUARD KIT
FOR RENEGADE
Integrated extended fender
flairs for sporty look and full
body protection from dirt
and water. Kit of 4 includes
front and rear extensions
and all mounting hardware.
Renegade 2007 to 2011
715001115 Black

$189.99

X PACKAGE FRONT SHOCK & SPRING KIT
Rebound and dual speed compression adjustable gas
shocks. Kit includes matching springs and hardware.
Sold in pairs.
715000536

$614.99

FRONT SWAY BAR KIT
Enhances vehicle stability
and control during hard
cornering.
Renegade 2010-2011 - 715000967

$149.99

REAR ALUMINUM RACK
30 lbs (14 kg) capacity. Compact, lightweight
aluminum construction. Engraved Can-Am logo.
Stamped 5052 aluminum center plate.
Easy to install.
715000242

$164.99

CENTER CONSOLE DAY LIGHT
Mountable on top end of center console.
Enhance look of vehicle.
715000691

$69.99

REAR HITCH PLATE
Includes bolt-on hitch plate and hardware.
Renegade & Outlander X xc 2011 - 715000286

$39.99

RENEGADE & OUTLANDER PARTS & ACCESSORIES 15

UNI† FOAM FILTER
Ease of maintenance. Can be easily washed, re-oiled
and re-used when subject to severe dusty/muddy
environments. Contains a rigid adaptor with an added
flair providing retention of the air filter.
Outlander 500, 650, 800 & Renegade 2010-2011 and prior,
except 800R and 650 2010-2011 - 715000310

$30.99

NEW CAN-AM FOAM AIR FILTER
BY TWINAIR†
Maximizes performance by increasing air flow
throughout RPM range. Maintenance-friendly,
i.e. just wash, re-oil and re-use after riding in
severely dusty/muddy environments.
Renegade & Outlander 800R 2009-2011
and 650 2010 & 2011 - 715001130

$69.99

CVT AIR INTAKE
Designed to relocate and maximize height of the
CVT air intake to prevent belt slippage in deep snow
or muddy conditions. Equipped with integrated CVT
pre-filter to also reduce dust and extend CVT
and belt life.
Renegade 500, 800 2007-2009 - 715000984
Outlander 500, 650, 800 2008-2009 - 715000970

$64.49

NEW SHOCK PROTECTOR

AIR PRE-FILTER

Provides X-package shock rods with additional
protection against pitting.
Fit X-package KYB shocks except DS 450 X xc
715001209 Black

$29.99

Filters out even the tiniest of contaminants in dusty
conditions. Extends service period. Use in conjunction
with stock filter. Air filter not included.
DS 450 & Outlander 400 - 707800293

$20.99

AIR BOX PRE-FILTER
AIR PRE-FILTER
Adds extra protection to your engine in harsh riding
conditions. Filter blocks particles larger than 0.005".
Note: A pre-filter is necessary to maintain the vehicle
warranty when an Apache Track kit is installed.
Renegade & Outlander 500, 650 & 800 2008 and prior,
500, 650 2009 and 500 2010 - 715000291

(Not illustrated)
Add extra protection to your engine in harsh riding
conditions. Filter blocks particles larger than 0.005”.
Note: A pre-filter is necessary to maintain the vehicle
warranty when an Apache Track kit is installed.
Renegade & Outlander 650 2010-2011, 800R 2009-2011
715000908

$36.49

$24.99

FRONT SHOCK PROTECTORS
HEATED HAND GRIP KIT

HEATED THROTTLE LEVER ASSEMBLY

Keep your hands warm while riding with this
easy-to-install hand grip kit. Includes a 3-position
switch, switch cover, wiring harness, hand grip and
handlebar end cap. Grips are 4 7/8" (12 cm) long with
an interior diameter of 7/8" (22 mm). Grip heat control
can be set to High (20 watts) or Low (10 watts).
Renegade & Outlander - 715000322

Improved heating element provides faster warm-up
time and increased maximum temperature. For a
perfect fit and finish, designed especially for your
Can-Am ATV. Kit includes a 3-position switch, switch
cover, wiring harness and throttle lever assembly.
Renegade & Outlander - 715000584

$79.99

Feature ventilation holes. Sold in pairs.
Renegade & Outlander - 715500301

$29.99

$61.99

SHIFTER LOCK
Locking device locks transmission shifter
in “Park” position. Minimum 5000 key
combination. Fully integrated.
Renegade & Outlander 500, 650, 800 2009-2011 - 715000689
Outlander 400 - 715000690

NEW LOCKABLE GAS TANK CAP

$49.99

$39.99

Protects your fuel. Meets latest EPA requirements.
Renegade & Outlander - 860200387 Black

16 PARTS & ACCESSORIES RENEGADE & OUTLANDER

XT RIM

XT-P RIM

LTD RIM

Made of aluminum. Upgrade for non XT models.
Renegade & Outlander, except Outlander 800 2006
Front - 705400648
Rear - 705500986

Made of aluminum. Upgrade for non XT models.
Renegade & Outlander, except Outlander 800 2006
Front - 705400687
Rear - 705501019

Made of aluminum. Upgrade for non XT models.
Renegade & Outlander, except Outlander 800 2006
Front - 705400683
Rear - 705501015

$119.99

$124.99

$124.99

$129.99

$139.99

$139.99

NOTE: MATCHING NUTS - 250100100 Black and 250100082 Chrome — MATCHING CAP - 705400680 Black

XTR CUSTOM WHEEL KIT

RENEGADE RIM

Custom Can-Am XTR branded 12” (30.5 cm) painted aluminum rims. Includes matching chrome nuts and
center covers. Set of 4.
Renegade & Outlander, except Outlander 800 2006 - 715000611 Black - 715000612 Yellow

Center cast aluminum rims.
Renegade & Outlander, except Outlander 800 2006
Rear 705500837
Front 705400506

$499.99

$119.99

COLORED FINS FOR RIMS

BEAD LOCK

Plastic fins that enhance appearance of your vehicle. Pack of 8.
Fits on following wheels: XT, XT-P and LTD 2010-2011 (705500986,
705501015, 705501019, 705400687, 705400648, 705400683)
705400681 Yellow
705400950 Steel Grey (Not illustrated)

Cast aluminum. Must be installed
on rims 705400794 and 705501137.
Renegade & Outlander 650 and 800,
except 800 2006 - 705400841

$13.04

$79.99

$129.99

RENEGADE X RIM
Center cast aluminum rims. Welded exterior and
interior reinforcement rings. Needs to be installed
with Bead Lock (705400841).
Renegade & Outlander 650 and 800, except 800 2006
Front - 705400794
Rear - 705501137

$124.99

$139.99

RENEGADE, OUTLANDER & DS 450 PARTS & ACCESSORIES 17

FULL WRAP ALUMINUM
MOUNTING KIT

SHORT ALUMINUM
MOUNTING KIT

Lightweight black die cast
aluminum construction.
Includes complete hardware.
Handlebar wind deflectors
sold separately.
Renegade, Outlander 500, 650,
800 & DS 450 - 715000545

Lightweight black die cast
aluminum construction.
Includes complete hardware.
Handlebar wind deflectors
sold separately.
Renegade, Outlander 500, 650,
800 & DS 450 - 715000513

$79.99

$49.99

MIRROR KIT FOR HANDLEBAR WIND DEFLECTORS
Handlebar wind deflector mount design. To be used with handlebar wind deflectors.
Sold in pairs.
Renegade, Outlander 500, 650, 800 & DS 450 - 860200080

$24.99

HANDLEBAR WIND DEFLECTORS
Rugged injected plastic construction with Can-Am logo. Includes removable
cap for air flow adjustment. Mounting kit sold separately.
Renegade, Outlander 500, 650, 800 & DS 450
715000733 Yellow / Black (Not illustrated)

$44.99

ALUMINUM TAPERED HANDLEBAR

715000537 White / Black
715000525 Black / Yellow

7 8

/ "- 1 1/8" (22 mm - 28 mm) tapered handlebar made of 6061-T6 aluminum.
Includes all hardware, center steering foam and cover.
Renegade & Outlander 500, 650, 800 - 715000550

$49.99

$99.99

18 PARTS & ACCESSORIES DS 450

DS 450

X PACKAGE CHASSIS SKID PLATE
X PACKAGE NERF BARS
REAR ALUMINUM BASKETS
FRONT SHOCK PROTECTORS
NUMBER PLATE
X PACKAGE FRONT
ALUMINUM BUMPER
X PACKAGE ADJUSTABLE
FRONT SHOCKS
SPEEDOMETER

P.19
P.19
P.19
P.21
P.21
P.21
P.21
P.22

DS 450 PARTS & ACCESSORIES 19

A-ARM PROTECTORS
Lightweight injected plastic A-arm protectors provide
strong protection for lower aluminum A-arm. Can-Am
branding visible from top and underneath vehicle.
Easy installation, no holes to drill. Sold in pairs.
Does not fit DS 450 X mx.
715000517 Black
715000589 Yellow

$69.99

X PACKAGE CHASSIS SKID PLATE
Lightweight and strong full chassis skid plate.
5052 1/8” (3 mm) stamped aluminum construction.
Recessed bolt holes. Includes all necessary hardware.
715000506

$124.99

FRONT FENDER EXTENSIONS
Lightweight aluminum extension connects the front
fender to the nerf bar. Sold in pairs.
715000514

$74.99

X PACKAGE NERF BARS
Strong lightweight rectangular aluminum tubing
provides extra protection for assertive riding.
Complete with mounting hardware and black
webbing. Must be installed with Rear Aluminum
Baskets (715000673). Sold in pairs.
2009 - 715000672

$199.99
2008 and prior - 715000505

$209.99

REAR ALUMINUM BASKETS
For direct replacement of stock plastic version.
1 8
/ ” (3 mm) 5052 aircraft aluminum construction
and 7/8” (22 mm) tubing. Stronger construction
than stock model. Must be installed with X Package
Nerf Bars (715000672).
X Package 2009 - 715000673

$259.99
Can be installed with
or without X Package Nerf Bars (715000505).
715000526

$264.99

X PACKAGE SWING ARM SKID PLATE
Lightweight protection for your swing arm, rear disc,
sprocket and chain. 5052 3/16” (5 mm) aluminum
construction. Replaces stock plastic protector.
715000507

$124.99

20 PARTS
20
PAR
PPA
AAR
RTTSS & ACCESSORIES
ACCE
CESSO
CE
SSORIE
SS
RIESS DS 450

X XC FRONT RIM KIT

X XC REAR RIM KIT

Dimensions: 10” x 5” (25 cm x 13 cm) diameter.
ITP† T-9 Trac-Lock† rims. Sold in pairs.
715000902

Dimensions: 9” x 8” (23 cm x 20 cm) diameter.
ITP T-9 Trac-Lock rims. Sold in pairs.
715000905

$459.99

$474.99

X MX FRONT RIM KIT

X MX REAR RIM KIT

X PACKAGE REINFORCED RIM KIT

Dimensions: 10” x 5” (25 cm x 13 cm) diameter.
ITP T-9 GP rims. Sold in pairs.
715000903

Dimensions: 8” x 8” (20 cm x 20 cm) diameter.
ITP T-9 Trac-Lock rims with bead lock and inside
reinforcement. Sold in pairs.
715000906

Black painted aluminum rims with exterior reinforcement ring.
Sold in sets of 4. Tires not included. Always respect tire size
appropriate for your vehicle. Bead lock with inside reinforcement.
715000510

$399.99

$374.99

$219.99

DS 450 PARTS
PARRTS & ACCESSORIES
ACCESSO
SORIE
OR S 211

X PACKAGE FRONT ALUMINUM BUMPER

X PACKAGE ADJUSTABLE FRONT SHOCKS
Ultra-high performance KYB† fully adjustable shock.
Includes rebound and high/low speed compression
adjustments. More performance oriented valving than
stock vehicle. Uses original stock spring. Sold in pairs.
715000511

Extra-large and lightweight front bumper offers the best protection for all forms
of racing. 6063 aluminum construction. Provides superior coverage to the front
of your DS 450. Required to install number plate.
715000508

$109.99

$569.49

FRONT SHOCK PROTECTORS

NUMBER PLATE

Offer added protection against tough terrain
and weather conditions. Sold in pairs.
715500302

Injection molded high gloss finish. To be used with X Package front aluminum
bumper (715000508).
715000521 Black
715000522 Yellow

$34.99

$21.99

22 PARTS & ACCESSORIES DS 450

FRONT SPROCKETS
Hardened steel construction. Changing sprocket
ratio will vary vehicle top speed and behaviour.
Includes snap ring. For racing applications only.
13-tooth (-1) - 715000519
14-tooth (stock) - 715000591
15-tooth (+1) - 715000518

$24.99

REAR SPROCKETS
Lightweight 7075 T-6 aluminum construction.
Changing sprocket ratio will vary vehicle top
speed and behaviour. For racing applications only.
39-tooth (-3) - 715000527
42-tooth (stock) - 715000592 44-tooth (+2) - 715000515

$74.99

$79.99

SPEEDOMETER
Digital speedometer. Complete kit with mounting
pod. Includes reliable speed sensor built into
transmission and extra race functions, e.g.
maximum speed, average speed, lap counter,
comparative average vs. actual speed and RPM.
Easy to install.
2009-2011 - 715000512

$249.99

REGINA Z-RING CHAIN
This chain is the best choice for the most severe and demanding applications.
Among other characteristics, the ZR chains feature high alloy steel plates
and pins, solid bushings and rollers, shot-peening of plates, pins and
rollers, performance-enhancing pre-stretched and “Can-Am yellow” outer
plates. Stronger than stock chain (32000N). 102 link to match with
different sprocket sizes. Includes connecting link.
715000523

$109.99

FRONT PLASTIC GRILLE
Add color to your vehicle.
2009 and prior - 715000516

$16.99

DS 250
DS
2550
50 PARTS
PPAAARRTS
PAR
TS & ACCESSORIES
ACCCE
CCCE
C SSO
SSO
SS
SORIE
RIEES 23
23

DS 250
FRONT BUMPER BRACKET
Adds extra protection to the front of your vehicle.
715000241

$69.99

A-ARM PROTECTORS
These aluminum parts provide maximum
A-arm protection.
703500618

$124.99

NERF BARS
Strong lightweight rectangular aluminum tubing
provides extra protection for hard riding. Complete
with mounting hardware and black webbing.
Sold in pairs.
703500617

$249.99

FULL-BODY SKID PLATE
Aluminum full chassis skid plate designed
to protect your frame and engine case from rocks
and undercarriage damage. Maximum underbody
protection when driving your DS on the most
rugged terrain.
703500616

$159.99

MIRROR

REAR RACK

REAR RACK BAG

Stem includes 5/16" (8 mm) thread.
Right - S88110RA1000
Left - S88120RA1000

Sturdy steel construction, powder paint finish.
Can be used with rear rack bag (715000264).
715000243 Black

100% water-repellent polyester bag. Specially
designed to fit on the rear rack (715000243).
715000264 Black

$20.99

$224.99

$89.99

24 PARTS
24
PARTTSS & ACCESSORIES
PAR
ACCE
ACC
CCCEESSO
CC
CCES
SSSOORI
SS
RRIE
IIEES TRAC
TTRA
TRACK
RRAACK
CK SYSTEM
SSYYSSTTE
TEM
EM

APACHE WT SYSTEMS

TRA
TR
TRACK
RAACK
RACK
CK SYSTEM
SYST
SY
STEEM
M PARTS
PARTSS & ACCESSORIES
ACC
CCESSOR
SSO
SSO
SS
SORRIE
IEES 255

THE WIDEST TRACK
IN THE INDUSTRY
The 13 5/8” x 1” (34.6 cm x 2.5 cm) rear track profile provides a
larger footprint and industry-leading flotation and a 11 1/2” (29 cm)
arc-shaped front track reduces vibration and steering effort.

REAR AND FRONT MOUNTING KITS
A simplified system that
reduces installation time.
New and improved front
mounting kit allows for
smoother steering with less
effort and reduced stress
on the front suspension.

+ 1 1/16”

FRONT ARC
SHAPED PROFILE

NOW INCLUDED WITH THE
NEW APACHE WT SYSTEMS

REAR STRAIGHT
PROFILE NOW LARGER
+ 1 1/16”

APACHE WIDE TRACK SYSTEM

STUDDED APACHE WIDE TRACK SYSTEM

(Not illustrated)
Same great features that have made
this a must-have and more. Specially
designed for your Can-Am ATV.
Outlander & Outlander MAX - 715001086

Additional traction providing more control
in icy conditions. Factory pre-studded tracks.
114 studs per rear track. 76 studs per front track.
380 studs total.
Outlander & Outlander MAX - 715001087

$3,399.99

$3,659.99

Note: The Apache WT System is the only track kit available that maintains
the Can-Am ATV vehicle warranty.

PRE-FILTERS
CVT PRE-FILTER

CVT AIR INTAKE

Designed to prevent snow intrusion in the CVT
and belt slippage when Apache Track System is used
in deep snow. Easy to install and remove. Comes
standard on Renegade and Outlander 800 2009.
Renegade & Outlander 500, 650, 800, 2009 and prior - 715000552

Designed to relocate and maximize height of the CVT air
intake to prevent belt slippage in deep snow or muddy
conditions. Equipped with integrated CVT pre-filter
to also reduce dust and extend CVT and belt life.
Outlander 500, 650, 800 2008-2009 - 715000970

$6.49

$64.49

See P.15
Add extra protection to your engine
in harsh riding conditions. Filter blocks
particles larger than 0.005”.
715000908 - Air Box Pre-Filter
715000291 - Air Pre-Filter
Note: A pre-filter is necessary to maintain the vehicle
warranty when an Apache System is installed.

26 PARTS
26
PAR
PA
ARTTSS & ACCESSORIES
ACC
CCCEESS
CCE
ESSSO
SORRIIIEES TRA
TTRACK
RRAACK
CK SYSTEM
SYSSTTEM
SY
EM

INDUSTRY
REVOLUTION:
3RD DPS MODE

ONLY AVAILABLE WITH
THE APACHE WT SYSTEMS
The 3rd DPS mode, when installed with the Apache WT system,
optimizes power steering performance. It is a module for the
Dynamic Power Steering maximizing steering agility at lower speeds
while providing firmer steering at cruising speeds. In addition,
it provides a speed correction factor for the speedometer.

PLOW ACCESSORIES PARTS & ACCESSORIES 27

BUILD YOUR PLOW SYSTEM IN 3 EASY STEPS BY SELECTING:

1

THE PUSH FRAME
& OPTIONAL FEATURES

Super-duty push tubes withstand the roughest use. Mid-mount carriage
provides up to 11½” (29 cm) of lift. Push frame fits all blade styles.

PUSH FRAME
Quick-attach not included.
715001064 Black

$239.99

PUSH FRAME
WITH QUICK-ATTACH SYSTEM
Fully assembled quick-attach system.
Pin-ready for reduced installation time.
715001063 Black

$374.99

PUSH FRAME FEATURES

PUSH FRAME EXTENSION
12 ¼" (31 cm) chassis extension for use with Apache Track
systems. Increases angle and enables extra blade rotation.
Cannot be used with Manual EZ Lift System (703500522)
and Remote Angling System (715000260).
703500603

$119.99

QUICK-ATTACH SYSTEM

REMOTE ANGLING SYSTEM

Available as an option to upgrade base Push Frame. The plow
will be easy to install with this quick-attach system. Durable
with a powder-coated rust-resistant finish.
715000731

Increases operator convenience. Swivel system allows the driver
to manually pivot the plow blade from the driver’s seat.
Cannot be used with the Push Frame Extension (703500603).
715000260

$129.99

$169.99

28 PARTS & ACCESSORIES PLOW ACCESSORIES

2

THE PLOW

Straight or One Way State

STRAIGHT PLOW
Super-duty plow blades made from 12-gauge steel.
Replaceable wear blades. When angled, 60” (1.5 m)
blade clears 53½” (1.36 m) path, 54” (1.37 m)
blade clears 48” (1.23 m) path. Blades swivel left
or right, 5 positions. Large pin designed for easy
blade rotation to eliminate dirt and snow buildup
at pivot point. Blade design provides best snow/dirt
roll-off at any angle. Yellow-colored version
Can-Am branded.
54" (1.37 m)
- 715000647 Yellow
- 715000208 Black

$184.99
60" (1.5 m)
- 715000648 Yellow
- 715000209 Black

$189.99

ONE WAY STATE PLOW
One-way “winged” state plow designed to throw snow
higher. Wing end measures 25” (63 cm) high
and plow tapers down to 16” (41 cm). Rubber flap
designed to keep snow away from driver.
Yellow-colored version Can-Am branded.
60" (1.5 m)
- 715000649 Yellow
- 715000207 Black

$299.99
66" (1.68 m)
- 715000650 Yellow
- 715000253 Black

$339.99

3

THE MOUNTING SYSTEM
FOR YOUR VEHICLE

Quick release pins attach and detach plow blade and base assembly
in minutes. Can be used with or without Quick Attach System (715000731).
Simplified installation. No frame drilling required.

(Not illustrated)
Renegade 2010-2011
& Outlander X xc 2011 - 715001206

$134.99
Outlander 2006-2011
& Renegade 2007-2009 - 715001205

$104.99
(Not illustrated)
Outlander 400 2004-2005 - 715000586

$79.99
Traxter & Quest - 715000258

$79.99

PLOW ACCESSORIES PARTS & ACCESSORIES 29

REAR TIRE CHAIN
Improve your traction in mud and snow. Sold in pairs.
25 X 10 X 12 - 715000225
26 X 10 X 12 - 715500218

$79.99

PLOW LIGHTS
Featuring 35W H3 halogen bulbs and a lens design that
achieves 110-degree beam spread to provide excellent
lighting for plowing.
Outlander - 715000063

$69.49

PULLEY KIT

DRIFT CUTTER

Pulley kit to be used in conjunction with the winch when
using a snow plow. Recommended to increase winch
efficiency. To be used with the XT Front Bumper.
715000279

Helps keep snow in the plow. Designed with a rear pivot point.
Works with both Straight and One Way State blades.
Left: - 715000217
Right: - 715000218

$44.99

$79.99

SYNTHETIC WINCH CABLE FOR PLOW
Specially designed for plowing applications. 8' (2.4 m)
section of durable, extra-strong synthetic rope. Stands
up to repeated, sharp angle pulls used to lift heavy plow
blades. Temporarily replace your winch rope for plow
season to save wear and tear on wire rope.
715000540

$39.99

30 PARTS & ACCESSORIES WINCHES

RT25 WARN† WINCH KIT
Fully-sealed Warn winch with 2,500 lbs (1,134 kg) of pulling strength. Includes
a 0.9hp motor, 50' (15 m) of 3/16" (5 mm) wire rope, an ergonomically
designed clutch knob, mechanical brake, sealed mini-rocker handlebar
switch, a waterproof contactor and a roller fairlead. CE certified.
715000553

$424.99

XT15 WARN WINCH KIT
Lightweight Warn 1,500 lbs (680 kg) winch kit complete with synthetic
rope, roller fairlead, mounting plates and hardware. Specifically designed
for the Renegade.
715000254

$584.99

RT30 WARN WINCH KIT
Fully-sealed winch capable with 3,000 lbs (1,361 kg) of pulling
strength. Includes a 0.9hp motor, 50' (15 m) of 3/16" (5 mm) wire rope,
an ergonomically designed clutch knob, mechanical brake,
hand-held remote and a potted-and-sealed mini-rocker handlebar
switch, a waterproof contactor and a roller fairlead. CE certified.
715000528

$524.99

XL2500 WINCH KIT FOR
TRAXTER/QUEST
(Not illustrated)
Complete 2,500 lbs (1,134 kg)
winch and mounting kit including
a roller fairlead.
Traxter & Quest - 715000546

WINCH MOUNTING KIT
(Not illustrated)
All Traxter models - 715500108
All Outlander models - 703500547

$34.99

$529.99

NEW WINCH BRAKE KIT
(Not illustrated)
Upgrades standard winch with brake kit. Convenient for use with plow.
Fits all production Outlander with XL3000 winch
715001135

$79.99

WINCHES PARTS & ACCESSORIES 31

SYNTHETIC WINCH CABLE
Easier to manipulate than steel cable.
Replaces the original cable on any factory
installed Warn winch or sold as an
accessory by BRP. Kit includes synthetic
rope and rock guard sleeve. Always
use with roller fairlead (715000011)
to prevent premature wear.
50' (15 m) long. 3,000 lbs (1,361 kg)
of strength. - 715000539

$109.99
For XT15 winch only. 40' (12 m) long.
1,500 lbs (680 kg) of strength. - 715000593

$99.99

WINCH ACCESSORIES KIT
Get the most out of your winch. Double your pulling power, change your pulling
direction and keep your winch in proper working order. Includes tree straps, snatch
block and shackle.
715000005

$134.99

WIRE ROPE REPLACEMENT
Play it safe. Always carry a replacement
wire rope. 50' (15 m) aircraft grade steel
wire. 3/16" (5 mm) diameter. 3,000 lbs
(1,361 kg) of strength.
All Warn winches - 715000047

$44.99

WIRED REMOTE CONTROL

WIRELESS REMOTE CONTROL

(Not illustrated)
This kit allows the winch owners
to add the hand-held remote to their
winch. Works in conjunction with
the mini-rocker switch.
715000197

The system is quick and easy to install, thanks to a wiring harness with an integrated
antenna, and all necessary mounting hardware. The system allows you to operate your
winch from anywhere within a 50’ (15 m) radius, increasing your recovery options. All
components are weatherproof. Works with all Outlander XT, Traxter/Quest XT MY 2004
and up and BRP accessory winches with a handlebar mounted mini-rocker switch.
715000544

$74.99

$164.99

HOOK WITH SAFETY LATCH
& STRAP KIT

ROLLER FAIRLEAD

Allows for more winch cable clearance
when using XT-style bumpers.
Outlander XT, MAX XT - 715000696

Heavy-duty winch-rope hook with
stainless steel snap. Includes a nylon
safety strap.
715000069

Features top, bottom and side rollers for
less cable wear and smoother operation
from any direction for easier winching.
715000011 Black

$39.99

$16.99

$44.99

WINCH FAIRLEAD BRACKET

32 PARTS
32
PAR
ARTTS & ACCESSORIES
ACCE
CEESSS
SSO
SORRIE
IES CO
CCOVERS
OVER
EERS
RS
RS

RENEGADE TRAILERING COVER
300-denier solution-dyed, water-repellent polyester construction. Fits with or without
mirrors and windshield attachment brackets (windshield must be removed). Key wear
areas are reinforced.
280000316

$149.99

DS 450 TRAILERING COVER

OUTLANDER TRAILERING COVER

X-attachment system. 300-denier
solution-dyed, water-repellent nylon.
Key areas are reinforced. Includes
sponsor graphics.
280000346

(Not illustrated)
X-attachment system. 300-denier
solution-dyed, water-repellent polyester
construction. Fits with or without mirrors
and windshield. Key areas are reinforced.
Outlander with Trunk Box - 715000675

$149.99

STORAGE COVER

$179.99

For storage use only. Fits with or without windshield and mirrors.
Heavy-duty elastic cord around bottom for secure fit.
Vinyl construction
100-denier polyester construction
DS 250 - 715000261 Black
Renegade - 715000678 Black
Outlander MAX - 715000676 Black

Outlander - 715000682

$109.99

$99.99

Outlander - 715000677 Black

DS 450 - 280000347 Black

$99.99

$99.99

$149.99
Outlander MAX - 715000681

$159.99

$84.99

BAG
BBA
BAGS
AAGGS
GS PA
PPAR
PARTS
ARRTTSS & ACCE
AACCESSORIES
CCE
CESSSSO
ORRIE
ORIE
IEES
ES 33
33

PREMIUM MODULAR BAG
Multi-configuration four section bag. Constructed of 600-denier,
solution-dyed, water-repellent polyester. Semi-rigid thermoformed
structure. Heavy-duty water-resistant zipper. Easily converts into
a duffle bag.
Outlander 2006-2011 - 280000296 Black

$179.99

FRONT BAG
100% water-repellent polyester construction. Designed to fit with or
without a rack extension. Integrated map holder. Waterproof zippers.
Outlander 2006-2011 - 715000235 Black

$119.99
Outlander 2004-2005 - 295100276 Black

$114.99

REAR BAG
REAR BAG

$114.99

Constructed of 600-denier,
solution-dyed, water-repellent
polyester. Semi-rigid
thermoformed structure.
Quickly and easily converts into
a practical backpack. Heavy-duty
water-resistant zipper. Easy to
install and remove.
Renegade - 280000295 Black

DS 250 - 715000264 Black

$89.99

100% water-repellent polyester construction. Designed
to fit with or without a rack extension. Waterproof zippers.
Outlander 2006-2011 - 715000234 Black

$119.99
Outlander 2004-2005 - 295100277 Black

$89.99

34 PARTS & ACCESSORIES MULTI-FIT

GPS MOUNT

CELL PHONE MOUNT

HOOK HOLDER

Find your way home. Great for the ATV riding
environment. This mount holds steady any
GPS under high vibration conditions.
715000120 Black

Keep your phone close by when working or
riding. The unique design of this mounting
system offers easy installation, mobility,
strength and versatility.
715000122 Black

An easy way to carry your tools, firearm or bow over any terrain with confidence.
Swivels to allow various mounting positions for multiple applications.
Allen wrench is included for easy installation to your tubular rack.
Single - 715000042 Black
Double - 715000043 Black

$89.99

$89.99

$49.99

$69.99

BRP CAN-AM VANITY PLATE
484800455

$12.99

HAND HELD LIGHT

CUP HOLDER

High-intensity rubber spotlight comes standard
with a one-inch diameter double ball and
socket system. Designed to withstand more
than 50 g of shock. Can be easily moved from
your handlebar, rack or any other location you
choose. Plugs into 12V DC outlet.
715000007 Black

Mounts easily to handlebars or racks.
715000121

$73.49

TIE-DOWN
Our 100% polyester ratchet-style tie-down measures 10' (3 m) in length
and ensures a safe load with its unique soft loop strap design.
715000276 Black

$79.99

$14.99

MIRROR
True vision surface. Matte finish. Stem
includes 3/8" (10 mm) thread. Bracket
(715000190) is required for installation
on an Outlander without windshield.
Right 5/16” (8 mm) - 709400407
Right 3/8” (10 mm) - 709400523
Left 3/8” (10 mm) - 709400406

$18.49

FLAG
Make sure everyone knows
what you’re riding. Perfect for
the dunes and new riders.
8-foot (2.4 m) length.
Includes flag mount (715000127).
715000277 Yellow

$19.99

FLAG MOUNT
715000127

$19.99

35

PRIME TLC
FOR YOUR

ATV
Original Equipment
Manufacturer
and Manufacturer
Recommended
Products & Kits

XPS 4-STROKE OIL CHANGE KIT

CARLISLE† TIRES

Complete maintenance right out of the box: O-Ring,
XPS oil, Rotax oil filter and instruction sheet.
Summer use - 703500736
All climate use - 703500735

The complete collection of Carlisle tires
for Can-Am ATVs under one roof.
Rear - 705500606
Front - 705400431

$96.99

You own a Can-Am ATV because

$93.49

UNI FOAM OIL FILTER

you demand the very best from your

Allows maximum airflow
while keeping the dirt
and dust particles out.
5½ oz. 219700340

machine. Take care of your ATV
by maintaining it using strictly BRP

$73.99

and Rotax OEM or 100% Can-Am
approved parts and products,
and enjoy levels of performance
that make every Can-Am ATV ride
or functional application a uniquely
original experience.

BRAKE PAD KIT
One-stop replacement brake pad kit designed to
replace the parts while keeping your ATV’s
performance intact.
705600349
705600350

UNI FOAM
FILTER CLEANER
Uni Filter Cleaner’s powerful
agents quickly strip away grease
and dirt, yet won’t damage
air filters.
14½ oz. 219700341

$39.99

$101.99

YUASA† BATTERIES
Top of the line models from
the leading preferred original
equipment battery supplier
in the U.S.
18 Amps. Wet (YTX20L-BS)
410301203

$114.49
19 Amps. Dry (YB16CL-B)
278001756

$76.99
13 Amps. Wet (YTX15L-BS)
710000283

$121.99
Dry (YB30CLB)
278001882

$133.49
3 Amps. Wet (YT4L-BS)
410301204

$53.99

NGK† SPARK PLUGS
BRP dealers carry the full line of premium
NGK spark plugs for Can-Am ATVs.
707000246

$3.50

BECAUSE ONCE YOU RIDE WITH THE BEST,
ANYTHING LESS IS MIDDLE OF THE ROAD.
See your Can-Am ATV Authorized Dealer for the full line of OEM and manufacturer recommended parts and products.

36 PARTS
36
PAARRTS
PAR
PA
T & ACCESSORIES
TS
ACC
CCESSORI
SSO
SSS
SORIIE
IES M
MAI
MA
MAINTENANCE
AAIINNTE
TENANC
NANCE
CE

MAINTENANCE

MAINTENANCE PARTS & ACCESSORIES 37

XPS DOT 4 BRAKE FLUID

XPS 4-STROKE OIL CHANGE KIT

XP-S SYNTHETIC SUSPENSION GREASE

Exceeds DOT 3 and 4 requirements. Unique
low-moisture formulation providing maximum
protection against vapor lock. Recommended in
Ski-Doo snowmobiles and Can-Am off-road
vehicles.
293600131

Kit includes: 3 quarts of XPS synthetic blend oil, oil filter,
o-ring and instruction sheet.
For Renegade, Outlander & Commander
Summer use - 703500736
All climate - 703500735

Specially designed for Can-Am off-road vehicle suspensions.
Offers optimal lubrification at low and high temperature extremes
while protecting critical suspension components from dirt and
other contaminants.
400 g - 293550033

$94.99

$4.99

FUEL STABILIZER
Fuel additive to protect against fuel contamination
and residue build-up in carburetors and gas
lines. Should always be used before storing your
Can-Am off-road vehicle. Suitable for all
gasoline engines.
413408601

$8.49

XPS 4-STROKE SYNTHETIC OIL
- ALL CLIMATE GRADE

XPS 4-STROKE BLEND OIL - SUMMER GRADE

Unlike other ordinary 4-stroke motor oils, XPS all climate grade
synthetic 4-stroke oil is specifically engineered to meet the
particular lubrication requirements of the Can-Am off-road
vehicles equipped with Rotax 4-TECTM 4-stroke engines.
Provides easier starting in very cold temperatutes.
1 quart / 946 ml - 293600112
1 US gallon / 3.785 L - 293600115

Synthetic blend 4-stroke engine oil for the Rotax 4-TEC
engine. XPS summer grade synthetic blend off-road vehicle
engine oil is a high performance oil developped for riders
that demand maximum engine performance and protection
during all operating conditions.
1 quart / 946 ml - 293600121
1 US gallon / 3.785 L - 293600122

PRE-MIXED ANTIFREEZE/COOLANT
Pre-mixed ready to top up your coolant level.
Blended to perform best in our Rotax engines with
anti-corrosive additive.
219700362

$7.49

XP-S LUBE

XP-S STORAGE OIL

To use your 1 quart / 946 ml, 1 US gallon / 3.785 L
oil bottles for spill-free pouring. Easy installation.
414837300

A multipurpose lubricant that
prevents rust, corrosion and
moisture intrusion. Contains active
extreme-pressure additives which
provide excellent lubricity and
antiwear properties. Comes in a
spray can that works upside down.
14 oz. - 293600016

This specialty oil is a must when
putting your Can-Am off-road
vehicle away for extended periods.
Specially formulated to protect the
engine’s internal parts from the
hazards of rust and corrosion due
to condensation during storage
or prolonged periods of non-use.
350 g - 413711900

$6.49

$9.99

$8.99

FLEXIBLE SPOUT

Note: Please contact your nearest dealer for suggested retail prices of oil based products.

XPS OFF-ROAD VEHICLE
HPG-T/A GAS SHOCK OIL
Recommended for all top quality
gas shocks for off-road vehicle
including our own Can-Am
HPG-T/A nitrogen gas charged
shocks. High viscosity index for
extreme temperatures encountered
in off-road vehicle conditions.
293600136

$65.99

38 PARTS & ACCESSORIES MAINTENANCE & DECALS

XPS CLEANING PRODUCTS

DECALS

6" x 12 3/4" (15 cm x 32 cm)
704901484

$11.99

XPS MICROFIBER TOWELS

XPS OFF-ROAD VEHICLE WASH

The latest in high-quality detailing towels. Made up of
extremely fine fibres, their soft surfaces have been
perfected for drying and polishing motorcycles, boats,
cars or any shiny finish. They are so absorbent they hold
up to seven times their weight in water. Machine
washable means they can be used over and over again.
Packs of 2 219701759

A biodegradable and non-toxic cleaner that removes mud
and dried-on dirt from your off-road vehicle. Whether grimy
from the track, the woods or the fields, this cleaner will leave
your off-road vehicle sparkling. When used as directed,
XPS ATV Wash is safe for all off-road vehicle finishes.
32 oz. / 946 ml 219701702

$8.49

$9.99

6" x 12 3/4" (15 cm x 32 cm)
704901483

$11.99

12" x 4" (30 cm x 10 cm)
704901482

$11.99

XPS FINISHING SPRAY

XPS BRAKES & PARTS CLEANER

The final touch to your detailing job. Uses an advanced
silicone product. Melon-scented spray quickly treats
faded plastics, vinyl, rubber and more to restore their
original look. Long lasting, it helps keep mud and dirt
from sticking to your vehicle’s finish and does not leave
streaks or spots. Contain no ozone depleters and
no chlorinated solvents.
12 oz. / 340 g 219701704

A concentrated blend of solvents with a powerful blasting
spray that effectively removes grease, grime, brake fluid
and other contaminants from brake components and
metal parts without the need for disassembly. Evaporates
instantly and completely leaving no residue to hinder
performance. Contains no ozone depleters.
14 oz. / 397 g 219701705

$8.49

$7.99

Set of 2. 2" x 6" (5 cm x 15 cm)
704901480

$9.99

XPS OFF-ROAD VEHICLE
CLEANING KIT
Kit includes: XPS off-road vehicle
Wash, XPS Finishing Spray and
XPS Microfiber Towels.
219701713

$24.99
9 per sheet. 24" x 8" (60 cm x 20 cm)
704901481

$10.99

OFFICIAL LICENSED PRODUCTS PARTS & ACCESSORIES 39

OFFICIAL
LICENSED PRODUCTS

TRUCK ACCESSORIES

CAN-AM MUD FLAPS
Keep dirt and mud off trucks, SUVs. Reduce damage from rock chips
and other road debris. Fit most trucks and SUVs. Quick and easy
installation. Sold in pairs.
4849410086

CAN-AM X-TEAM UMBRELLA
58” (147 cm) arc umbrella with
fiberglass shaft and black tire grip handle.
CA08A70090

CAN-AM MULTI-TOOL

CAN-AM X-TEAM HITCH PLUG

High-Sierra† 15-function multi-tool.
Includes can and bottle opener,
phillips head screw driver, 3 driver
bits (2 – 4 mm), 3 blades (3 – 5 mm),
serrated blade, pliers, needle nose pliers,
wire cutter and dual-function file.
CA08A60090

Gives trucks, SUVs custom finished look. Keeps dirt, snow
and other debris out of receiver. Fits 2” (5 cm) receivers.
4849510086

CAN-AM FLEECE BLANKET
Anti-pill blanket. 100% polyester.
50’’ × 60’’ (130 cm × 150 cm) fleece
blanket with carry handles.
CA08A80090

CAN-AM X-TEAM REAR WINDOW SKIN
Great looking rear window skin. Provides shade from the sun to help
keep interior temps low. Clear view from the inside looking out. Trim to
fit almost any vehicle. Non-permanent adhesive for easy removal.
4849110086

CAN-AM WIRELESS
AQUA MOUSE
Wireless mouse with floating vehicle
replica. PS/2, USB Port. Compatible
with Windows†.
CA09A20030

CAN-AM LICENSE PLATE
For additional information or to purchase these items,
please contact your nearest BRP dealer.

Made of stainless steel with mirror finish. Raised letters to give 3D look.
Thicker and more durable. Universal to fit all vehicles.
4849610008

40

SIZING CHART

CHEST/BUST: Measure under your arms,
around the fullest part of your chest.
WAIST: Measure around your natural
waistline, keeping one finger between
the tape and body.

HOW TO MEASURE
For best results, have someone
else take measurements.
Measure body in underwear.
Tape must be snug but not tight.
If measurements fall between
two sizes, order the larger size.

GLOVES: Measure palm width.
HELMET: Measure around your head
at the temple above the eye brow.

MEN/JACKET
XS
33 - 35
28 - 30
31
32 - 34
31

CHEST
WAIST
ARM LENGTH
HIPS (SEAT)
INSEAM

S
36 - 38
30 - 32
33
35 - 37
32

M
39 - 41
33 - 35
33
38 - 40
32

MT
39 - 41
33 - 35
34 1/2
38 - 40
34

L
42 - 44
36 - 39
34
41 - 43
32

XL
46 - 48
41 - 43
34
45 - 47
33

LT
42 - 44
36 - 39
35 1/2
41 - 43
34

XLT
46 - 48
41 - 43
35 1/2
45 - 47
35

2XL
50 - 52
45 - 48
35
49 - 51
33

3XL
54 - 56
50 - 52
35
53 - 55
33

MEN/PANTS
30
30 - 32
35 - 37
32

WAIST
HIPS (SEAT)
INSEAM

32
32 - 34
37 - 39
32

34
34 - 36
39 - 41
32

36
36 - 38
41 - 42
32

38
38 - 40
42 - 44
32

40
40 - 42
44 - 46
33

S
34 1/2 - 35 1/2
26 1/2 - 27 1/2
30

M
36 1/2 - 38
28 1/2 - 30
31

L
39 1/2 - 41
31 1/2 - 33
32

XL
43 - 45 1/2
35 - 37
32

2XL
47 - 49 1/2
39 - 41
32

LADIES’/JACKET
XS
32 1/2 - 33 1/2
24 1/2 - 25 1/2
29

CHEST
WAIST
ARM LENGTH

LADIES’/PANTS
5-6
26 - 28
36 - 38
29

WAIST
HIPS (SEAT)
INSEAM

7-8
28 - 30
38 - 40
30

9-10
30 - 32
40 - 42
30

11-12
32 - 34
42 - 44
30

MEN GLOVES (MEASURE PALM WIDTH)
S
3
7.5

INCHES
CM

13-14
34 - 36
44 - 46
30

SOCKS

M
3 3/8
8.5

L
3 3/4
9.5

XL
4 1/8
10.5

2XL
4 1/2
11.5

S/M
6-9

L/XL
10 - 13

2XL
7 7/8 - 8
3 4
24 / - 25 1/8
63 - 64

3XL
8 1/8 - 8 1/4
3 8
25 / - 25 7/8
65 - 66

WHAT CODE
REPRESENTS
YOUR SIZE?
1. Find your size
2. The corresponding code is
THE CODE you use to complete
the part number on your order.
Example: 440 227_90
Size: M = code 06
Therefore 440 227 0690

LADIES’ GLOVES (MEASURE PALM WIDTH)
S
2 5/8
6.8

INCHES
CM

M
3
7.5

L
3 1/4
8.3

XL
3 1/2
9

HELMETS
XS
6 1/2 - 6 3/4
7 8
20 / - 21 1/4
53 - 54

HELMET SIZE
HEAD (INCHES)
HEAD (CM)

S
6 7/8 - 7
5 8
21 / - 22
55 - 56

M
7 1/8 - 7 1/4
3 8
22 / - 22 3/4
57 - 58

L
7 3/8 - 7 1/2
1 8
23 / - 23 5/8
59 - 60

XL
7 5/8 - 7 3/4
24 - 24 3/8
61 - 62

KIDS/TEEN
CHEST
WAIST
HIP (SEAT)
ARM LENGTH
INSEAM

2
21
20
21
15 1/2
13 1/2

3-4
22 - 23
20 1/2 - 21
22 - 23
17 - 18 1/2
15 1/2 - 17 1/2

5-6
24 - 25
21 1/2 - 22
24 - 25
20 - 21 1/2
19 1/2 - 21

7-8
26 - 27
22 1/2 - 23
26 - 27
23 - 24 1/2
22 3/4 - 24 1/2

10-12
28 1/2 - 30
24 - 25
28 1/2 - 30
28 1/2 - 30
26 1/4 - 28

14-16
31 1/2 - 33
26 - 27
31 1/2 - 33
31 1/2 - 33
29 1/2 - 31

SIZE
One Size
XS
S
M
MT
L
LT
XL
XLT
2XL
3XL
S/M
L/XL
2
3-4
6-8
10-12
14-16
30
32
34
36
38
40
5-6
7-8
9-10
11-12
13-14

CODE
00
02
04
06
07
09
10
12
13
14
16
72
73
21
79
48
49
50
37
38
39
40
41
42
52
54
55
56
80

TECHNICAL TERMINOLOGY
WE KEEP YOU DRY
Respiractive Performance Matrix or RPM coating
exclusive to BRP Riding Gear. Delivers extremely high
performance and durability for perfect climate control
under even the most extreme conditions. Trademark
waterproofness, windproofness and breathability
required of BRP Riding Gear shell fabric developed for
intensive use and demanding riders.
Same great RPM coating PLUS total seam and logo
sealing. Also, added direct venting in strategic jacket
areas for more efficient moisture management during
intense activity.

TEFLON†

Teflon provides an invisible barrier around fabric fibers
to repel water and stains. In addition to retaining its water
shedding properties longer than standard Teflon, Teflon
HT and HP are also even more resistant to soiling and
staining without altering the fabric’s color, appearance,
structure, texture and breathability. Teflon HT, good up
to 20 washes and Teflon HP up to 30 washes compared
to manufactured coatings washable only 1 to 5 times.

WE KEEP YOU WARM
W
HIPORA†

Windproof, breathable and waterproof membrane
that features unique polyurethane coating technology
and delivers excellent moisture management.

DWR†

DWR stands for Durable Water Repellency. This
treatment helps prevent the outer fabric surface
from absorbing water, keeping the outerwear both
light and comfortable.

SEAM
SEALING

Seams and embroidery can act as tiny entry points
through which wind and water can infiltrate. That’s
why jackets and pants with RPM are critical seam
and logo sealed. And Riding Gear with RPM Max
are 100% seam and logo sealed for an even more
comprehensive barrier from all the elements.
The proprietary tape is also waterproof and breathable
to fully seal the deal for complete performance.

CRESTA BY PRIMALOFT
Primaloft Cresta offers
warmth without weight
and extra bulk. It is
designed to keep you
warm and comfortable
throughout the day.

PRIMALOFT ONE
Warmer wet or dry than
any other synthetic
insulation. The ultimate
down-like microfiber
insulation. Quick
drying, soft, and
breathable. Primaloft
One is lightweight,
compressible and
thermally efficient.

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