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Summary of Contents for Can-Am Renegade 570 2016
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Page 1
2016 Can-Am Renegade 570 / 850 Series Here is combined the Base service manual with the 2016 supplement manual into one manual. -
Page 2
This shop manual supplement has been prepared NOTE: Indicates supplementary information re- as a guide to correctly service and repair the 2016 quired to fully complete an instruction. Can-Am ™ Renegade ATVs as described in the Although the mere reading of such information… -
Page 3: Vehicle Information
INTRODUCTION This shop manual supplement covers the follow- A VIN (Vehicle Identification Number) decal is lo- ing BRP made 2016 Can-Am Renegade Series ve- cated under the seat, and another on the forward hicles. RH side of the lower frame member. A vin num- ber is also stamped on the frame in this area.
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Page 4
INTRODUCTION The owner/operator is not to, and should not al- low anyone else to modify the engine in any man- ner that would alter the horsepower or allow emis- sions levels to exceed their predetermined factory specifications. EMISSION REGULATIONS The vehicle you are servicing may have been certified to applicable emission regulations in your country or state. -
Page 5
INTRODUCTION A number of procedures throughout the book re- quire the use of special tools. Before starting any procedure, be sure that you have on hand all re- quired tools, or their approved equivalents. The use of RIGHT and LEFT indications in the text are always referenced to the driving position (sit- ting on the vehicle). -
Page 6
INTRODUCTION TYPICAL PAGE Page heading Section 06 ENGINE indicates section Subsection 01 (MAGNETO) and subsection. MAGNETO Subsection title Indicates applicable Models models. Drop represents a Loctite 243 service product Exploded view assists to be applied. Model you in identifying parts and their related Dotted box contains positions. -
Page 7
INTRODUCTION TYPICAL PAGE Section 03 ENGINE Section 03 ENGINE Subsection 09 (MAGNETO SYSTEM) Subsection 09 (MAGNETO SYSTEM) Tittle in bold indicates category GENERAL GENERAL of information to be carried out. NOTE: The following procedures can be done NOTE: The following procedures can be done without removing the engine. -
Page 8: Tightening Torque
INTRODUCTION TIGHTENING TORQUE Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When a torque is not specified, refer to the following table. WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices must be replaced when removed (e.g.: locking tabs, elastic stop nuts, self-lock- ing fasteners, cotter pins, etc.).
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Page 9
INTRODUCTION FASTENER INFORMATION Threadlocker Application for Uncovered Holes (Bolts and Nuts) NOTICE Most components in the vehicles are built with parts dimensioned in the metric system. Most fasteners are metric and must not be replaced by customary fasteners or vice-versa. Mismatched or incorrect fasteners could cause damage to the vehicle or possible personal injury. -
Page 10
INTRODUCTION Threadlocker Application for 4. Apply several drops along the threaded hole Pre-Assembled Parts and at the bottom of the hole. 5. Apply several drops on bolt threads. 6. Tighten as required. Threadlocker Application for Stud Installation in Blind Holes A00A3OA 1. -
Page 11
INTRODUCTION Gasket Compound Application NOTE: If it is difficult to readjust, heat screw with a soldering iron (232°C (450°F)). Application for Stripped Thread Repair A00A3QA 1. Release agent 2. Stripped threads 3. Form-A-Thread lmr2007-040-006_a 4. Tape 5. Cleaned bolt 1. Proper strength Loctite 6. -
Page 12
INTRODUCTION Threadlocker Application for Mounting 2. Spray housing and gasket with LOCTITE 7649 on a Shaft (PRIMER) (P/N 293 800 041) 3. Apply a strip of proper strength Loctite on lead- Mounting with a Press ing edge of outer metallic gasket diameter. NOTE: Any Loctite product can be used here. -
Page 13: Periodic Maintenance Schedule
Subsection 01 (PERIODIC MAINTENANCE SCHEDULE) PERIODIC MAINTENANCE SCHEDULE GENERAL Maintenance is very important for keeping your vehicle in safe operating condition. Proper maintenance is the owner’s responsibility. The vehicle should be serviced as per the maintenance schedule. The maintenance schedule does not exempt the pre-ride inspection. WARNING Failure to properly maintain the vehicle according to the maintenance schedule and procedures can make it unsafe to operate.
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Page 14
Subsection 01 (PERIODIC MAINTENANCE SCHEDULE) EVERY 1 500 KM (1,000 MI) OR 50 HOURS (whichever comes first) EVERY 750 KM (500 MI) OR 25 HOURS (whichever comes first) Tighten wheel beadlock bolts (If equipped) Lubricate lower shock absorber spherical bearings (Outlander LTD and XT-P, Renegade Xxc and X mr) Lubricate upper shock absorber spherical bearings (Outlander LTD and Outlander X mr 1000) EVERY 3 000 KM (2,000 MI) OR 100 HOURS (whichever comes first) EVERY 1 500 KM (1,000 MI) OR 50 HOURS (whichever comes first) -
Page 15
Subsection 01 (PERIODIC MAINTENANCE SCHEDULE) EVERY 6 000 KM (4,000 MI) OR 200 HOURS (whichever comes first) EVERY 3 000 KM (2,000 MI) OR 100 HOURS (whichever comes first) Inspect input and output shaft seals (gearbox, differential and final drive) Clean vehicle speed sensor Clean and lubricate lower and upper steering column half bushings The following must be performed every 2 years:… -
Page 16: Periodic Maintenance Procedures
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) PERIODIC MAINTENANCE PROCEDURES SERVICE TOOLS Description Part Number Page 529 035 991 ……….8 TEST CAP ………………529 021 800 ……..8, 23 VACUUM/PRESSURE PUMP …………SERVICE PRODUCTS Description Part Number Page 219 700 341 ……….3 AIR FILTER CLEANER …………..
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Page 17
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) NOTE: A socket wrench may be used to ease re- moval of the filter cover. vmr2012-010-017_a SOME PARTS REMOVED FOR CLARITY 1. Air filter housing drain tube vmo2015-005-014_a 1. Air filter cover 3. Check air filter dirty chamber for cleanliness. 4. -
Page 18
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) NOTICE Oiling the Foam Filter It is not recommended to blow com- pressed air on the paper filter; this could dam- 1. Spray recommended air filter oil on the foam fil- age the paper fibers and reduce its filtration ter previously cleaned and dried. -
Page 19
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) Reinstall the console. 3. Remove carbon deposits from the spark ar- rester using a brush. EXHAUST SYSTEM NOTICE Use a soft brush and be careful to avoid damaging spark arrester mesh. Cleaning and Inspecting the Muffler Spark Arrester WARNING Never run engine in an enclosed area. -
Page 20
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) Verifying the Engine Oil Level Repeat the above procedures until oil level reaches the dipstick’s upper mark. Do not over- NOTICE Operating the engine with an im- fill. Wipe off any spillage. proper engine oil level may severely damage Properly tighten dipstick. -
Page 21
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) 850 and 1000R Engines TIGHTENING TORQUE 30 N•m ± 2 N•m Magnetic drain plug (22 lbf•ft ± 1 lbf•ft) REPLACING THE 11. Replace oil filter. Refer to ENGINE OIL FILTER in this subsection. 12. Refill engine with recommended engine oil. ENGINE OIL CAPACITY 2 L (2.1 qt (U.S. -
Page 22
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) BODY 2. Remove gauge support. Refer to sub- section. With the vehicle on a level surface, coolant level should be between the MIN. and MAX. marks of the reservoir. vmr2006-008-001_a 1. Slightly oil 2. Slightly oil 5. -
Page 23
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) Engine Cooling System Leak Test 1. Remove the console. Refer to BODY subsec- tion. 2. Remove pressure cap. 3. Pressurize cooling system as follows. REQUIRED TOOLS TEST CAP (P/N 529 035 991) vmr2016-009-002_a VACUUM/PRESSURE 1. Leak indicator hose 2. -
Page 24
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) vmr2015-029-202_a vmr2012-013-010_a 1. Outer exhaust heat shield TYPICAL — SOME PARTS REMOVED FOR CLARITY 1. Coolant drain plug 4. Remove CVT duct outlet. 4. Drain cooling system into a suitable container. 5. Disconnect the lower radiator hose and drain the remaining coolant. -
Page 25
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) 2. Before checking or adjusting the valve clear- ance, turn crankshaft clockwise to TDC ignition CAMSHAFT of the respective cylinder, refer to TIMING GEAR TIMING CHAIN in the subsec- tion. NOTICE Crankshaft must be turned clock- wise only to avoid loosening the magneto retaining bolt. -
Page 26
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) GEARBOX 3. Check oil level. The oil should be level with the bottom of the oil Recommended Gearbox Oil level hole. RECOMMENDED QUANTITY NOTICE Operating the gearbox with an im- PRODUCT proper oil level may severely damage gearbox. XPS SYNTHETIC Approximately 450 ml GEAR OIL (75W 140) -
Page 27
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) NOTE: A dirty VSS will cause erratic speedometer readings. CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Cleaning the CVT Air Inlet / Outlet 1. Remove CVT cover, refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT) subsection. 2. Inspect and clean the air inlet and outlet open- ings from inside the CVT cover. -
Page 28
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) Inspecting the Drive Belt 1. Inspect belt for cracks, fraying or abnormal wear. Replace if necessary. 2. Check drive belt width at cord level. Replace if it is out of specification. DRIVE BELT WIDTH SERVICE LIMIT 30 mm (1.181 in) vmr2006-021-021_a LUBRICATE… -
Page 29
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) WARNING Always use a silicone-based lubricant. Using another lubricant (like a water-based lubri- cant) could cause the throttle lever/cable to become sticky and stiff. Open the throttle lever housing. V07I0HA 1. Inner housing protector Remove the cable from the throttle lever housing. NOTE: Slide cable in clip slot and remove the end V07I0FY of cable from clip. -
Page 30
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) vmo2006-007-032_a vmr2015-043-019_d 1. Throttle body 1. Vent breather filter 2. Side cover screws 2. Vent inlet check valve Insert the needle of the lubricant can in the end of Inspecting the Fuel System throttle cable adjuster. 1. -
Page 31
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) Replacing the Spark Plugs Spark Plug Access To access the front cylinder spark plug, remove the exhaust system outer heat shield. Refer to EXHAUST SYSTEM subsection. To access the rear cylinder spark plug, remove the RH side panel. -
Page 32
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) tmr2011-032-006_a LH REAR SIDE OF VEHICLE 1. Filler plug vmr2016-107-001_a RH SIDE OF VEHICLE 4. Verify the oil level by inserting a wire with a 90° NOTE: Allow enough time for oil to flow out. bend through the oil filler hole. -
Page 33
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) TIGHTENING TORQUE TIGHTENING TORQUE 5 N•m ± 1 N•m 11 N•m ± 1 N•m Drain plug Beadlock screws (44 lbf•in ± 9 lbf•in) (97 lbf•in ± 9 lbf•in) 7. Refill the rear final drive. RECOMMENDED OIL QUANTITY XPS SYNTHETIC GEAR OIL (75W 140) -
Page 34
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) Tie-Rod End SPHERICAL BEARING LUBRICATION Check tie-rod end ball joint for: SUSPENSION GREASE (P/N 293 550 033) – Damage – Pitting – Abnormal play. Replace if necessary. Cleaning and Lubricating the Steering Column Half Bushing Clean, inspect and lubricate upper and lower steering column half bushings and O rings. -
Page 35
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) – Bearings – Inner spacers. 4. Check ball joint for: – Damage – Pitting – Play. 5. Check ball joint bellows for: – Damage – Cracks. Inspecting and Lubricating the Rear Stabilizer Bar Bushings vmr2012-040-013_a TYPICAL Inspecting the Rear Stabilizer Bar Bushings 1. -
Page 36
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) Verifying the Brake Fluid Reservoir WARNING Level Clean filler cap before removing. With vehicle on a level surface, check brake fluid in reservoirs for proper level. Remove screws retaining the reservoir cap. NOTE: A low level may indicate leaks or worn Remove reservoir cap. -
Page 37
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) NOTICE Brake pads must always be replaced 2. If required, clean then lubricate brake pedal in pairs. pivot using XPS SYNTHETIC GREASE (P/N 293 550 010) Brake Caliper Brake Hoses 1. Remove caliper then check the following com- ponents: 1. -
Page 38
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES) 2. Pump up system pressure slowly using brake WARNING pedal and/or lever(s) until resistance is felt. Use only DOT 4 brake fluid from a sealed con- 3. Depress and hold brake pedal and/or lever(s). tainer. Do not use brake fluid from an old or already 4. -
Page 39: Storage Procedure
Subsection XX (STORAGE PROCEDURE) STORAGE PROCEDURE SERVICE PRODUCTS Description Part Number Page 293 110 001 ……….3 BRP HEAVY DUTY CLEANER …………413 408 601 ……….1 XPS FUEL STABILIZER…………..293 600 016 ……… 1, 3 XPS LUBE………………219 701 709 ……….3 XPS MULTI-PURPOSE CLEANER ……….
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Page 40: Battery Removal
Subsection XX (STORAGE PROCEDURE) vmr2012-007-001_a TYPICAL vmr2012-011-007_c 1. CVT cover 2. Exhaust system heat shield TYPICAL — RENEGADE MODEL ILLUSTRATED 3. CVT outlet 1. Muffler 2. Block with rag here 6. Block CVT outlet hose using a rag. ELECTRICAL SYSTEM Battery Removal Remove battery from ATV.
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Page 41
Subsection XX (STORAGE PROCEDURE) RECOMMENDED PRODUCT FOR PLASTIC PARTS XPS ATV Wash (P/N 219 701 702) Soapy water NOTICE It is necessary to use flannel cloths on plastic parts to avoid damaging surfaces. Never clean plastic parts with strong deter- gent, degreasing agent, paint thinner, acetone, products containing chlorine, etc. -
Page 42: Preseason Preparation
Subsection 05 (PRESEASON PREPARATION) PRESEASON PREPARATION Proper vehicle preparation is required after a stor- age period. Any worn, broken or damaged parts found must be replaced. Remove rags that were installed for storage: en- gine air inlet hose, CVT outlet hose and muffler. Clean drive and driven pulleys to remove storage protective lubricant, then reinstall drive belt.
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Page 43: Special Procedures
Subsection XX (SPECIAL PROCEDURES) SPECIAL PROCEDURES SERVICE PRODUCTS Description Part Number Page 293 600 016 ……….. 2 XPS LUBE………………GENERAL WHAT TO DO IF WATER IS IN THE AIR FILTER HOUSING NOTE: Component failures resulting from these events are not warrantable. Inspect the drain reservoir underneath the air filter housing to validate if water is present.
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Page 44
Subsection XX (SPECIAL PROCEDURES) – Check rear final drive oil level and refill if neces- Replace the engine oil (without starting the en- sary. gine). – Inspect suspension components and steering Replace gearbox oil. system components. Inspect fuel tank for water intrusion. If in doubt, –… -
Page 45: Engine Removal And Installation
Subsection XX (ENGINE REMOVAL AND INSTALLATION) ENGINE REMOVAL AND INSTALLATION SERVICE TOOLS Description Part Number Page 529 036 022 ……….. 5 ENGINE LIFTING TOOL …………..Outlander models 13 ± 2 N•m (115 ± 18 lbf•in) 7 ± 1 N•m (62 ± 9 lbf• in ) 4 ±…
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Page 46: Engine Removal
Subsection XX (ENGINE REMOVAL AND INSTALLATION) PROCEDURES ENGINE REMOVAL 1. Place vehicle on a workstation equipped with an engine-lifting hoist. 2. Disconnect negative (-) cable from battery. 3. Carry out the following operations. Refer to ta- ble. REFERENCES OPERATIONS (SUBSECTION) Safely lift and support vmr2012-009-003_a INTRODUCTION…
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Page 47
Subsection XX (ENGINE REMOVAL AND INSTALLATION) 11. Disconnect ignition coil connector. vmr2012-009-004_a TYPICAL 1. Crankcase vent hose vmr2012-009-007_a 8. Disconnect both engine harness connectors TYPICAL — FROM LH SIDE 1. Ignition coil connector (HIC). 12. Remove the following locking ties. vmr2012-009-005_a TYPICAL 1. -
Page 48
Subsection XX (ENGINE REMOVAL AND INSTALLATION) 16. Remove magneto harness from its location along vehicle and gather it in a bundle near engine. NOTE: It may be necessary to slightly lift the rear body module to ease magneto harness removal. Refer to BODY subsection. -
Page 49
Subsection XX (ENGINE REMOVAL AND INSTALLATION) Engine Lifting 1. Install the ENGINE LIFTING TOOL (P/N 529 036 on engine. 022) 529036022 vmr2012-009-025_a 500/650/800R ENGINES — SOME PARTS REMOVED FOR CLARITY 1. Disconnect the following coolant hoses vmr2012-009-015 TYPICAL 2. Remove upper retaining screws from engine. vmr2012-009-013_a 1000 ENGINE — SOME PARTS REMOVED FOR CLARITY 1. -
Page 50
Subsection XX (ENGINE REMOVAL AND INSTALLATION) vmr2012-009-020_a 1. Oetiker clamps vmr2012-009-017_a 7. Move front propeller shaft bellows forward. LH SIDE 1. Rear retaining bolt 4. Remove front retaining bolt from engine. vmr2012-009-021_a 1. Front propeller shaft bellows vmr2012-009-018_a 8. Remove propeller shaft screw from gearbox LH SIDE output shaft. -
Page 51: Engine Installation
Subsection XX (ENGINE REMOVAL AND INSTALLATION) 10. Move propeller shaft yoke downwards to TORQUE make room. 62.5 N•m ± 7.5 N•m Engine retaining bolts (46 lbf•ft ± 6 lbf•ft) 6. If applicable, fill engine as per specification. Re- LUBRICATION SYSTEM fer to subsection.
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Page 52: Air Filter Housing
Subsection XX (AIR INTAKE SYSTEM) AIR INTAKE SYSTEM AIR FILTER HOUSING 1.6 ± 0.4 N•m Loctite 5150 (14 ± 4 lbf•in) (silicone sealant) 6 ± 1 N•m (53 ± 9 lbf•in) Suspension grease 6 ± 1 N•m (53 ± 9 lbf•in) Loctite 5150 (silicone sealant) 2.5 ±…
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Page 53: Air Filter
Subsection XX (AIR INTAKE SYSTEM) GENERAL NOTICE Never modify the air intake system. Otherwise, engine performance degradation or damage can occur. The engine is calibrated to operate specifically with these components. PROCEDURES AIR FILTER For air filter servicing, refer to PERIODIC MAIN- TENANCE PROCEDURES subsection.
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Page 54
Subsection XX (AIR INTAKE SYSTEM) 7. Move ECM aside. vmr2012-010-004_a AIR INTAKE TUBE MOVED TO GAIN ACCESS 1. Coolant tank LH retaining screw vmr2012-009-005_a TYPICAL 1. Engine harness connectors (HIC) 8. Remove air intake tube retaining screw. vmr2012-010-005_a 1. Coolant tank RH retaining screw 11. -
Page 55
Subsection XX (AIR INTAKE SYSTEM) vmr2012-010-007 vmr2012-010-010_a TYPICAL — OUTLANDER SHOWN TYPICAL 1. Gearbox vent hose 13. Remove the following locking ties. 15. Detach crankcase vent hose from air filter housing. vmr2013-010-001_a TYPICAL — OUTLANDER SHOWN 1. Locking tie to remove — location shown vmr2012-010-011_a TYPICAL 1. -
Page 56
Subsection XX (AIR INTAKE SYSTEM) vmr2012-010-013_a vmr2012-010-015_a SCREW LOCATED UNDER COOLANT TANK TYPICAL — OUTLANDER SHOWN 1. Air filter housing retaining screw 1. Throttle body 20. Remove air filter housing by pulling it towards rear. vmr2012-010-014_a SCREW LOCATED ON LH SIDE — ACCESS FROM UNDER SHIFT LEVER vmr2012-010-016_a 1. -
Page 57
Subsection 03 (EXHAUST SYSTEM) EXHAUST SYSTEM 9 ± 1 N•m (80 ± 9 lbf•in) 13 ± 1 N•m (115 ± 9 lbf•in) 40 ± 1 N•m (30 ± 1 lbf•ft) Bolt down, nut facing outwards 13 ± 1 N•m (115 ± 9 lbf•in) 10 ±… -
Page 58: Spark Arrester
Subsection 03 (EXHAUST SYSTEM) GENERAL BODY 3. Refer to and remove both rear bumper braces. WARNING Never touch exhaust system components im- mediately after the engine has run. PROCEDURES SPARK ARRESTER PERIODIC For spark arrester servicing, refer to MAINTENANCE PROCEDURES subsection.
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Page 59
Subsection 03 (EXHAUST SYSTEM) HEAT SHIELD Heat Shield Removal BODY 1. Refer to and remove LH panel. 2. Remove heat shield retaining bolts. NOTICE Do not use impact tool to remove or install heat shield bolts. vmr2015-014-512_a 1. Inner heat shield 2. -
Page 60
Subsection 03 (EXHAUST SYSTEM) vmr2012-011-010_a 1. Y-exhaust pipe vmr2015-027-004_a 2. Springs 1. Head pipe retaining nuts Y-Exhaust Pipe Inspection 3. Remove front head pipe from vehicle. Check Y-exhaust pipe for cracks, bending or other damages. Replace if needed. Y-Exhaust Pipe Installation The installation is the reverse of the removal pro- cedure. -
Page 61
Subsection 03 (EXHAUST SYSTEM) Exhaust System Tightening System Sequence Install all nuts and bolts loosely. Install springs. Tighten all fasteners as per following tightening sequence. Refer to exploded view for torque specifications. vmr2016-401-002_a EXHAUST SYSTEM TIGHTENING SEQUENCE vmr2016-401… -
Page 62
Subsection 04 (LUBRICATION SYSTEM) LUBRICATION SYSTEM SERVICE TOOLS Description Part Number Page 529 035 652 ……….5 ADAPTER HOSE …………….529 035 714 ……….5 DISCONNECT TOOL …………..529 035 709 ……….5 PRESSURE GAUGE…………… SERVICE PRODUCTS Description Part Number Page 293 800 060 …….. -
Page 63
Subsection 04 (LUBRICATION SYSTEM) COMPONENTS 570 Engine 20 ± 2 N•m (15 ± 1,5 lbf•ft) Loctite 243 12 ± 1 N•m (106 ± 9 lbf•in) 10 ± 1 N•m (89 ± 9 lbf•in) Engine oil Engine oil 6 ± 0,7 N•m (53 ±… -
Page 64
Subsection 04 (LUBRICATION SYSTEM) COMPONENTS 850 and 1000R Engines 20 ± 2 N•m (15 ± 1.5 lbf•ft) Loctite 243 12 ± 1 N•m (106 ± 9 lbf•in) 10 ± 1 N•m (89 ± 9 lbf•in) Engine oil 30 ± 2 N•m (22 ±… -
Page 65
Subsection 04 (LUBRICATION SYSTEM) ENGINE LUBRICATION CIRCUIT vmr2007-033-001_a 1. Camshaft bearings 2. Oil pressure switch 3. Oil filter 4. Oil pressure regulator valve 5. Oil strainer 6. Oil pump 7. Crankshaft main bearings 8. Crankshaft support bearing 9. Connecting rod bearings vmr2016-402… -
Page 66
Subsection 04 (LUBRICATION SYSTEM) INSPECTION Remove oil pressure gauge and adapter hose. NOTE: To remove adapter hose from oil pressure TESTING THE ENGINE OIL gauge, use the disconnect tool. PRESSURE REQUIRED TOOL NOTE: The engine oil pressure test should be DISCONNECT TOOL done with a warm engine 100°C (212°F) and the (P/N 529 035 714) -
Page 67
Subsection 04 (LUBRICATION SYSTEM) 2. Cylinder head or cylinder base gasket leak. — Retighten cylinder head to specified torque, refer to TOP END subsection. Replace gasket if tight- ening does not solve the problem. 3. Engine internal damage. — Repair engine. 4. -
Page 68
Subsection 04 (LUBRICATION SYSTEM) OIL PRESSURE SWITCH (OPS) ENGINE NOT ENGINE CONNECTOR RUNNING Oil Pressure Switch Access RESISTANCE ( ) Remove OPS cover. Close to 0 Engine (normally closed ground switch) ENGINE ENGINE RUNNING CONNECTOR RESISTANCE ( ) Infinite (open) when Engine pressure reaches ground… -
Page 69: Oil Pump
Subsection 04 (LUBRICATION SYSTEM) ENGINE OIL PRESSURE SPRING FREE LENGTH REGULATOR NEW NOMINAL 39 mm (1.535 in) Oil Pressure Regulator Location SERVICE LIMIT 37 mm (1.457 in) The oil pressure regulator is located on the engine NOTE: Replace worn or damaged components. magneto side, integrated in the magneto cover.
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Page 70
Subsection 04 (LUBRICATION SYSTEM) tmr2011-010-012_a 1. Outer rotor 2. Needle pin tmr2011-010-011_a 3. Oil pump shaft 1. Thrust washer 4. Inner rotor 2. Needle pin 3. Oil pump gear Inspecting the Oil Pump 4. Retaining ring Inspect oil pump and oil pump cover bore for 2. -
Page 71
Subsection 04 (LUBRICATION SYSTEM) vmr2006-042-013_a 1. Pittings on the teeth Using a feeler gauge, measure the clearance of inner and outer rotors as shown. CLEARANCE OF INNER AND OUTER ROTOR 0.25 mm (.0098 in) SERVICE LIMIT vmr2006-042-015 OIL PUMP — MEASUREMENT “A” vmr2006-042-014_a 1. -
Page 72: Reed Valve
Subsection 04 (LUBRICATION SYSTEM) vmr2015-114-005_a 1. Markings After reinstallation of the remaining parts, check vmr2006-042-017_a for smooth operation of the oil pump assembly. 1. Engine oil strainer 2. Retaining plate Testing the Oil Pump Function 3. Screws After engine is completely reassembled, start en- Cleaning and Inspecting the Oil gine and make sure oil pressure is within specifi- Strainer…
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Page 73
Subsection 04 (LUBRICATION SYSTEM) vmr2006-042-018_a 1. Reed valve 2. Stopper 3. Screws Removing the Reed Valve Remove: – Engine from vehicle PTO COVER BOT- – PTO cover (refer to in the TOM END subsection) – Reed valve retaining screws – Stopper plate –… -
Page 74
COOLING SYSTEM SERVICE TOOLS Description Part Number Page 420 877 650 ……….. 17 HANDLE ………………529 035 757 ……….. 17 OIL SEAL PUSHER……………. 529 036 130 ……….. 14 ROTARY SEAL PUSHER PLATE………… 529 035 766 ……..14, 17 SEAL PUSHER …………….SERVICE PRODUCTS Description Part Number… -
Page 75
RADIATOR 570 Engine 2.5 ± 0.5 N•m (22 ± 4 lbf•in) 10 ± 2 N•m (89 ± 18 lbf•ft) 10 ± 2 N•m (89 ± 18 lbf•ft) = Component must be replaced when removed. vmr2016-417-100_a vmr2016-417… -
Page 76
850 and 1000R Engine 2.5 ± 0.5 N•m (22 ± 4 lbf•in) X mr STD, X xc 10 ± 2 N•m (89 ± 18 lbf•ft) 1000R = Component must be replaced when removed. vmr2016-417-102_a vmr2016-417… -
Page 77
WATER PUMP AND THERMOSTAT Renegade 570 6 ± 0.7 N•m 3,5 ± 0,4 N•m 3,5 ± 0,4 N•m (53 ± 6 lbf•in) (31 ± 4 lbf•in) (31 ± 4 lbf•in) Loctite 6 ± 0.7 N•m (53 ± 6 lbf•in) Loctite CTS See Electronic Fuel Injection (EFI) 16 ±… -
Page 78: Water Pump
WATER PUMP Renegade 850 and 1000R 3,5 ± 0,4 N•m (31 ± 4 lbf•in) 6 ± 0.7 N•m (53 ± 6 lbf•in) Loctite 243 16 ± 2 N•m (142 ± 18 lbf•in) 3,5 ± 0,4 N•m (31 ± 4 lbf•in) CTS, see ELECTRONIC FUEL 6 ±…
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Page 79
GENERAL 570 Engine 1. Remove thermostat housing screws and re- NOTICE Never start engine without coolant. move thermostat cover. Some engine parts such as the rotary seal on the water pump shaft can be damaged. PROCEDURES THERMOSTAT Renegade 570 Thermostat Location 570 Engine The thermostat is located in the thermostat hous- ing at the top of the front cylinder (RH side). -
Page 80
570 Engine TIGHTENING TORQUE 6 N•m ± 0.7 N•m (53 lbf•in ± 6 lbf•in) Thermostat cover retaining screws LOCTITE 243 (BLUE) (P/N 293 800 060) 850 and 1000R Engines Install NEW Oetiker clamps. All Engines vmr2016-417-002_a PERI- Refill and bleed cooling system, refer to 2. -
Page 81: Installing The Radiator
Installing the Radiator Reverse the removal procedure. However, pay at- tention to the following. Ensure that rubber bushings are properly installed between frame and fan shroud. Ensure that vent hose of the cooling fan mo- tor is properly rooted as prior to removal (if so equipped).
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Page 82
COOLING FAN TROUBLESHOOTING CHART Is fan working? Everything is OK Check FAN fuse (F9) Replace fuse Is fan working? Is fuse burnt? vmr2015-044-006_a Bypass fan relay R1 (refer to RELAY Testing the Radiator Cooling Fan OPERATION TEST 1. -
Page 83
2. Remove radiator cooling fan retaining screws. 3. If the radiator cooling fan is activated, replace the relay. Relay Continuity Test Refer to POWER DISTRIBUTION AND GROUNDS subsection. WATER PUMP HOUSING Water Pump Housing Location The water pump housing is located on the engine MAG side. -
Page 84
NOTICE Water pump shaft and impeller have right-hand threads. Inspecting the Water Pump Impeller Check impeller for cracks or other damage. Re- place impeller if damaged. Installing the Water Pump Impeller The installation is the reverse of the removal pro- cedure. -
Page 85
tmr2011-011-050_a 1. Inner part of rotary seal tmr2011-011-051_a 1. Small chisel 4. Use 2 screwdrivers and carefully remove the outer part of the rotary seal. vbs2008-011-005 TYPICAL — INNER PART OF ROTARY SEAL REMOVED 3. Carefully bend down the outer part of rotary seal lip using a small chisel. -
Page 86
5. Thoroughly remove sealing residue and burr of rotary seal using a scraper. NOTICE Be careful not to damage water pump shaft. tmr2011-011-055_a 1. Pull on screws to remove seal 8. Check water pump shaft axial play. NOTE: If axial play is not adequate, engine must be disassembled to replace water pump shaft. -
Page 87
vbs2008-011-034 tmr2011-011-057_a OIL SEAL INSTALLATION 1. Rotary seal 2. M8 robust flat washer (P/N 420 227 935) 5. Ensure that the oil seal is properly seated in wa- 3. M8 x 1.25 nut (P/N 233 281 414) ter pump cavity. 11. -
Page 88
tmr2011-011-060_a SEAL PUSHER INSTALLATION 1. Seal pusher aligned with pusher bolt tmr2011-011-058_a ROTARY SEAL PUSHER PLATE ASSEMBLY 12.5 Tighten the pusher bolt by hand until it 1. 4 x tubes (70 mm (2.75 in) length) 2. 4 x screws M6 x 85 stops against the seal pusher. -
Page 89
vbs2008-011-040 WATER PUMP SHAFT PROPERLY ADJUSTED WITH ROTARY tmr2011-011-010_a SEAL 1. Water pump shaft 2. Crankcase MAG side NOTICE The water pump shaft must 3. Install a blind hole puller expander snugly be properly adjusted with rotary seal. against outer part of rotary seal and pull seal The water pump shaft must move freely out. -
Page 90
Push NEW oil seal in place. tmr2011-011-011_a 1. Oil seal 2. Machined surface for rotary seal tmr2011-011-014_a 1. Oil seal 2. Installer handle with oil seal pusher Lubricate sealing lip of the oil seal. SERVICE PRODUCT DOW CORNING 111 Sealing lip of the oil seal (P/N 413 707 000) tmr2011-011-012_a OIL SEAL REMOVAL — VIEW FROM INSIDE CRANKCASE MAG… -
Page 91
WATER PUMP GEARS Water Pump Gears Identification mmr2009-112-028_a WATER PUMP SHAFT ASSEMBLY 1. Surface where rotary seal is pushed by tool NOTICE Never use a hammer for rotary seal installation. Only use a press to avoid damag- ing the ceramic component. vmr2012-013-009_a 1. -
Page 92
vmr2015-029-001_a CRANKCASE PTO SIDE tmr2011-011-009_a 1. Water pump intermediate drive gear CRANKCASE MAG SIDE 2. Circlip 1. Water pump gear 3. Water pump intermediate shaft 2. Needle pin 4. Crankcase PTO side 3. Thrust washer Water Pump Drive Gear Water Pump Intermediate Drive Gear BOTTOM END subsection. -
Page 93
NOTICE A missing thrust washer will cause a Water Pump Drive Gear leaking rotary seal. BOTTOM END subsection. tmr2011-011-009_a 1. Water pump gear 2. Needle pin 3. Thrust washer NOTE: Ensure water pump gear snaps properly onto needle pin. Install NEW circlip to retain water pump gear. NOTICE Never use the circlip a second time. -
Page 94
Subsection XX (MAGNETO AND STARTER) MAGNETO AND STARTER SERVICE TOOLS Description Part Number Page 529 035 617 ……….6 CRANKSHAFT LOCKING BOLT…………. 529 036 034 ……….6 CRANKSHAFT PROTECTOR …………529 035 868 ……….4 FLUKE 115 MULTIMETER …………529 035 748 ……….6 MAGNETO PULLER ………….. -
Page 95
Subsection XX (MAGNETO AND STARTER) Engine with 6 ± 0,7 N•m 650W magneto (53 ± 6 lbf•in) See ELECTRONIC FUEL Engine oil INJECTION (EFI) 10 ± 1 N•m (89 ± 9 lbf•in) 5 ± 0,6 N•m (44 ± 5 lbf•in) Drei Bond sealing compound Loctite 243 Loctite 243… -
Page 96
Subsection XX (MAGNETO AND STARTER) PROCEDURES MAGNETO COVER Magneto Cover Access BODY Refer to the subsection and remove the fol- lowing part. vmr2015-030-002_a 1. Dipstick 2. O-ring 3. Crank position sensor (CPS) Remove magneto cover retaining screws. vmr2016-403-001 ENGINE WITH 420W MAGNETO vmr2015-030-003_a vmr2016-403-002 1. -
Page 97
Subsection XX (MAGNETO AND STARTER) Installing the Magneto Cover For installation, reverse the removal procedure. However, pay attention to the following. Install a NEW magneto cover gasket. Apply DREI BOND SEALING COMPOUND (P/N 420 on stator cable grommet as shown in next 297 906) illustration. -
Page 98
Subsection XX (MAGNETO AND STARTER) Removing the Stator Remove MAGNETO COVER . See procedure in this subsection. Remove screws securing the wire holding strip. Remove stator retaining screws then the stator. V07G05A TYPICAL 5. If any reading is out of specification, replace sta- tor. -
Page 99
Subsection XX (MAGNETO AND STARTER) vmr2006-041-007_a 1. Screw M16 2. Washer vmr2015-030-004_a 3. Rotor 1. Threads for cable holding strip 2. Notch for stator Remove rotor. TIGHTENING TORQUE REQUIRED TOOL 4 N•m ± 0.5 N•m (35 lbf•in ± 4 lbf•in) CRANKSHAFT PROTECTOR Holding strip screws (P/N 529 036 034) -
Page 100
Subsection XX (MAGNETO AND STARTER) Oil sprag clutch and install sprag clutch gear. tmr2011-012-007_a 1. Rotor vmr2006-041-015_b 2. Oil bore 1. Sprag clutch 2. Sprag clutch housing Check keyway of the rotor for wear or damages. 3. Sprag clutch gear 4. -
Page 101
Subsection XX (MAGNETO AND STARTER) Inspecting the Sprag Clutch TIGHTENING TORQUE Inspect sprag clutch and sprag clutch housing for 150 N•m ± 10 N•m wear and damage. (111 lbf•ft ± 7 lbf•ft) Rotor retaining screw Also check the collar of the sprag clutch gear. LOCTITE 648 (GREEN) Rotate sprag clutch gear in sprag clutch. -
Page 102
Subsection XX (MAGNETO AND STARTER) Check needle bearing condition. Replace sprag clutch gear if necessary. vmr2006-041-015_b 1. Sprag clutch 2. Sprag clutch housing 3. Sprag clutch gear 4. Apply engine oil here vmr2006-041-016_a ROTOR Install rotor, refer to in this subsection. INSPECT Tighten sprag clutch housing screws to specifica- 1. -
Page 103: Electric Starter
Subsection XX (MAGNETO AND STARTER) vmr2015-030-102_a vmr2006-041-017_a 1. Starter 1. Intermediate gear 2. Starter power cable connection at starter 2. Starter double gear 3. Starter power cable 3. Starter gear 4. Starter power cable connection at solenoid 4. Location pins Inspecting the Starter Drive Gear Inspect gears and location pins for wear and dam- age.
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Page 104
Subsection XX (MAGNETO AND STARTER) STARTER AC- 3. Remove body parts as listed in TIGHTENING TORQUE CESS 25 N•m ± 3 N•m Starter mounting screw 4. For models using the gearbox with GBPS, re- (18 lbf•ft ± 2 lbf•ft) fer to CONTINUOUSLY VARIABLE TRANSMIS- SION (CVT) subsection and remove the:… -
Page 105
Subsection 07 (INTAKE MANIFOLD) INTAKE MANIFOLD See ELECTRONIC FUEL INJECTION (EFI) 0,7 ± 0,1 N•m (6 ± 1 lbf•in) 10 ± 1 N•m (89 ± 9 lbf•in) 6 ± 0,7 N•m (53 ± 6 lbf•in) Loctite 243 ELECTRONIC FUEL INJECTION (EFI) Engine oil Engine oil Engine oil… -
Page 106
Subsection 07 (INTAKE MANIFOLD) PROCEDURES INTAKE MANIFOLD Intake Manifold Access BODY Refer to subsection and remove the follow- ing: – Console – RH side panel and extension. Removing the Intake Manifold FUEL TANK 1. Release fuel pressure. Refer to AND FUEL PUMP subsection. -
Page 107
Subsection 07 (INTAKE MANIFOLD) vmr2012-015-005_a 1. Remove 8. Remove intake manifold from engine. vmr2015-031-004_a 1. Manifold retaining screws (4x) Inspecting the Intake Manifold Check intake manifold for cracks, warping at flanges or any other damage. Replace if neces- sary. Installing the Intake Manifold The installation is the reverse of the removal pro- cedure. -
Page 108: Top End
Subsection 08 (TOP END) TOP END SERVICE TOOLS Description Part Number Page 529 035 617 ……….. 21 CRANKSHAFT LOCKING BOLT…………. 529 036 159 ……….. 6 DIAL INDICATOR ADAPTER …………529 035 661 ……….. 6 ENGINE LEAK DOWN TEST KIT ……….. 529 035 921 ………..
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Page 109
Subsection 08 (TOP END) CYLINDER HEAD NO. 1 7 ± 0,8 N•m (62 ± 7 lbf•in) 12 ± 1 N•m (106 ± 9 lbf•in) Engine oil See tightening procedure Engine oil 10 ± 1 N•m (89 ± 9 lbf•in) Engine oil Engine See ignition system… -
Page 110
Subsection 08 (TOP END) CYLINDER HEAD NO. 2 7 ± 0,8 N•m (62 ± 7 lbf•in) 12 ± 1 N•m Engine oil (106 ± 9 lbf•in) See ignition system Engine oil Engine oil See tightening procedure 10 ± 1 N•m (89 ±… -
Page 111
Subsection 08 (TOP END) CYLINDERS AND PISTONS Engine oil Engine oil Engine oil Engine oil Engine oil Engine vmr2006-043-003_d vmr2016-419… -
Page 112
Subsection 08 (TOP END) GENERAL WARNING Always respect this order for disassembly; Special reference are made in the text for proce- disconnect BLACK (-) cable first. dures which are different for cylinder no. 1 and cylinder no. 2. 2. Remove radiator cap. WARNING To prevent being burned, ensure the radiator is cool and wear the appropriate safety equip-… -
Page 113
Subsection 08 (TOP END) ENGINE REQUIRED TOOL REQUIRED TOOL TDC DIAL INDICATOR ENGINE LEAK DOWN TEST (P/N 414 104 700) KIT (P/N 529 035 661) DIAL INDICATOR 850 and ADAPTER (P/N 529 1000R 2. Connect to an adequate air supply. 036 159) 3. -
Page 114
Subsection 08 (TOP END) PROCEDURES Installing the Valve Cover For installation, reverse the removal procedure. VALVE COVER However, pay attention to the following. Tighten valve cover retaining screws to specified Valve Cover Access torque in a criss-cross sequence. Front Cylinder TIGHTENING TORQUE BODY Refer to… -
Page 115
Subsection 08 (TOP END) R400motr67A 1. 2 thrust washers 2. Rocker arm (exhaust side) 3. Cylinder head (spark plug side) 4. Big taper to spark plug side Inspecting the Rocker Arm Inspect each rocker arm for cracks and scored fric- vmr2006-043-016_a tion surfaces. -
Page 116: Installing The Rocker Arm
Subsection 08 (TOP END) R400motr69A 1. Free movement of adjustment screw top Inspecting the Rocker Arm Shaft Check for scored friction surfaces; if so, replace parts. Measure rocker arm shaft diameter. vmr2006-043-016_b 1. Rocker arm shaft 2. Thrust washer (timing chain side) 3.
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Page 117
Subsection 08 (TOP END) NOTICE Each camshaft is different in design. Thus, it is important not to mix up any parts of the camshaft assembly with that of the other cylinder. Keep parts as a group. VALVE COVER 1. Remove valve cover (see in this subsection). -
Page 118: Removing The Cylinder Head
Subsection 08 (TOP END) CAMSHAFT LOBE (INTAKE) CAMSHAFT JOURNAL (TIMING CHAIN SIDE) 32.890 mm to 33.090 mm (1.2949 in to 1.3028 in) 34.959 mm to 34.975 mm (1.3763 in to 1.377 in) engine SERVICE 32.870 mm (1.2941 in) LIMIT SERVICE LIMIT 34.950 mm (1.376 in) 32.960 mm to 33.160 mm CAMSHAFT JOURNAL…
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Page 119
Subsection 08 (TOP END) PERIODIC MAINTE- 2. Drain coolant (refer to NANCE PROCEDURES subsection). 3. Disconnect the coolant hose from the thermo- stat housing. NOTE: Before removing cylinder head, blow out remaining coolant by air pressure. During cylin- der head removal, the remaining coolant in cylin- der head could overflow into the engine and a little quantity of coolant could drop into the engine. -
Page 120: Installing The Cylinder Head
Subsection 08 (TOP END) R400motr77A A. Camshaft bearing (timing chain side) B. Camshaft bearing (spark plug side) vmr2016-033-002_b 1. Timing chain guide (tensioner side) mounted in crankcase CAMSHAFT BEARING 2. Timing chain guide (fixed) between cylinder and cylinder head (TIMING CHAIN SIDE) Install a NEW cylinder head gasket.
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Page 121
Subsection 08 (TOP END) Check timing chain guide (tensioner side) for CYLINDER HEAD SCREW IDENTIFICATION movement. Location no. 1 M10 x 140 Refer to applicable subsection for installation de- tails of remaining removed parts. Location no. 2 M6 x 85 engines VALVE SPRINGS Location no. -
Page 122
Subsection 08 (TOP END) R400motr80A A. Valve spring length VALVE SPRING FREE LENGTH R400motr78A NOMINAL 1. Valve spring compressor clamp 570 ENGINE 40.81 mm (1.607 in) 2. Valve spring compressor cup 3. Valve cotter 850 AND NOMINAL 4. Remove tools and withdraw valve spring re- 1000R 40.41 mm (1.591 in) tainer and valve spring. -
Page 123
Subsection 08 (TOP END) NOTICE Inspecting the Valve An improperly locked valve spring will cause engine damage. Whenever valves are removed always inspect valve guides. Refer to VALVE GUIDES in this VALVES subsection. Removing the Valve Valve Stem Seal VALVE SPRING 1. -
Page 124
Subsection 08 (TOP END) VALVE STEM DIAMETER VALVE SEAT CONTACT WIDTH EXHAUST VALVE EXHAUST VALVE 4.956 mm to 4.970 mm 1.25 mm to 1.55 mm (.1951 in to .1957 in) (.049 in to .061 in) engine 2.00 mm (.079 in) SERVICE SERVICE LIMIT 4.930 mm (.1941 in) -
Page 125
Subsection 08 (TOP END) NOTE: Clean valve guide area from contamination before removal. 3. Drive valve guide out of cylinder head using specified tool. ENGINE REQUIRED TOOL VALVE GUIDE REMOVER 5 MM engine (P/N 529 035 924) 850 and VALVE GUIDE R400motr85A 1000R REMOVER (6 MM) -
Page 126: Removing The Cylinder
Subsection 08 (TOP END) VALVE GUIDE (MEASUREMENT A) INTAKE and 14.00 mm to 14.40 mm ENGINE EXHAUST (.5512 in to .5669 in) 13.1 mm to 13.5 mm INTAKE 850 AND (.5157 in to .5315 in) 1000R 14.3 mm to 14.7 mm ENGINES EXHAUST (.563 in to .579 in)
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Page 127: Installing The Cylinder
Subsection 08 (TOP END) CYLINDER TAPER SPECIFICATION NEW (MAXIMUM) 0.038 mm (.0015 in) SERVICE LIMIT 0.090 mm (.0035 in) Distance between measurements should not ex- ceed the service limit. Otherwise, replace cylin- der and piston rings. Cylinder Out of Round Measure cylinder diameter: –…
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Page 128
Subsection 08 (TOP END) WARNING REQUIRED TOOL Piston circlips are spring loaded. Piston ring compressor with band width of 15 mm to 20 mm (.59 in to .79 in) 3. Remove one piston circlip and discard it. First mount cylinder 2. NOTE: The cylinder can not be pushed fully over the piston unless the piston is located at TDC. -
Page 129
Subsection 08 (TOP END) R400motr96A 1. Measuring perpendicularly (90°) to piston pin A. 8 mm (.315 in) The measured dimension should be as described F00B09A in the following tables. If not, replace piston. 1. Use the micrometer to set the cylinder bore gauge 2. -
Page 130
Subsection 08 (TOP END) If clearance exceeds specified tolerance, replace piston by a new one and measure piston/cylinder clearance again. NOTE: Make sure the cylinder bore gauge indica- tor is set exactly at the same position as with the micrometer, otherwise the reading will be false. Connecting Rod/Piston Pin Clearance Using synthetic abrasive woven, clean piston pin from deposits. -
Page 131
Subsection 08 (TOP END) R400motr100A 1. Circlip 2. Sleeve 3. Assembly jig from piston clip installer Push taper side of assembly jig until circlip reaches middle of sleeve. Align sleeve with piston pin axis and push assem- vmr2016-118-002_a 570 , 850 AND 1000R ENGINES bly jig until circlip engages in piston. -
Page 132: Piston Rings
Subsection 08 (TOP END) R400motr103A 1. Piston 2. Feeler gauge Ring End Gap RING END GAP UPPER COMPRESSION RING vmr2016-033-006 CORRECT POSITION OF THE PISTON CIRCLIP 0.10 mm to 0.30 mm (.004 in to .012 in) PISTON RINGS engine SERVICE LIMIT 0.50 mm (.02 in) Removing the Piston Rings 0.20 mm to 0.35 mm…
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Page 133
Subsection 08 (TOP END) NOTE: Use a ring expander to prevent breakage during installation. The oil ring must be installed by hand. Install the oil scraper ring first, then the lower compression ring with the word “N and TOP “ facing up, then the upper compression ring with the word “N and TOP“… -
Page 134
Subsection 09 (TIMING CHAIN) TIMING CHAIN SERVICE TOOLS Description Part Number Page 529 036 268 ……….5 CAMSHAFT TIMING TOOL…………529 036 201 ……… 5, 9 CRANKSHAFT TDC POSITION TOOL ……….. SERVICE PRODUCTS Description Part Number Page 293 800 060 ……..6, 11 LOCTITE 243 (BLUE)………….. -
Page 135
Subsection 09 (TIMING CHAIN) TROUBLESHOOTING UNUSUAL ENGINE NOISE OR VIBRATION 1. IMPROPER VALVE CLEARANCE ADJUSTMENT AND/OR WORN OUT ROCKER ARM(S) — Readjust valve clearance and/or replace defective part(s), refer to TOP END subsection. 2. DEFECTIVE CHAIN TENSIONER — Replace chain tensioner. 3. -
Page 136
Subsection 09 (TIMING CHAIN) Check chain tensioner plunger for freedom of CAUTION Tensioner is spring loaded. movement and/or scoring. 3. Remove: Ensure O-rings are not brittle, cracked or hard. Re- – O-ring place if necessary. – Spring Check spring condition. Replace if bent, broken or –… -
Page 137
Subsection 09 (TIMING CHAIN) tmr2013-069-008_a Step 1: Compress spring tmr2013-069-006_a Step 2: Screw in plug 1. Plug 2. Slot 9. Remove locking tool and install all other re- 3. Spring moved parts. 4. Spring end 5. O-Ring 10. Tighten the chain tensioner screw plug to 7. -
Page 138
Subsection 09 (TIMING CHAIN) 2. Set applicable piston to TDC ignition position and install the crankshaft position tool, refer to CAMSHAFT TIMING in this subsection. REQUIRED TOOL CRANKSHAFT TDC POSITION TOOL (P/N 529 036 201) 3. Install camshaft timing tool on the cylinder head. -
Page 139: Camshaft Timing
Subsection 09 (TIMING CHAIN) vmr2015-033-002_a vmr2015-033-004_a PRESS TOOL LEVER DOWN 1. Camshaft timing gear 1. Lever 2. Timing gear retaining screws 2. Flat portion 3. Camshaft TIGHTENING TORQUE NOTICE Crankshaft camshaft must LOCTITE 243 (BLUE) Service product be locked at TDC ignition position to place (P/N 293 800 060) camshaft timing gear and timing chain in the Camshaft timing gear…
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Page 140
Subsection 09 (TIMING CHAIN) vmr2015-033-005_a vmr2015-033-007_a 1. Screw plug TURN CRANKSHAFT CLOCKWISE TO PISTON NO. 2 TDC 2. O-ring 1. Allen key 14 mm 4. Remove the crankshaft position sensor (CPS). 5.1 The rear piston is at TDC when it’s index mark on the magneto flywheel is aligned with the notch in the magneto cover. -
Page 141
Subsection 09 (TIMING CHAIN) tmr2011-045-003_c vmr2007-036-006_b TYPICAL — PISTON AT TDC IGNITION CYLINDER 1 AT TDC 1. Printed marks on camshaft timing gear 1. Number 1 piston identifier 2. Cylinder head base 2. Index mark “1” on magneto flywheel 3. Notch on magneto cover 4. -
Page 142
Subsection 09 (TIMING CHAIN) Install tool in magneto cover CPS bore. REQUIRED TOOL CRANKSHAFT TDC POSITION TOOL (P/N 529 036 201) NOTE: Make sure to match the teeth on the crankshaft TDC position tool with the magneto rotor. vmr2015-033-009_a 1. Magneto cover 2. -
Page 143
Subsection 09 (TIMING CHAIN) tmr2011-045-015_a 1. Timing chain Vmr2012-016-005_a 2. Lower timing chain guide 1. Timing chain 3. Timing chain guide (tensioner side) 2. Lower timing chain guide 3. Timing chain guide (tensioner side) NOTE: Mark the operating direction of the timing NOTE: Mark the operating direction of the timing chain and check for excessive radial play before TIMING CHAIN INSPECTION… -
Page 144
Subsection 09 (TIMING CHAIN) Inspecting the Timing Chain Guide (Tensioner Side) Check timing chain guide for wear, cracks or de- formation. Replace if necessary. Installing the Timing Chain Guide (Tensioner Side) vmr2006-044-018_a 1. Timing chain The installation is the reverse of the removal pro- If chain is excessively worn or damaged, replace cedure. -
Page 145: Bottom End
Subsection 10 (BOTTOM END) BOTTOM END SERVICE TOOLS Description Part Number Page 529 036 031 ……….. 14 CRANKCASE SUPPORT MAG/PTO ……….529 035 617 ……….. 18 CRANKSHAFT LOCKING BOLT…………. 529 036 028 ……… 6–7 DRIVE SHAFT OIL SEAL INSTALLER ……….. 529 036 029 ……….
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Page 146
Subsection 10 (BOTTOM END) CRANKCASE AND PTO COVER Engine oil See tightening sequence 25 ± 3 N•m Loctite 243 (18 ± 2 lbf•ft) 6 ± 0,7 N•m 10 ± 1 N•m (53 ± 6 lbf•in) (89 ± 9 lbf•in) Engine oil 25 ±… -
Page 147
Subsection 10 (BOTTOM END) CRANKSHAFT See tightening procedure Engine See tightening procedure Engine oil vmr2016-421-100_a vmr2016-421… -
Page 148
Subsection 10 (BOTTOM END) PROCEDURES IMPORTANT: Note position of parts on disas- sembly. This may help to find the root cause of a problem. A component that is not replaced should be reinstalled in the same position as originally mounted. ENGINE DRIVE SHAFT NOTE: The engine drive shaft transmits the power from the gearbox to the front differential… -
Page 149
Subsection 10 (BOTTOM END) tmr2011-014-009_a 1. Bearing cover 2. Drive shaft bearing Check drive shaft for cracks, bend, pitting or other F12R17A visible damages. Do not apply in excess as it will spread out inside Check drive shaft splines for wear or damages. crankcase. -
Page 150
Subsection 10 (BOTTOM END) Installing the Front Bearing Cover tmr2013-018-005_a 1. Bearing cover 2. Oil seal 5. Install drive shaft oil seal using the following vmr2016-120-001_a tool. FRONT OF ENGINE 1. Bearing cover front side 2. Drive shaft REQUIRED TOOL 3. -
Page 151
Subsection 10 (BOTTOM END) ENGINE 2. Remove rear bearing cover, refer to DRIVE SHAFT REMOVAL/INSTALLATION this subsection. 3. Remove O-ring from bearing cover. vmr2013-018-002_a 1. Bearing cover 2. Oil seal 3. Oil seal installer 6. Install O-ring in rear bearing cover. vmr2013-018-003_a 1. -
Page 152
Subsection 10 (BOTTOM END) PTO COVER NOTICE Avoid scoring surfaces with tool. Removing the PTO Cover CONTINUOUSLY VARIABLE TRANS- 1. Refer to MISSION (CVT) subsection to remove the fol- lowing parts: – CVT cover – Drive pulley – Driven pulley –… -
Page 153
Subsection 10 (BOTTOM END) Replacing the Plain Bearing WARNING (PTO Cover) Always wear skin and eye protection. Chem- icals can cause skin rash, skin burns and se- Removing the Plain Bearing vere eye injury. NOTICE Unless otherwise instructed, never use a hammer to install plain bearings. Always 4. -
Page 154
Subsection 10 (BOTTOM END) Tighten PTO cover screws following the sequence illustrated. vmr2006-044-008_a 1. Mark position of oil bore on PTO cover 2. Mark position of oil bore on plain bearing remover/installer NOTICE Misalignment of plain bearing and PTO cover oil bores will prevent proper oil supply to plain bearings. -
Page 155
Subsection 10 (BOTTOM END) tmr2011-014-014_a tmr2011-014-016_a 1. Breather gear 1. Thrust washer 2. Intermediate gear 2. Water pump drive gear 3. Water pump drive gear 3. Needle pin 4. Oil pump drive gear Inspecting the Drive Gears Removing the Drive Gears Intermediate Gear/Oil Pump Drive Gear/Water PTO COVER 1. -
Page 156
Subsection 10 (BOTTOM END) CRANKCASE – Oil cooler (if applicable) – Oil pump drive gear. Disassembling the Crankcase NOTE: Oil pump removal from crankcase is not PERIODIC MAINTENANCE PROCE- 1. Refer to necessary, but recommended to see condition of DURES subsection and carry out the following: oil pump. -
Page 157
Subsection 10 (BOTTOM END) Models With Oil Cooler vmr2006-044-023_b 1. Water pump intermediate shaft 17. Remove engine oil strainer. tmr2011-014-021_a 1. Four screws M8 x 65 NOTE: Oil strainer removal for inspection and 2. 13 screws M6 x 75 3. Two screw M6 x 25 LUBRICA- cleaning is recommended. -
Page 158
Subsection 10 (BOTTOM END) Inspecting the Crankcase Replacing the Plain Bearing (Main) Check crankcase halves for cracks or other dam- Removing the Plain Bearing age. Replace if damaged. NOTICE Always properly support crankcase Check MAG and PTO plain bearings for scoring or halves when removing plain bearings. -
Page 159
Subsection 10 (BOTTOM END) During reassembly, make sure not to damage the sealing surfaces of the crankcase halves. NOTE: Place the proper crankcase support sleeve under crankcase halves before installing the plain bearings, refer to PLAIN BEARING REMOVAL PROCEDURE in this subsection. Install plain bearings in a cold crankcase. -
Page 160
Subsection 10 (BOTTOM END) Models With Oil Cooler Reinstall water pump intermediate shaft and WATER PUMP GEARS gears, refer to in the COOLING SYSTEM subsection. Tighten crankcase retaining screws as per follow- ing sequence. All Models tmr2011-014-021_c M6 SCREWS TIGHTENING SEQUENCE All Models TIGHTENING TORQUE vmr2016-035-002_b… -
Page 161
Subsection 10 (BOTTOM END) Crankshaft Locking Procedure NOTE: When the crankshaft is locked, the rear piston no. 2 is at TDC (top dead center). The crankshaft cannot be locked with front piston no. 1 at TDC. NOTICE To see if the rear piston no. 2 is CAMSHAFT TIMING at TDC ignition, refer to GEAR… -
Page 162: Removing The Crankshaft
Subsection 10 (BOTTOM END) vmr2015-034-007_a 1. Crankshaft locking bolt vmr2007-037-008_b CYLINDER 2 AT TDC 8. Gradually insert the tool in the crankshaft 1. Number 2 piston identifier groove. Make sure that the tool tip enters the 2. Index mark on magneto flywheel 3.
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Page 163
Subsection 10 (BOTTOM END) Connecting Rod Big End Radial Play Measure axial play on PTO end of crankshaft using a dial indicator. NOTE: Prior to removing connecting rod from the crankshaft, mark big end halves together to en- CRANKSHAFT AXIAL PLAY sure a correct reinstallation (cracked surface fits 0.200 mm to 0.500 mm in only one position). -
Page 164
Subsection 10 (BOTTOM END) CRANK PIN DIAMETER 40.001 mm to 40.025 mm (1.5748 in to 1.5758 in) SERVICE 39.990 mm (1.5744 in) ENGINES LIMIT 41.986 mm to 42.010 mm (1.653 in to 1.6539 in) 1000R ENGINE SERVICE 41.967 mm (1.6522 in) LIMIT If the crank pin diameter is out of specification, replace crankshaft. -
Page 165
Subsection 10 (BOTTOM END) Crankshaft Radial Play (PTO Cover Bearing) Measure crankshaft journal diameter (PTO cover bearing). Compare to plain bearing inside diame- PTO COVER ter (PTO cover). Refer to in this sub- section. R1004motr20A 1. Half plain bearing of connecting rod big end 2. -
Page 166: Installing The Crankshaft
Subsection 10 (BOTTOM END) tmr2011-014-036_a 1. Connecting rod small ends 2. Connecting rod offset 3. Connecting rod screws TIGHTENING TORQUE Tighten to 1/2 of Step A specified torque vmr2006-044-043_a Tighten to 1. Angle torque wrench Connecting rod Step B 30 N•m ± 2 N•m 570 and 850 Engines screws (22 lbf•ft ±…
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Page 167
Subsection 10 (BOTTOM END) vmr2006-044-035_a 1. Crankcase half MAG side 2. Connecting rod cylinder 1 3. Connecting rod cylinder 2 vmr2016-421… -
Page 168
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (570/850) SERVICE TOOLS Description Part Number Page 529 036 238 ……6, 14, 20–22 CLUTCH HOLDER…………….. 529 035 746 ……….6 CLUTCH PULLER …………….529 036 098 ……… 5, 19, 22 PULLER/LOCKING TOOL………….. -
Page 169
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) Loctite 767 Isoflex grease Topas NB 52 10 ± 1 N•m (89 ± 9 lbf•in) Loctite 243 engine Pulley flange cleaner engine Loctite 243 10 ± 1 N•m (89 ± 9 lbf•in) Isoflex grease 5 ±… -
Page 170
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) 8 ± 1 N•m (71 ± 9 lbf•in) 5 ± 1 N•m (44 ± 9 lbf•in) 2.5 ± 0.5 N•m (22 ± 4.5 lbf•ft) 5 ± 1 N•m (44 ± 9 lbf•in) 2.5 ± 0.5 N•m (22 ±… -
Page 171: Cvt Cover
WARNING Remove the CVT cover and its gasket. Any drive pulley repairs must be performed by an authorized Can-Am dealer. Subcompo- nent installation and assembly tolerances re- quire strict adherence to procedures detailed. WARNING The clutch assembly is a precisely balanced unit.
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Page 172: Drive Belt
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) Inspecting the Drive Belt TIGHTENING TORQUE For drive belt inspection refer to DRIVE BELT 7 N•m ± 0.8 N•m CVT cover screws INSPECTION in the PERIODIC MAINTENANCE (62 lbf•in ± 7 lbf•in) PROCEDURES subsection. DRIVE BELT Installing the Drive Belt For installation, reverse the removal procedure.
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Page 173
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) CAUTION Sliding sheave of drive pulley is spring loaded. vmr2006-021-011_a 1. Mark on drive pulley sliding sheave 2. Mark on governor cup 3. Lock the drive pulley. tmr2011-015-004_a Step 1: Push REQUIRED TOOL 1. Thrust washer 2. -
Page 174
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) Vmr2012-018-009_a 1. Drive pulley puller 2. Fixed sheave R400motr171A 1. Slider shoe Disassembling the Drive Pulley 3. Place the governor cup on a vice to push out the Governor Cup roller sleeve in the direction illustrated (against 1. -
Page 175
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) Fixed Sheave WARNING Always wear safety glasses to remove spring sleeves. Pull and rotate one-way clutch slowly until the spring sleeves are visible. vmr2006-021-016_a 1. Removal direction 2. Assembly direction NOTE: Whenever removing a governor cup which already has two marked boxes, replace it by a new one. -
Page 176
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) Cleaning the Drive Pulley Clean pulley faces and shaft with fine steel wool and a dry cloth. Using a paper towel with the recommended cleaning solvent, clean: – Crankshaft tapered end – Taper inside the fixed sheave of the drive pulley –… -
Page 177
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) tmr2011-015-007_a 1. Centrifugal lever 2. Bushing A. Bushing inner diameter CENTRIFUGAL LEVER BORE DIAMETER 6.035 mm to 6.078 mm (.238 in to .239 in) vmr2016-036-002_a 1. Roller 6.200 mm (.244 in) SERVICE LIMIT 2. Slider shoe 3. -
Page 178
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) SLIDING SHEAVE LARGE BUSHING 55.000 mm to 55.040 mm (2.165 in to 2.167 in) SERVICE LIMIT 55.200 mm (2.173 in) vmr2006-021-024_a A. Centrifugal lever pivot bolt bore diameter CENTRIFUGAL LEVER PIVOT BOLT BORE DIAMETER 6.113 mm to 6.171 mm (.241 in to .243 in) SERVICE LIMIT… -
Page 179
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) Assembling the Drive Pulley Check for any marks on fixed sheave plate. Re- place if necessary. For assembly, reverse the disassembly proce- dure. Pay attention to following details. Spring Measure spring free length and squareness. If One-Way Clutch spring is out of specification, replace by a new Clean parts. -
Page 180
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) WARNING Do not apply antiseize or any lubricant on crankshaft and drive pulley tapers. NOTICE Never use any type of impact wrench for drive pulley removal and instal- lation. DRIVE Clean mounting surfaces as described in PULLEY CLEANING Install drive pulley on crankshaft extension. -
Page 181: Driven Pulley
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) 5. Remove driven pulley screw and washer. Dis- card driven pulley screw. CAUTION Driven pulley is spring loaded. Hold driven pulley tight and slowly remove the driven pulley screw to release spring tension. tmr2013-019-006_a 1.
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Page 182
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) vmr2006-021-035_a 1. Retaining ring 2. Torque gear 3. Fixed sheave of driven pulley R610tran18A NOTE: The following procedure is not necessary except if ball bearing or shaft must be removed. 1. Soft hammer 2. Shaft INSPECTION Refer to before proceeding. -
Page 183
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) Using a paper towel with PULLEY FLANGE REQUIRED TOOL , clean countershaft CLEANER (P/N 413 711 809) Dial bore gauge end and shaft bore. NOTICE MEASURING POINT To avoid damage, make sure cleaner does not contact the countershaft oil seal. At least 5 mm (1/4 in) from bushing edge BUSHING INNER DIAMETER 30.060 mm to 30.100 mm… -
Page 184
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) BUSHING INNER DIAMETER 30.060 mm to 30.100 mm (1.183 in to 1.185 in) SERVICE LIMIT 30.200 mm (1.189 in) Check torque gear for visible damage and cracks. Measure for wear limit using a caliper. vmr2006-021-041_a 1. -
Page 185
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) Install torque gear then secure it with the retaining SPRING FREE LENGTH ring. Service limit 125 mm (4.921 in) ENGINES CLUTCH SPRING SQUARENESS Service limit 3.8 mm (.15 in) ENGINES Assembling the Driven Pulley For installation, reverse the removal procedure. -
Page 186
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) NOTICE 570 Engine A cam not correctly engaged will cause damage to the driven pulley and cam. Install cam on countershaft. As you hold the pulley compressed, install a NEW NOTICE Cam splines must engage on coun- driven pulley screw and thrust washer. -
Page 187
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) REQUIRED TOOL CLUTCH HOLDER (P/N 529 036 238) TIGHTENING TORQUE 20 N•m ± 1 N•m Step A Driven pulley (15 lbf•ft ± 1 lbf•ft) screw Step B 180° ± 5° Check driven pulley end play. SPECIFICATION Vmr2012-018-017_a Driven pulley end play… -
Page 188
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) Vmr2012-018-011_a 1. Driven pulley screw 2. Thrust washer tmr2013-019-008_a Insert a screwdriver of approximately 5 mm 850 ENGINE (.197 in) diameter in the cam. 1. Fixed sheave 2. Clutch holder NOTE: For clarity of understanding, some parts 3. -
Page 189
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) TIGHTENING SEQUENCE (DRIVEN PULLEY SCREW) STEP 1 20 N•m ± 1 N•m (15 lbf•ft ± 1 lbf•ft) STEP 2 180° ± 5° tmr2013-019-009_b 850 ENGINE 1. Clutch holder 2. Screwdriver A. Cam freedom of movement Install drive belt. -
Page 190
Subsection 11 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT)(570/850)) vmr2012-018-020_a 1. CVT air guide 2. O-rings Installing the CVT Air Guide For installation reverse the removal procedure. Always install NEW O-rings before installing the CVT air guide. vmr2016-404… -
Page 191
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES) SERVICE TOOLS Description Part Number Page 529 036 030 ……….. 13 BACKLASH MEASUREMENT TOOL……….529 035 763 ……….. 29 BEARING INSTALLER (GEARBOX) ……….529 035 762 ……….. -
Page 192
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) GEARBOX COMPONENTS AND 4X4 COUPLING MECHANISM Super Lube grease Engine 10 ± 1 N•m (89 ± 9 lbf•in) Engine Loctite 243 25 ± 3 N•m (18 ± 2 lbf•ft) Engine oil Loctite Super Lube grease… -
Page 193
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) GEARBOX HOUSING AND 4X4 ACTUATOR UNIT 2.5 ± 0.3 N•m (22 ± 3 lbf•in) Petamo grease Petamo grease Petamo grease = Component must be replaced when removed. vmr2015-036-001_a vmr2016-422… -
Page 194
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) GENERAL OVERVIEW GEARBOX IDENTIFICATION Gearbox with GBPS This gearbox is equipped with 1 gearbox position sensor. vmr2012-019-003_a 1. Right housing 2. Center housing 3. Left housing 4. Output shaft 5. Bearing cover 6. -
Page 195
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) 4 WHEEL DRIVE INDICATION FAILS 1. 4WD indicator switch failure. — Test 4WD indicator switch. Replace as required. — Bad contact. Check for corrosion or loose con- nector. — Damaged wires. Repair as required. 4 WHEEL DRIVE DOES NOT ENGAGE OR DISENGAGE 1. -
Page 196
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) VSS Circuit Protection REQUIRED TOOL CONDITION CIRCUIT PROTECTION FLUKE RIGID BACK-PROBE (P/N TP88) Supplied with main Fuse 5 of fuse block 1 4. Turn ignition switch ON. relay activated (from main relay R2) 5. -
Page 197
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) Testing the Gearbox Position Indicator Switch Continuity 1. Remove parts required for access, refer to GEARBOX POSITION INDICATOR SWITCH ACCESS in this subsection. NOTE: Take note of corresponding switch posi- tion and wire color. -
Page 198
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) A blank space indicates switch is not making con- If all switches are removed, make sure to put the tact, there should be no continuity (R = infinite). wires back in the correct location as noted prior to removal. -
Page 199
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) Unplug actuator connector. SWITCH SWITCH WIRE RESISTANCE POSITION Turn ignition key ON. Close to 0 Set emergency engine stop switch to RUN. BLACK/ Engine ground BEIGE Measure voltage as follows. Infinite (OL) SWITCH If the resistance is out of specification, replace the… -
Page 200
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) ACTUATOR O-RING SUPER LUBE GREASE Service product (P/N 293 550 030) Tmr2011-016-027_a 1. Actuator 2. Actuator fork 3. Coupling fork Rotate the actuator counterclockwise until it ori- ents itself to mounting position. Vmr2015-123-003_a NOTICE Do not cut or break the actuator… -
Page 201
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) GEARBOX OIL SEALS Replacing the Gearbox Oil Seals Replace oil seals if they are brittle, hard or dam- aged. A small flat screwdriver can be used to remove most of these oil seals. NOTICE Avoid scoring parts during oil seal removal. -
Page 202
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) vmr2012-019-007_a 1. Countershaft oil seal 2. Oil seal pusher vmr2012-019-008_a Shift Shaft Oil Seal 1. Distance sleeve 2. O-ring The shift shaft oil seal can be removed without removing the gearbox from the vehicle. BODY To replace the shift shaft oil seal, refer to subsection and remove:… -
Page 203
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) 3. Remove: – Distance sleeve – O-ring. vmr2006-022-008_a 1. Output shaft oil seal 2. Oil seal installer OUTPUT SHAFT AND COUPLING MECHANISM vmr2006-022-011_a 1. Distance sleeve GEARBOX Remove gearbox. Refer to in this sub- 2. -
Page 204
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) vmr2006-022-021 POSITION FOR BIG FLAT SCREWDRIVER vmr2006-022-012_a 1. Backlash measurement tool 2. Mark on tab A. 47 mm (1.85 in) 6. Position the head of the dial indicator, against the tab at a 90° angle and on the line. Then, gently rotate the output shaft. -
Page 205
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) vmr2012-019-009_a vmr2012-019-010_a 1. Output shaft 1. Ball bearing 2. Coupling sleeve 2. Thrust washer 3. Soft hammer 3. Distance ring 6. Remove: 8. Remove: – Coupling sleeve – Screw – O-ring –… -
Page 206
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) Replace oil seal if brittle, hard or damaged. COUPLING FORK CLAW THICKNESS Replace O-rings if brittle, hard or damaged. 4.95 mm to 5.05 mm (.195 in to .199 in) Check splines of coupling sleeve for wear or other damages. -
Page 207
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) If backlash is within specifications, remove dial indicator, backlash measuring tool, bearing cover and right housing. NOTE: Install coupling fork, pin and screw in right housing before applying sealant to the mating sur- face. -
Page 208
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) Disassembling the Gearbox TIGHTENING TORQUE NOTE: During gearbox disassembly, inspect the Hand tightened Step A condition of each part closely. Right housing 25 N•m ± 3 N•m M8 screws Step B OUTPUT 1. -
Page 209
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) BEVEL GEAR AXIAL CLEARANCE 0.02 mm to 0.15 mm (.0008 in to .0059 in) SERVICE LIMIT 0.19 mm (.0075 in) 3. Unscrew the left housing screws. 4. Place the left housing on a wood stand, center housing pointing upwards. -
Page 210
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) vmr2006-022-058_a vmr2006-022-060_a 1. Bevel gear 1. Thrust washer 2. Low range gear 2. Needle bearing 3. Shim 3. Reverse gear 11. Remove sliding gear with shift fork. 13. Remove shim on CVT side. vmr2006-022-059_a vmr2006-022-061_a 1. -
Page 211
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) vmr2006-022-066_a 1. Parking lock lever 17. Remove index lever with washer, step ring and spring. vmr2006-022-062_a 1. Countershaft 2. Low range gear 3. High range gear 15. Insert a flat screwdriver in the slot of index lever. -
Page 212
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) vmr2006-022-049_a 1. Bevel gear needle bearing vmr2006-022-068_a 2. Punch PRESS SHAFT IN THE DIRECTION AS SHOWN BY THE ARROW 3. Center housing 1. Intermediate gear shaft 2. Left housing To remove ball bearings of bevel gear and needle Removing the Bearings bearing of countershaft, use a blind hole bearing puller. -
Page 213
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) – Worn or scoured shift fork – Worn or scoured shift fork shaft – Rounded engagement dogs and slots – Bent shift forks – Bent shift fork shaft – Worn shift fork engagement pins –… -
Page 214
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) DIAMETER FREE PINION 29.000 mm to 29.013 mm (1.1417 in to 1.1422 in) SERVICE LIMIT 29.015 mm (1.1423 in) Shafts Check shift shaft for worn splines and gears. Check intermediate shaft for wear. vmr2006-022-077_a 1. -
Page 215
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) a brass brush. Brush a first pass in one direction then make the final brushing perpendicularly (90°) to the first pass cross (hatch). NOTICE Do not wipe with rags. Use a new clean hand towel only. -
Page 216
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) D(E) I(J) vmr2006-022-079_a 1. Mating surface — output shaft 2. Mating surface — left housing Bevel Gear Backlash Procedure Use the following course of calculation to determine the theoretical shim thickness D: D = B — C — A B = The distance between the thrust surface of the bevel gear and the theoretical center of its taper. -
Page 217
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) This bevel gear reference number could be be- When the measurements are taken, calculate the tween — 10 and + 10. theoretical shim thickness (D) using the formula: (D = B — C — A). Take the obtained theoretical shim thickness (D) and choose the corresponding shim number (E) according to the following table. -
Page 218
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) nominal thickness of axial 2 mm (.0787 in) needle bearing. E = The shim number nominal value as found in BEVEL GEAR BACKLASH PROCEDURE For example, shim number 150 represents a value of 1.50 mm (.0591 in). -
Page 219
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) Place new bearing in freezer for 10 minutes be- fore installation. Use a suitable installer for installing ball bearings of countershaft and bevel gear. NOTE: Place gearbox housings on a wood stand before installing ball bearings. -
Page 220
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) vmr2006-022-066_a 1. Parking lock lever vmr2006-022-052_b Place shim of CVT side on bearing. 1. Intermediate gear shaft Fit support flange in the left housing and install index lever. NOTE: Fit step ring into index lever. vmr2006-022-090_a vmr2006-022-092_a 1. -
Page 221
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) vmr2006-022-095_a 1. Bevel gear 2. Sliding gear 3. Shift fork vmr2006-022-093_a 1. Reverse gear Install a new needle bearing and shim. 2. Needle bearing 3. Thrust washer 4. Countershaft bearing screw Install countershaft with low gear and high gear assembly. -
Page 222
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) vmr2006-022-097_a vmr2006-022-098_a 1. Index lever 1. Shift shaft assembly 2. Shift drum 2. Isolating washer 3. Neutral position 3. Marks Install shift fork then engage both shift fork pins in their corresponding groove on the shift drum. NOTE: Move sliding gears to facilitate engage- ment of pins inside grooves. -
Page 223
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) Gearbox housing mating surfaces are best TIGHTENING TORQUE cleaned using a combination of LOCTITE CHISEL Hand tightened Step A and a brass (GASKET REMOVER) (P/N 413 708 500) Gear housing brush. -
Page 224
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES)) vmr2016-037-001_a 1. O-ring 2. Bearing cover Tighten the three (3) nuts that attaching the gear- box to the engine. TIGHTENING TORQUE LOCTITE 243 (BLUE) Service product (P/N 293 800 060) 25 N•m ±… -
Page 225
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS) SERVICE TOOLS Description Part Number Page 529 036 222 ……….. 12 COUNTERSHAFT OIL SEAL PUSHER ………. 529 036 166 ……….8 ECM ADAPTER TOOL…………..529 035 868 …….. -
Page 226
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) GEARBOX COMPONENTS AND 4X4 COUPLING MECHANISM The shaded parts are not serviceable. Gearbox replacement is requied. Loctite 5910 10 ± 1 N•m (89 ± 9 lbf•in) 25 ± 3 N•m 25 ± 3 N•m (18 ±… -
Page 227
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) GEARBOX COMPONENTS AND 4X4 COUPLING MECHANISM 10 ± 1 N•m (89 ± 9 lbf•in) Super Lube Petamo Grease Grease 25 ± 3 N•m 3 ± 0,3 N•m (18 ± 2 lbf•ft) (27 ±… -
Page 228
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) GENERAL GEARBOX OVERVIEW GEARBOX IDENTIFICATION Gearbox with GBPS This gearbox is equipped with 1 gearbox position sensor. Tmr2011-016-003_a 1. Gearbox position sensor (GBPS) 2. Right cover 3. Vehicle speed sensor (VSS) 4. -
Page 229
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) GEAR INDICATION FAILS The VSS connector is located between the cylin- ders, behind the OPS cover. 1. Defective gearbox position sensor (GBPS). — Perform a gearbox position sensor test. VSS Access — Damaged wires. -
Page 230
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) NOTE: Since we measure pulsating voltage, the numeric display will continuously change. The analog display may be easier to follow. vmr2012-020-020_a smr2005-056-010_a 1. VSS connector 1. Analog display 5. Measure voltage as per following table. Removing the VSS VEHICLE SPEED SENSOR INPUT VOLTAGE TEST Remove screw retaining the VSS. -
Page 231
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) Installing the VSS For installation, reverse the removal procedure. Pay attention to the following. Lubricate VSS O-ring. VSS O-RING SUPER LUBE GREASE Service product (P/N 293 550 030) Tighten VSS retaining screw to specification. TIGHTENING TORQUE 10 N•m ±… -
Page 232
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) Testing the GBPS Signal Wire Continuity Unplug ECM connector and connect it to the adapter tool. REQUIRED TOOL ECM ADAPTER TOOL (P/N 529 036 166) MULTIMETER PROBE RESISTANCE POSITIONS @ 20°C (68°F) GBPS connector (pin 2) and ECM adapter tool (pin D2) vmr2016-424-001… -
Page 233
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) IMPORTANT: Do not force to install GBPS if shaft SWITCH SWITCH WIRE RESISTANCE flat is not properly aligned. If alignment is incor- POSITION rect, check shift rod adjustment. Close to 0 BLACK/ Engine ground… -
Page 234
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) REQUIRED TOOL ACTUATOR O-RING SUPER LUBE GREASE Service product FLUKE 115 MULTIMETER (P/N 293 550 030) (P/N 529 035 868) Unplug actuator connector. Turn ignition key ON. Set emergency engine stop switch to RUN. Measure voltage as follows. -
Page 235
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) GEARBOX OIL SEALS Gearbox Oil Seal Replacement Replace oil seals if they are brittle, hard or dam- aged. A small flat screwdriver can be used to remove most of these oil seals. NOTICE Avoid scoring parts during oil seal removal. -
Page 236
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) Tmr2011-016-013_a 1. Countershaft oil seal 2. Distance sleeve vmr2012-020-005_a 1. Countershaft oil seal 2. Oil seal pusher Shift Shaft Oil Seal The shift shaft oil seal can be removed without removing the gearbox from the vehicle. BODY To replace the shift shaft oil seal, refer to and remove:… -
Page 237
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) REAR DRIVE Remove propeller shaft. Refer to REQUIRED TOOL subsection. OIL SEAL INSTALLER (P/N 529 036 204) Flat washer (P/N 250 200 102) M12 x 1.25 x 35 hexagonal screw Tmr2011-016-015_a 1. -
Page 238
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) Tmr2011-016-038_a Tmr2011-016-043_a LH SIDE OF ENGINE 1. 3 screws M6 x 35 1. Nut M8 2. 13 screws M6 x 55 Place the center housing on a wood stand, left cover pointing upwards. Using a big flat screwdriver and a soft hammer to lift the left cover. -
Page 239
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) Index Lever and Index Washer Set gearbox to NEUTRAL position. Remove screw retaining the index washer to the shift drum. Tmr2011-016-075_a 1. Washer 2. Index lever 3. Step ring 4. Index spring Tmr2011-016-073_a Main Shaft and Shift Forks 1. -
Page 240
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) vmr2012-020-006_a Tmr2011-016-047_a 1. Shifting sleeve (HIGH range gear) 1. Shift fork shaft 2. Shift fork 2. Shift fork 3. Shift drum When required, remove from main shaft assem- bly: Remove main shaft assembly with shift fork. –… -
Page 241
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) Tmr2011-016-032 POSITION FOR BIG FLAT SCREWDRIVER vmr2012-020-008_a 1. Snap ring 2. Shifting sleeve (LOW/REVERSE range gear) 3. Snap ring 4. Free pinion (REVERSE range gear) 5. Needle bearing 6. Main shaft assembly Gearbox Right Cover Remove ACTUATOR… -
Page 242
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) Tmr2011-016-072_a Tmr2011-016-077_a 1. Screw 1. Shift drum 2. Washer 2. Thrust washer 3. Intermediate gear 4. Dowel pin Output Shaft and 4×4 Coupling Mechanism Remove output shaft from center housing and Remove shift fork shaft. -
Page 243
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) NOTICE Always support gearbox housings properly when ball bearings are removed. Housing damages may occur if this procedure is not performed correctly. To remove ball bearings of countershaft (right cover) and main shaft (left cover) use a blind hole bearing puller. -
Page 244
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) DIAMETER FREE PINION 29.000 mm to 29.013 mm (1.1417 in to 1.1422 in) SERVICE LIMIT 29.015 mm (1.1423 in) Shifting Sleeves Check shifting sleeves for worn inner splines and rounded or damaged engagement dogs. Tmr2011-016-054_a 1. -
Page 245
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) WIDTH OF SHIFT FORK ENGAGEMENT GROOVE COUNTERSHAFT BEARING JOURNALS 5.30 mm to 5.40 mm MAG SIDE (.209 in to .213 in) CVT SIDE SERVICE LIMIT 5.50 mm (.217 in) 24.977 mm to 24.990 mm (.983 in to .984 in) Shafts SERVICE LIMIT… -
Page 246
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) Output Shaft Check output shaft and its gear for cracks, bend, pitting or other visible damages. Check output shaft splines for wear or other dam- ages. Check if the output shaft bearings turn freely and smoothly. -
Page 247
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) vmr2006-022-032_a 1. Coupling fork 2. Micrometer vmr2012-020-011_a COUPLING FORK CLAW THICKNESS 1. Main shaft 2. Free pinion (REVERSE range gear) 4.95 mm to 5.05 mm 3. Snap ring (.195 in to .199 in) 4. -
Page 248
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) Tmr2011-016-075_b vmr2012-020-006_a 1. Index spring 1. Shifting sleeve (HIGH range gear) 2. Step ring 2. Shift fork 3. Index lever 4. Washer Carefully fit main shaft assembly with shift fork 5. Screw (LOW/REVERSE range gear) into inner splines of Install index washer on shift drum. -
Page 249
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) Install coupling fork, coupling fork shaft and Clean all metal components in a solvent. hexagonal screw in right cover before applying Gearbox housing mating surfaces are best sealant to the mating surface. cleaned using a combination of LOCTITE CHISEL and a brass… -
Page 250
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) At installation of left cover, engage parking lock lever slot onto index washer pin. Tmr2011-016-067_a COUNTERSHAFT END CVT SIDE 1. O-ring 2. Distance sleeve 3. Countershaft end CVT side Right Cover Tmr2011-016-065_a Apply sealing compound on mating surfaces of 1. -
Page 251
Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH GBPS)) Before gearbox installation check O-ring in bearing cover if brittle, hard or damaged. Replace if nec- essary. Tmr2011-016-040_a 1. Bearing cover 2. O-ring Tighten the four (4) nuts that attach the gearbox to the engine. -
Page 252
Subsection 15 (SHIFTER (GEARBOX WITH EXTERNAL SWITCHES)) SHIFTER (GEARBOX WITH EXTERNAL SWITCHES) SERVICE PRODUCTS Description Part Number Page 293 800 060 ……….2 LOCTITE 243 (BLUE)…………..Loctite 243 5 ± 1 N•m (44 ± 9 lbf•in) 13 ± 2 N•m (115±… -
Page 253
Subsection 15 (SHIFTER (GEARBOX WITH EXTERNAL SWITCHES)) PROCEDURES HANDLE Handle Removal vmr2015-024-004_a SHIFT LEVER POSITION 3. Secure vehicle using wheel chocks. 4. Remove parts as indicated in following illustra- tions. vmr2015-024-002_a Step 1: Loosen lock nut Step 2: Unscrew shift lever handle Handle Installation Reverse the removal procedure. -
Page 254: Shift Lever Installation
Subsection 15 (SHIFTER (GEARBOX WITH EXTERNAL SWITCHES)) Shift Lever Installation The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Adjust shift lever handle as per following illustra- tion. vmr2015-024-005_a vmr2012-021-005_a SHIFT LEVER HANDLE ALIGNMENT 1.
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Page 255
Subsection 15 (SHIFTER (GEARBOX WITH EXTERNAL SWITCHES)) SHIFT ROD Shift Rod Adjustment 1. Place shift lever in NEUTRAL position. NOTICE Move vehicle back and forth to en- sure gearbox is set in neutral position. 2. Secure vehicle using wheel chocks. 3. -
Page 256
Subsection 15 (SHIFTER (GEARBOX WITH EXTERNAL SWITCHES)) vmr2015-037-004_a vmr2015-037-006_a 1. Shift rod ball joint 1. Trace a mark on both parts 2. Shift plate A. Parallel within +/- 5° 5. Remove shift plate nut and bolt. WARNING After adjustment, make sure the PARK posi- tion is also properly set. -
Page 257
Subsection 15 (SHIFTER (GEARBOX WITH EXTERNAL SWITCHES)) If there are no index marks, adjust shift plate as per following illustrations. vmr2015-037-010_a SHIFT PLATE ALIGNMENT 1. «ATV OUT» marking this side 2. Forward edge of shift plate 3. Horizontal plane (top surface of gearbox) 4. -
Page 258
Subsection 16 (SHIFTER (GEARBOX WITH GBPS)) SHIFTER (GEARBOX WITH GBPS) SERVICE PRODUCTS Description Part Number Page 293 800 060 ……….. 2 LOCTITE 243 (BLUE)…………..Loctite 243 5 ± 1 N•m (44 ± 9 lbf•in) 13 ± 2 N•m (115± 18 lbf•in) 10 ±… -
Page 259
Subsection 16 (SHIFTER (GEARBOX WITH GBPS)) PROCEDURES HANDLE Handle Removal vmr2012-021-002_a 1. Unhook 6. Detach shift rod from shift lever. vmr2015-024-002_a Step 1: Loosen lock nut Step 2: Unscrew shift lever handle Handle Installation Reverse the removal procedure. SERVICE PRODUCT WHERE USED LOCTITE 243 (BLUE) Shift lever threads… -
Page 260
Subsection 16 (SHIFTER (GEARBOX WITH GBPS)) Shift Lever Inspection Check shift lever for bending or cracks. Check spring and bushing condition. Check ball joint condition. Replace all damaged parts. Shift Lever Installation The installation is the reverse of the removal pro- cedure. -
Page 261
Subsection 16 (SHIFTER (GEARBOX WITH GBPS)) WARNING After adjustment, make sure that PARK posi- tion works properly. SHIFT PLATE Shift Plate Removal NOTE: Do not remove shift plate needlessly. 1. Place shift lever in NEUTRAL position. BODY 2. Refer to subsection and remove the RH engine cover. -
Page 262
Subsection 16 (SHIFTER (GEARBOX WITH GBPS)) Ensure that shift shaft protrudes shift plate as per illustration. vmr2012-021-011_a 1. Shift shaft end 2. Shift plate A. 2.5 mm ± 1 mm (.1 in ± .040 in) SHIFT ROD ADJUST- Adjust shift rod, refer to MENT in this subsection. -
Page 263
Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS)) ENGINE MANAGEMENT SYSTEM (EMS) Engine with Gearbox using External Switches GBPS INJ 1 INJ 2 IACV MAPTS IGN COIL COOLING FAN IGN SW START SW STARTER SOLENOID FUEL PUMP vmr2015-064-001_aen vmr2016-127… -
Page 264
Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS)) Engine with Gearbox using External Switches HIC2 HIC1 IACV MAPTS INJ1 INJ2 GBPS vmr2015-064-002_a vmr2016-127… -
Page 265
Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS)) Engine with Gearbox using GBPS GBPS INJ 1 INJ 2 IACV MAPTS IGN COIL COOLING FAN IGN SW START SW STARTER SOLENOID FUEL PUMP vmr2015-125-001_a vmr2016-127… -
Page 266
Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS)) Engine with Gearbox using GBPS HIC2 HIC1 IACV INJ1 MAPTS INJ2 GBPS vmr2015-125-002_a vmr2016-127… -
Page 267
Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS)) ABBREVIATION DEFINITION Ignition coil Crankshaft position sensor Coolant temperature sensor Electronic control module GBPS Gear box position sensor HIC1‡ Harness interconnect 1 HIC2‡ Harness interconnect 2 IACV Idle air control valve vmr2008-132-005 TYPICAL — ECM INJ1 Injector 1 (front) The ECM is located behind the LH panel. -
Page 268
Subsection 01 (ENGINE MANAGEMENT SYSTEM (EMS)) Engine RPM Limiter that they can be monitored. Some problems will turn on a warning lamp or will set the engine in The ECM limits the maximum engine speed with DIAGNOSTIC AND limp home mode. Refer to the shifter selected to any position. -
Page 269
Subsection XX (CONTROLLER AREA NETWORK (CAN)) CONTROLLER AREA NETWORK (CAN) GENERAL SYSTEM DESCRIPTION The CAN (Controller Area Network) protocol is an ISO standard for serial data communication. The CAN bus links the ECM, multifunction gauge and DPS module together so that they can communi- cate to each other and interact as required. -
Page 270
Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.) COMMUNICATION TOOLS AND B.U.D.S. SERVICE TOOLS Description Part Number Page 710 000 851 ……… 1, 3 DIAGNOSTIC CABLE …………..529 036 018 ……….1 MPI-2 INTERFACE CARD ………….. 529 036 353 ……….1 MPI-3 INTERFACE CARD ………….. GENERAL Multi-Purpose Interface Card Connection Troubleshooting… -
Page 271
Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.) If one or more “ECU” is not communicating with USB LIGHT DIAGNOSTIC AND FAULT the MPI card, refer to STATUS WHAT TO DO CODES Check USB connection between No Vehicle is Detected Light is MPI card and PC computer. -
Page 272
Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.) mmr2006-079-200 vmr2012-023-003_a MPI CARD CABLE CONNECTED TO USB PORT 1. Diagnostic connector B.U.D.S. 6. Use B.U.D.S. as described further in Connecting the PC to the Vehicle SOFTWARE topic WARNING B.U.D.S. SOFTWARE If the computer you are using is connected B.U.D.S. -
Page 273
Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.) tmr2015-028-003_a TYPICAL — SUCCESSFUL CONNECTION 1. Connection protocol 2. Number of modules read MODEL NUMBER OF MODULES Models without (ECM and multifunction gauge) Models with (ECM, DPS and multifunction smr2010-030-002_a gauge) TYPICAL NUMBER If the number is less than indicated in If the update icon is visible, B.U.D.S. -
Page 274
Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.) NOTE: When selecting the update menu in B.U.D.S., a dialog box will appear and the update file description may give some clue to finding KNOWLEDGE the vehicle-related information on CENTER vbl2012-007-010_a 1. Greyed out: No update to perform Black: Update file available KNOWL- Before applying an update, log onto… -
Page 275
Subsection 03 (COMMUNICATION TOOLS AND B.U.D.S.) In such a case, turn ignition switch OFF, then wait for the message to disappear before disconnect- ing the MPI. Disconnect MPI card and store the vehicle diag- nostic connector in its protective cap. vmr2012-023-003_a 1. -
Page 276: Monitoring System
Subsection 01 (DIAGNOSTIC AND FAULT CODES) DIAGNOSTIC AND FAULT CODES GENERAL NOTE: In some cases, the CHECK ENGINE mes- sage can be displayed along with other messages. MONITORING SYSTEM MULTI- PILOT FUNCTION The Engine Management System (EMS) features CAUSE LAMP GAUGE a monitoring system that self-diagnoses various MESSAGE…
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Page 277
Subsection 01 (DIAGNOSTIC AND FAULT CODES) FAULT CODES The active fault may or may not compromise normal operation of the system(s). Service ac- Fault Code Categories tion should be taken to correct the problem that caused the fault code. A fault code consists of an alphanumeric designa- tor followed by a hexadecimal number of 3 digits. -
Page 278
Subsection 01 (DIAGNOSTIC AND FAULT CODES) 2. Press and HOLD mode button while QUICKLY toggling HI — LO beam. NOTE: A minimum of 3 HI — LO toggles must be completed within 2 seconds. rmr2011-021-001_a 1. Drop down list FAULT INFORMATION STATE Display all possible faults regardless… -
Page 279
Subsection 01 (DIAGNOSTIC AND FAULT CODES) FAULT PAGE DESCRIPTION ITEM INFORMATION To display possible causes and More Details service actions related to the button selected fault Clear Fault To clear occurred faults one at a button time Clear To clear all occurred faults in related Occurred ECU(s) Faults button… -
Page 280
Subsection 01 (DIAGNOSTIC AND FAULT CODES) NOTE: An active fault code cannot be cleared. MORE DETAILS PAGE DESCRIPTION In other words, the problem relevant to the fault ITEM INFORMATION code must be repaired before the fault can be cleared. Possible List the possible causes that causes triggered the fault… -
Page 281
Subsection 01 (DIAGNOSTIC AND FAULT CODES) NOTE: The page displays data whatever there is HISTORY PAGE DESCRIPTION fault code(s) or not. ITEM INFORMATION Display the minimum and maximum Minimum/ values encountered. Click «Clear Maximum Min/Max» to reset the values Display the time proportion in what Run time mode the engine was running in Display the RPM range proportion in… -
Page 282
Subsection 01 (DIAGNOSTIC AND FAULT CODES) GENERAL GUIDELINES TO SOLVE FAULT CODES CONDITION ACTION Check related fuse(s) and relay. Check related power and ground wires. Low system voltage Check for common power supply to several sensors/modules on one module. (refer to POWER DISTRIBUTION AND GROUNDS) Power problem on sensor(s) NOTE: Some sensors are supplied by the battery while others are… -
Page 283
Subsection 01 (DIAGNOSTIC AND FAULT CODES) ECUs share information and their systems may interact with each other. Certain faults may cause more than one ECU to set a fault code or indication (pilot lamp or message) as the failure of some components may affect the operation of several systems. -
Page 284
Subsection XX (DIAGNOSTIC AND FAULT CODES) DIAGNOSTIC AND FAULT CODES GENERAL FAULT CODE TABLE PCODE MODULE DESCRIPTION CAUSE ACTION 1- Go to Activations — SCM and start Rear Test routine. If the test passed, the system is working properly. Check the harness and connection to see a potential source of intermittent dysfunction, if nothing is found clear the occurred fault and… -
Page 285
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Go to Activations — SCM and start Rear Test routine. Verify that the Shock Absorber Pressure and the Auxiliary Line Pressure correlates in BUDS. If the test is done with no fault, the system is working properly. -
Page 286
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Check for leaks. If no leak found go to next action step. 2- Go to Activations — SCM and start Rear Test routine. If the test is done with no fault, the system is working properly. -
Page 287
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Disconnect the air line to the rear shocks. Go to Activations — SCM and start Rear Test routine. If the air blows out the system is working properly. Check the harness and connection to see a potential source of intermittent dysfunction, if nothing is found clear the occurred… -
Page 288
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Check for leaks. If no leak found go to next action step. 2- Go to Activations — SCM and start Rear Front routine. If the test is done with no fault, the system is working properly. -
Page 289
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Disconnect the air line from the front shocks. Go to Activations — SCM and start Front Test routine. If the air blows out of both shocks the system is working properly. Check the harness and connection to see a potential source of intermittent dysfunction, if nothing is found clear… -
Page 290
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Make sure sensor connector is fully inserted. Measure voltage between harness connector pins 1 and 3 . (Expected value: 4.8 to 5.1 volts) Measure resistance from Damaged sensor, connector: ECM-F3 to MAPTS-2 Manifold Air damaged circuit wires, (Expected value: <… -
Page 291
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Make sure sensor connector is fully inserted. Measure voltage between harness connector pins 1 and 3 . (Expected value: 4.8 to 5.1 volts) Measure resistance from connector: ECM-F3 to MAPTS-2 Intake Air Damaged sensor, wires (Expected value: <… -
Page 292
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Disconnect the sensor. Measure resistance from connector: ECM-F4 to CTS-1 (Expected value: < 2 ohms) Engine Coolant Temperature Disconnected sensor, or Measure resistance from P0118 Sensor 1 circuit sensor resistance too High. connector: ECM-C3 to CTS-2 High (Expected value: <… -
Page 293
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Check fuse Measure voltage between harness connector PF1-12B and ground (Expected value: 11 to 13 volts) Measure voltage between harness Blown fuse, damaged connector PF1-11B and ground Fuel Pump or disconnected (Expected value: 11 to 13 volts) circuit shorted to… -
Page 294
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Disconnect injector 1 Measure resistance between injector pin 1 and 2 (Expected value = 14 to15 ohms). Damaged injector, Measure resistance from Cylinder 1 injector damaged circuit wires, harness connector: INJ1-1 to P0262 shorted to battery damaged connector or… -
Page 295
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Check fuse Disconnect relay. Measure resistance between Blown fuse, damaged terminals 85 and 86 on relay. or disconnected relay, (Expected value: 70 to 90 Ohms) Radiator cooling damaged circuit wires P0480 Measure resistance between fan relay… -
Page 296
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Measure resistance between harness connector OPS and ground When engine stopped. Damaged switch, (Expected value < 2 ohms) Engine oil damaged circuit wires, Measure resistance between P0523 pressure sensor damaged connector, harness connector OPS and sticking… -
Page 297
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Measure battery voltage with engine stopped. (Expected value: 11 to 13 volts) Measure battery voltage with system voltage Rectifier failure, damaged engine Running at 3500RPM. P0563 high circuit wires or connection. (Expected value: 13 to 14.7 volts) Check connections on voltage regulator. -
Page 298
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Check start button, Check Run/Stop button, check if free weeling diode is in the good way. Disconnect starter solenoid relay Damaged relay, Measure resistance from harness Danaged start switch, Starter Relay connector: ECM-L3 to SS2 damaged circuit wires,… -
Page 299
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Check fuse Disconnect Accessory relay and Lights relay & turn key switch (on w/lights) Measure voltage between harness connector PF1-10E and ground. diagnosis related to (Expected value: 11 to 13 volts) Accessories or Light relay, Measure voltage between harness Blown fuse, damaged… -
Page 300
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Check fuse Disconnect radiator fan relay Measure voltage between harness Blown fuse, damaged or connector PF1-3D and ground. Radiator fan disconnected fan relay, (Expected value: 11 to 13 volts) circuit shorted P0691 damaged circuit wires,… -
Page 301
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Verify that gear position information change when you change the position of gear on vehicle. Disconnect GBPS Measure voltage between harness Gear position connector GBPS-1 and GBPS-3. sensor shorted to (Expected value: 4.8 to 5.1 volts) P0707 ground, or open… -
Page 302
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Power output Motor short circuit or Reset fault, If fault re-occur, replace P1F01 overload power output failed DPS unit Measure battery voltage with engine stopped. (Expected value: 11 to 13 volts) Power output High voltage at the unit Measure battery voltage with… -
Page 303
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Open the ECM Activation page in BUDS Perform an ignition coil activation and check if ignition coil is reacting as expected Damaged ignition coil, Measure resistance from harness Cyllinder 2 damaged circuit wires, connector: ECM-M1 to BA-1 P2303… -
Page 304
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Go to Activations — SCM and start Test routine. Verify that the Shock Absorber Pressure and the Auxiliary Line Pressure correlates in BUDS. If the test is done with no fault, the system is working properly. -
Page 305
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Check for leaks. If no leak found go to next action step. 2- Go to Activations — SCM and start Test routine. If the test is done with no fault, the system is working properly. -
Page 306
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Go to Activations — SCM and start Test routine. If the test passed, the system is working properly. Check the harness and connection to see a potential source of intermittent dysfunction, if nothing is found clear the occurred fault and no more actions have to be done. -
Page 307
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Disconnect MPI2 from DB connector. Measure resistance between DB-1 and DB-2 (Expected value = 50 to 70 ohms). CAN bus off, no Damaged circuit wires or Measure resistance U0073 messages damaged CLUSTER pins. -
Page 308
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION Check for Cluster fault or ECM fault Measure voltage between harness connector CL-17 and ground. (Expected value = 11 to 13 volts) Disconnect MPI2 from DB connector. Measure resistance between DB-1 and DB-2 (Expected value = 50 to 70 ohms). -
Page 309
Subsection XX (DIAGNOSTIC AND FAULT CODES) PCODE MODULE DESCRIPTION CAUSE ACTION 1- Verify in Setting — Vehicle Configuration page is correctly set up. Variant coding Faulty variant coding U0400 SCM-XMR 2- If Update File is available reflash failure Faulty programming the SCM. -
Page 310
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) ELECTRONIC FUEL INJECTION (EFI) SERVICE TOOLS Description Part Number Page 529 036 166 ……….5 ECM ADAPTER TOOL…………..529 035 868 ……….5 FLUKE 115 MULTIMETER …………295 000 070 ……….. 10 OETIKER PLIERS…………….SERVICE PRODUCTS Description Part Number… -
Page 311: Idle Speed
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) The fuel pressure applied to the fuel rails is regu- lated by the fuel pressure regulator located in the fuel pump module. Fuel Injectors The fuel injectors are used to inject fuel into the intake ports of the cylinder head.
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Page 312
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) NOTE: The multifunction gauge and B.U.D.S. use Open throttle approximately one quarter then the same signal to provide the engine RPM indi- quickly release. Repeat 2 — 3 times to settle throt- cation. tle plate. If stopper does not rest against its stop lever, perform throttle cable adjustment. -
Page 313
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) After a problem has been solved, be sure to clear NOTE: This wakes up the ECM, which then turns the fault(s) in the ECM using the B.U.D.S. soft- on the following. If the following do not turn on, ware. -
Page 314
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Testing the ECM Power Supply REQUIRED TOOL ECM ADAPTER TOOL (P/N 529 036 166) FLUKE 115 MULTIMETER (P/N 529 035 868) smr2009-030-010_a 1. Disconnect ECM connector. If any measurement is out of specification, refer to POWER DISTRIBUTION and check all grounds. -
Page 315
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) REPLACING 3. If a new ECM is installed, refer to TEST RESULT THE ECM in this subsection. READING RESULT Replacing the ECM Approximately ECM and CLUSTER CAN wires and resistors good ECM DATA 1. Transfer ECM data. Refer to TRANSFER for complete procedure. -
Page 316
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) IMPORTANT: Ensure to use the file that specifi- cally matches the vehicle you are servicing. NOTE: The file name structure is as follows: BUDS version_VIN_date read (yyyymmdd)_hour read (hhmmss).mpem Example: A3.5.0.3_3JBLKCK11DJ000319_20130924_093618.mpem B.U.D.S. version = A3.5.0.3 VIN = 3JBLKCK11DJ000319 Date file was read = 2013-09-24 Hour file was read = 09h 36m 18s… -
Page 317: Fuel Injector
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) – Engine number (do not enter the “M” at the beginning of the engine number) – Enter model number. – Customer name. vmr2006-012-100_ben FUEL INJECTOR ENGINE MANAGEMENT Refer to the applicable smr2009-030-007_a SYSTEM subsection for component and connec- VEHICLE TAB tor locations.
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Page 318
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) If supply voltage is not good, check fuse and if Using a multimeter, check resistance value be- INJECTOR POWER CIRCUIT good, perform an tween terminals as follows. RESISTANCE TEST INJECTOR If supply voltage is good, perform a FUEL INJEC- GROUND CIRCUIT CYLINDER… -
Page 319
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) vmr2006-014-071_a MANIFOLD O-RING POSITION Carefully insert injector in manifold paying atten- vmr2006-014-073_a tion to the manifold O-ring. To disconnect fuel rail from hose, cut clamp on FUEL TANK AND FUEL PUMP fuel hose. Refer to NOTICE Gently push O-ring in evenly all for clamp removal/installation procedures. -
Page 320: Throttle Cable
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) WARNING WARNING Perform a fuel pressure test and ensure that Make sure idle speed stopper contacts throt- FUEL TANK AND there is no leak. Refer to tle cam when throttle lever is fully released at FUEL PUMP handlebar.
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Page 321: Throttle Body
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) – Check if idle air control valve is loose. – Check for corroded or damaged connectors. NOTICE The throttle body must be replaced if idle set screw is loose or worn. Cleaning the Throttle Body 1.
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Page 322
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) vmr2006-014-060_b vmr2012-026-003_a 1. Throttle lever 1. Remove these screws 2. Cable barrel 2. Lift rear of air intake silencer as much as possi- 8. Remove barrel from cable. ble and block in this position. 9. -
Page 323
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Tighten clamps. – Check throttle cable adjustment. Refer to THROTTLE CABLE in this subsection. – If throttle body was replaced, perform the CLOSED THROTTLE AND IDLE ACTUATOR RESET and the IACV CALIBRATION . See pro- cedures in this subsection. -
Page 324
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Ensure TPS is connected to wiring harness. Disconnect the ECM connector. Using the ECM adapter tool and a multimeter, check resistance values. THROTTLE WIDE OPEN ECM ADAPTER IDLE THROTTLE POSITION POSITION RESISTANCE ( ) @ 20°C (68°F) 900-1600 2600-3100… -
Page 325
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) TIGHTENING TORQUE LOCTITE 243 (BLUE) Service product (P/N 293 800 060) TPS retaining screws 3 N•m (27 lbf•in) Perform the Closed Throttle And Idle Actuator CLOSED THROTTLE Reset procedure. Refer to AND IDLE ACTUATOR RESET in this subsection. -
Page 326
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) IDLE AIR CONTROL VALVE MEASUREMENT RESISTANCE ( ) @ 20°C (68°F) 50 ± 5 vmr2006-014-085_a 1. Clean bore from contamination Clean all remaining parts and install the idle air control valve on the throttle body. Proceed with the Closed Throttle and Idle Actu- ator Resetand the IACV CALIBRATION… -
Page 327
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) MANIFOLD ABSOLUTE Install ECM adapter tool on the ECM connector. PRESSURE AND TEMPERATURE Using a multimeter, measure resistance as per ta- ble. SENSOR (MAPTS) ECM ADAPTER MEASUREMENT ENGINE MANAGEMENT SYS- Refer to applicable subsection for component and connector lo- RESISTANCE cations. -
Page 328
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) Thereafter, once the engine is started, it mea- Testing the MAPTS Input Voltage sures the air pressure in the intake manifold at Check the voltage output from ECM to the pres- operating RPMs. sure sensor. The sensor must be correctly installed on intake 1. -
Page 329
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) MAPTS TEMPERATURE SENSOR TEST RESULTS RESULT SERVICE ACTION Circuit Continuity MAPTS Repair or Test of Input replace READING MAPTS Voltage wiring Temperature Test Function INCORRECT RESISTANCE Replace MAPTS VALUE vmr2016-045-001_a Testing the MAPTS Circuit Continuity 1. -
Page 330
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) TIGHTENING TORQUE LOCTITE 243 (BLUE) Service product (P/N 293 800 060) 6 N•m ± 0.7 N•m MAPTS retaining screw (53 lbf•in ± 6 lbf•in) CTS (COOLANT TEMPERATURE SENSOR) ENGINE MANAGEMENT Refer to appropriate SYSTEM subsection for component and connec- tor locations. -
Page 331
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI)) vmr2012-026-008_a 1. CTS 3. Disconnect CTS connector and remove CTS. 4. Install the new CTS and torque as specified. TIGHTENING TORQUE 16 N•m ± 2 N•m (142 lbf•in ± 18 lbf•in) 5. Reinstall remaining removed parts. 6. -
Page 332: Fuel Tank And Fuel Pump
Subsection 02 (FUEL TANK AND FUEL PUMP) FUEL TANK AND FUEL PUMP SERVICE TOOLS Description Part Number Page 529 035 868 ……….. 11 FLUKE 115 MULTIMETER …………529 036 023 ……….5 FUEL HOSE ADAPTER…………..529 035 899 ……….. 13 FUEL PUMP NUT TOOL ……………
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Page 333
Subsection 02 (FUEL TANK AND FUEL PUMP) = Component must be replaced when removed. To engine EUROPE vmr2015-043-100_a vmr2016-409… -
Page 334
Subsection 02 (FUEL TANK AND FUEL PUMP) GENERAL Air can enter the fuel tank at all times through the vent system INLET check valve. This prevents WARNING negative pressure within the fuel tank which could cause fuel starvation. Fuel is flammable and explosive under cer- tain conditions. -
Page 335
Subsection 02 (FUEL TANK AND FUEL PUMP) INSPECTION To access the fuel tank vent breather filter, re- move the rear body module. FUEL TANK LEAK TEST WARNING Always carry out a fuel tank leak test when- ever the fuel tank shows signs of wear or damage which may cause a leak, or when the fuel pump has been removed or replaced, or if you suspect a leak. -
Page 336
Subsection 02 (FUEL TANK AND FUEL PUMP) NOTE: For access to the fuel tank vent system, REQUIRED TOOLS FUEL PUMP ACCESS refer to in this subsection. PRESSURE GAUGE FUEL SYSTEM PRESSURE TEST (P/N 529 035 709) The pressure test will show the available pressure in the system. -
Page 337
Subsection 02 (FUEL TANK AND FUEL PUMP) Slow Pressure Drop If there is a slow pressure drop after the engine is stopped, check for a fuel injector leak. Refer to ELECTRONIC FUEL INJECTION (EFI) subsection. NOTE: The fuel pressure regulator or fuel pump check valve integral to the fuel pump module may also be at fault. -
Page 338
Subsection 02 (FUEL TANK AND FUEL PUMP) TROUBLESHOOTING FUEL SYSTEM DIAGNOSTIC FLOW CHART Fuel pump does not run Fuel pump runs Activate electric system to enable fuel pump for 2 sec. then stops Install fuel pressure gauge Check fuse, relay and connections. on fuel pressure line Check fuel pump operation. -
Page 339: Fuel Tank
Subsection 02 (FUEL TANK AND FUEL PUMP) PROCEDURES 3. Disconnect and remove the battery, refer to CHARGING SYSTEM subsection. FUEL HOSE AND OETIKER 4. Remove the rear body module, refer to BODY subsection. CLAMPS EXHAUST SYSTEM 5. Refer to and remove the Disconnecting a Fuel Pressure Hose following: 1.
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Page 340
Subsection 02 (FUEL TANK AND FUEL PUMP) vmr2012-028-013_a 1. Battery support 2. Support retaining screws vmr2012-028-017_a 1. Final drive unit NOTE: It is not necessary to remove the wiring 2. Vent tube to remove harness or other components from the battery 15. -
Page 341: Fuel Tank Installation
Subsection 02 (FUEL TANK AND FUEL PUMP) 19. Lift up on frame extension and pull fuel tank out of vehicle. NOTE: When lifting up on the frame extension, the shock absorbers will fall backwards. vmr2012-028-018_a 1. Rear frame extension 2. Loosen these 2 nuts 3.
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Page 342
Subsection 02 (FUEL TANK AND FUEL PUMP) TIGHTENING TORQUE Fuel tank retaining 6.5 N•m ± 0.5 N•m screws (58 lbf•in ± 4 lbf•in) Be sure to properly connect and route: – Fuel tank vent tube – Fuel pump pressure hose –… -
Page 343
Subsection 02 (FUEL TANK AND FUEL PUMP) FUEL PUMP INPUT VOLTAGE TEST FUEL PUMP RESISTANCE TEST (AT FUSE BOX) VOLTAGE TEST PROBES READING RESISTANCE TEST PROBES @ 20°C (68°F) Fuel pump Fuel pump connector connector Battery voltage Fuse box Battery Approximately 2 Pin 3 Pin 4… -
Page 344: Fuel Pump Installation
Subsection 02 (FUEL TANK AND FUEL PUMP) vmr2015-043-005_a 570 ENGINE vmr2012-028-026_a 1. Fuel pump connector 2. Vent hose TYPICAL — FUEL PUMP REMOVAL 3. High pressure fuel hose 1. Fuel pump retaining nut 4. Carefully pull out and rotate fuel pump as re- quired.
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Page 345
Subsection 02 (FUEL TANK AND FUEL PUMP) vmr2012-028-007_a vmr2015-130-004_a 850 AND 1000R ENGINES TYPICAL 1. Fuel tank pump index 1. Gasket ring here 2. Fuel pump index 2. Fuel pump flange 4. Insert fuel pump retaining nut over the fuel WARNING pressure hose and electrical wiring connector. -
Page 346
Subsection 02 (FUEL TANK AND FUEL PUMP) TIGHTENING TORQUE 29 N•m ± 1 N•m Fuel pump retaining nut (21 lbf•ft ± 1 lbf•ft) 7. Install fuel pressure hose on fuel pump using a NEW Oetiker clamp. 8. Install fuel vent tube on fuel pump. 9. -
Page 347
Subsection 02 (FUEL TANK AND FUEL PUMP) 6. Lubricate assembly area of new strainer and fuel pump with O-ring lubricant or clean oil vmr2008-135-221_a 4. Remove push nut securing strainer to fuel pump. Be careful not to break the plastic pin. vmr2015-043-031_a 7. -
Page 348
Subsection 02 (FUEL TANK AND FUEL PUMP) 7. Press in a NEW push nut to secure strainer. 8. Reinstall remaining removed parts. FUEL LEVEL SENDER The fuel level sender is a float actuated variable resistance type that is part of the fuel pump. vmr2006-020-052_c vmr2015-043-023_a 570 ENGINE… -
Page 349
Subsection 02 (FUEL TANK AND FUEL PUMP) TEST RESULT SERVICE ACTION REQUIRED TOOL Test wiring continuity between fuel level VACUUM/PRESSURE PUMP 5V is not read sender and multifunction (P/N 529 021 800) gauge Replace multifunction Wiring continuity is good gauge Wiring continuity is not Repair or replace wiring obtained… -
Page 350
Subsection 02 (FUEL TANK AND FUEL PUMP) vmr2015-130-002_e vmr2015-130-002_g 1. Inlet check valve 1. Vent breather filter 2. Fuel pump vent inlet fitting 2. White portion of inlet check valve 3. Install small hose pincher here Pressure Relief Valve Installation 2. -
Page 351
Subsection 01 (POWER DISTRIBUTION AND GROUNDS) POWER DISTRIBUTION AND GROUNDS GENERAL POWER DISTRIBUTION DIAGRAM DPS2 COMMUNICATION CONNECTOR DB-5 FUSE BOX 1 MAIN GAUGE RELAY (R2) COMMUNICATION 16 awg CONNECTOR DB-4 FL-1 IGNITION COIL DPS1-A 16 awg FL-2 FUEL INJECTORS HICA-C FUEL PUMP FUSE BOX 2 RELAY (R4) -
Page 352
Subsection 01 (POWER DISTRIBUTION AND GROUNDS) FUSE BOX 1 FUSE IDENTIFICATION 25 A Fuse vmr2012-028-006_g 30 A FUSES 20 A 20 A Jumper 1 (or 20 A fuse) vmr2012-028-006_h RELAYS RELAY RELAY STATE (ON) RELAY STATE (OFF) IDENTIFICATION COOLING SYSTEM Cooling fan When ignition key is turned ON Approximately 30 seconds after ignition… -
Page 353
Subsection 01 (POWER DISTRIBUTION AND GROUNDS) FUSE LINKS AND FUSE BOX 2 vmr2015-131-001_a TYPICAL — RH SIDE vmr2016-132-002_a 1. Battery ground LOCATION OF FUSE LINKS AND FB2 2. Engine ground 1. Connector support (right side of vehicle) 3. DPS ground 2. -
Page 354
Subsection 01 (POWER DISTRIBUTION AND GROUNDS) vmr2016-132-003_a PRE-ASSEMBLED REPLACEMENT FUSE LINK 1. Insulated fuse link wire 2. Butt end terminal 3. Terminal factory crimped on fuse link 4. Crimp here when installing in circuit 5. Solder ring 1. Disconnect the battery. 2. -
Page 355
Subsection 02 (WIRING HARNESS AND CONNECTORS) WIRING HARNESS AND CONNECTORS SERVICE TOOLS Description Part Number Page 529 035 730 ……….. 14 CRIMPING TOOL (HEAVY GAUGE WIRE) ……..529 036 166 ……….. 12 ECM ADAPTER TOOL…………..529 036 175 ……….. 12 ECM TERMINAL REMOVER 2.25………. -
Page 356
Subsection 02 (WIRING HARNESS AND CONNECTORS) ABBREVIATION DESCRIPTION RH License plate light (Used on European models only) LH License plate light (Used on European models only) Rear RH light Rear LH light Trailer harness (Used on European models only) Voltage regulator/rectifier Starter motor Starter solenoid Starter solenoid… -
Page 357: Wiring Harness Routing
Subsection 02 (WIRING HARNESS AND CONNECTORS) WIRING HARNESS ROUTING Main Harness (Front 1/2) HIC1 HIC2 DPS2 vmr2015-132-100_a vmr2016-133…
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Page 358
Subsection 02 (WIRING HARNESS AND CONNECTORS) Main Harness (Front 2/2) HICa DPS3 DPS1 vmr2016-133-100_a vmr2016-133… -
Page 359
Subsection 02 (WIRING HARNESS AND CONNECTORS) Main Harness (Rear) vmr2016-133-101_a vmr2016-133… -
Page 360
Subsection 02 (WIRING HARNESS AND CONNECTORS) WIRING HARNESS SPLICE LOCATION Main Harness (Rear Part) JT RD JT WH/OR JT WH/BK Jt WH/BE JT RD/PK JT BK2 vmr2016-133-102_a Main Harness (Front Part 1/2) Diode 5 Diode 6 JT RD/GN JT RD/GY DPS1 DPS2 vmr2015-132-105_a… -
Page 361
Subsection 02 (WIRING HARNESS AND CONNECTORS) Main Harness (Front Part 2/2) JT RD/YL JT VI/RD JT RD/BE JT BU/GY JT OR/BK JT BE JT BK/WH HICa JT VI/BE JT BU JT RD/BU JT GN JT BK/BR JT RD/BK JT RD/BR JT BK3 JT VI/GY JT RD/VI… -
Page 362
Subsection 02 (WIRING HARNESS AND CONNECTORS) PROCEDURES DEUTSCH CONNECTORS Deutsch Connector Application A variety of Deutsch connectors are used on var- ious systems: – Diagnostic connector – Vehicle speed sensor (VSS) connector. The following procedures may be used on each as they are similar in construction. -
Page 363
Subsection 02 (WIRING HARNESS AND CONNECTORS) PACKARD CONNECTORS Packard Connector Application Packard connectors are used to connect: – Electrical harnesses – Gauges. 3-Pin Packard Connector V01G0QA TYPICAL — FEMALE CONNECTOR 1. Retaining tabs Terminal Insertion 1. For insertion of a terminal, ensure the sec- ondary plastic lock is removed. -
Page 364
Subsection 02 (WIRING HARNESS AND CONNECTORS) A33Z01A TYPICAL 1. Retainer 2. Tab (one on each side) vmr2006-032-001_a Open housing by lifting 4 tabs. A33Z02A TYPICAL 1. Tabs (2 on each side) Lift the top plastic lock of the female terminal to be removed and hold in position. -
Page 365
Subsection 02 (WIRING HARNESS AND CONNECTORS) vmr2008-022-014_a A32E3XA Pull out connector. TYPICAL 1. Lift and hold plastic lock 2. Lift to unlock and push out MOLEX CONNECTOR Molex Connector Application Molex connectors are used on the following sys- tem: – ECM Molex Connector Removal Push and hold the locking tab. -
Page 366
Subsection 02 (WIRING HARNESS AND CONNECTORS) Rotate connector lock until it snaps locked. vmr2008-139-016_a 1. ECM connector (harness side) 2. ECM adapter NOTICE Never probe directly on ECM har- ness connector. This could change the shape or enlarge the terminals and create intermit- tent or permanent contact problems. -
Page 367
Subsection 02 (WIRING HARNESS AND CONNECTORS) 529036175 1. Remove rear protector from connector. 2. Pull out the connector lock. smr2009-045-027_a NOTICE Before installing wire terminals in the connector, ensure all terminals are prop- erly crimped on wires. After installation of wire terminals in the connectors, ensure they are properly locked by gently pulling on them as if to extract them. -
Page 368
Subsection 02 (WIRING HARNESS AND CONNECTORS) A32E2QA A. 10 mm (3/8 in) smr2010-050-022_a Step 2: Insert GM terminal extractor tool (P/N 12094430) NOTE: Make sure not to cut wire strands while stripping the wire. 3. Gently pull on the wire to extract the pin out the back of the connector. -
Page 369
Subsection 02 (WIRING HARNESS AND CONNECTORS) Install the protective heat shrink rubber tube on the terminal. Heat the heat shrink rubber tube us- ing the heat gun so that it grasps the wire and the terminal. NOTICE Make sure that the protective heat shrink rubber tube has been properly installed and no part of wire is exposed. -
Page 370: Ignition System
Subsection 03 (IGNITION SYSTEM) IGNITION SYSTEM SERVICE TOOLS Description Part Number Page 529 036 166 ……… 2, 4 ECM ADAPTER TOOL…………..529 035 868 ……… 3–4 FLUKE 115 MULTIMETER …………GENERAL 2. Defective CPS — Check operation of CPS and replace if necessary. SYSTEM DESCRIPTION Refer to ELECTRONIC FUEL INJECTION (EFI) subsection.
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Page 371: Ignition Switch
Subsection 03 (IGNITION SYSTEM) EMERGENCY ENGINE STOP 2. Damaged trigger wheel/defective or loose CPS SWITCH — Inspect trigger wheel and CPS, refer to MAG- NETO AND STARTER and ELECTRONIC FUEL INJECTION (EFI) subsections. Testing the Emergency Engine Stop Switch at ECM PROCEDURES 1.
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Page 372: Ignition Coil
Subsection 03 (IGNITION SYSTEM) Testing the Emergency Engine Stop Switch at Multifunction Switch Connectors Refer to WIRING HARNESS AND CONNECTORS subsection for connector locations. The emergency engine stop switch is wired into the LH multifunction switch connectors (MG1 and MG2). LIGHTS, 1.
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Page 373
Subsection 03 (IGNITION SYSTEM) Testing the Ignition Coil Resistance IGNITION COIL INPUT VOLTAGE TEST An ignition coil with good resistance measure- CONNECTORS VOLTAGE ment can still be faulty. Voltage leakage can occur Pin 2 with battery ground Battery voltage at high voltage levels which is not detectable with an ohmmeter. -
Page 374: Spark Plug
Subsection 03 (IGNITION SYSTEM) SPARK PLUG For spark plug replacement procedure, refer to PERIODIC MAINTENANCE PROCEDURES sub- section. Troubleshooting Fouled Spark Plug Fouling of the spark plug is indicated by irregular running of the engine, decreased engine speed due to misfiring, reduced performance, and in- creased fuel consumption.
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Page 375: Charging System
Subsection 04 (CHARGING SYSTEM) CHARGING SYSTEM SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page 380941 ……….2 EXTECH INDUCTIVE AMMETER ……….95260 ……… 2–4 NAPA ULTRA PRO BATTERY LOAD TESTER ……. GENERAL The voltage regulator output voltage is distributed as follows: SYSTEM DESCRIPTION –…
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Page 376: Battery Load Test
Subsection 04 (CHARGING SYSTEM) BATTERY REGULARLY DISCHARGED OR If battery voltage drops below specification dur- WEAK CHARG- ing test, replace battery and perform a ING SYSTEM LOAD TEST 1. Loose or corroded battery cable connections. — Tighten or repair battery cable connections. CHARGING SYSTEM LOAD TEST 2.
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Page 377
Subsection 04 (CHARGING SYSTEM) TEST CONDITIONS As required to decrease Load battery voltage to 12 Vdc Time 15 seconds ‡ Required for accurate testing 6. Read amperage on ammeter. MODEL SPECIFICATION Base models (no-DPS, 35 ± 5 Amps not CE) DPS models 41 ±… -
Page 378
Subsection 04 (CHARGING SYSTEM) TEST CONDITIONS RD1-3 Permanent ground BACKPROBE PROBE SPECIFICATION RD1-3 BAT1 (+) Battery voltage 2. Connect a battery load tester such as the NAPA ULTRA PRO BATTERY LOAD TESTER (P/N 95260) 3. Start vehicle. 4. Ensure proper test conditions. TEST CONDITIONS Battery voltage at idle‡… -
Page 379
Subsection 04 (CHARGING SYSTEM) WARNING TIGHTENING TORQUE Ensure battery is stored in a safe place, out of Battery retaining plate 4.5 N•m ± 0.5 N•m reach for children. screws (40 lbf•in ± 4 lbf•in) New Battery Activation Refer to the instructions provided with the battery. Battery Charging WARNING Always wear safety glasses and charge in a… -
Page 380: Starting System
Subsection 05 (STARTING SYSTEM) STARTING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 166 ……….. 4 ECM ADAPTER TOOL…………..529 035 868 ……….. 5 FLUKE 115 MULTIMETER …………GENERAL MAGNETO AND STARTER 4. Starter (refer to subsection) STARTING SYSTEM OPERATION 5.
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Page 381: Starting System Tests
Subsection 05 (STARTING SYSTEM) STARTING SYSTEM TESTS STARTER SOLE- 4. If starter does not turn, verify NOID CONTINUITY Starter Solenoid Starter Solenoid Control Circuit vmr2015-135-001_a vmr2015-135-003_a 1. Disconnect SS1 and SS2 TEST CONDITION Engine stop switch Ignition switch Pressed Start button vmr2015-048-012_a 1.
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Page 382
Subsection 05 (STARTING SYSTEM) If start switch tests as specified, repair wire to starter solenoid SS1 terminal. Starter Power Circuit Voltage Drop NOTE: Engine must be in starting condition for this test. Do not perform on a «No Start» vehicle. TEST CONDITION Fuse F5 Removed‡… -
Page 383
Subsection 05 (STARTING SYSTEM) Starter Solenoid Control Ground Starter Solenoid Continuity Circuit SS1- SS2- HIC1-J vmr2016-136-100_a vmr2015-048-005_a 1. Disconnect the BLACK (-) negative battery ca- ble. 1. Disconnect SS2. 2. Disconnect SS1 and SS2 2. Install the ECM connector onto the ADAPTER TOOL (P/N 529 036 166) vmr2015-048-012_a vmr2008-139-016_a… -
Page 384
Subsection 05 (STARTING SYSTEM) Solenoid Diode Test SS1- SS2- vmr2015-048-013_a vmr2015-048-007_a 1. Disconnect SS1 and SS2 from starter solenoid. PROBE PROBE SPECIFICATION Terminal to O.L. starter motor 4. Jump starter solenoid. vmr2015-048-012_a 1. SS1 2. Use the FLUKE 115 MULTIMETER (P/N 529 035 and set it to the diode symbol as shown. -
Page 385
Subsection 05 (STARTING SYSTEM) vmr2015-048-011_a FORWARD POLARITY, MUST BE AROUND 0.5 V vmr2015-048-010_a REVERSE POLARITY, MUST BE OPEN CIRCUIT 1. SS1 WIRING If test failed, replace diode. Refer to HARNESS AND CONNECTORS for diode loca- tion. NOTE: The diode is integrated in the harness near the starter solenoid. -
Page 386
Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.) GENERAL 2. Turn ignition switch to ON using any of the key provided with the vehicle. DO NOT start the SYSTEM DESCRIPTION engine. 3. Click the Read Data button in B.U.D.S. 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. -
Page 387
Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)) KEY TYPE Performance key BLACK key GRAY key Normal key 8. Click on the appropriate Add Key button. tbl2011-001-053_d 1. Add Performance Key button 2. Add Normal Key button NOTE: The Add Work Key button is not used for these vehicles. -
Page 388
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) LIGHTS, GAUGE AND ACCESSORIES SERVICE TOOLS Description Part Number Page 529 035 868 ……….9 FLUKE 115 MULTIMETER …………SERVICE PRODUCTS Description Part Number Page 293 550 004 ……….4 DIELECTRIC GREASE …………..GENERAL NOTICE It is recommended to always discon- nect the battery when replacing any electric… -
Page 389
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) 10) Turn signal/Hazard lights Indicator Lamp When this indicator is ON, it indicates: – A turn signal is activated, or – The hazard lights are activated. Multifunction Display Modes Speed Mode In this mode, the display shows the speed of the vmo2013-010-001_b vehicle either in km/h or in MPH. -
Page 390
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Odometer (OD) Odometer records the total distance travelled ei- ther in miles or kilometers. vsi2009-018-032 Press and HOLD the selector button for 2 seconds to reset the hour meter. Engine Hour Meter (EH) vsi2009-018-030 The engine hour meter records engine running Clock time. -
Page 391
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) TROUBLESHOOTING 3. Press and release selector button once to dis- play OD (odometer). DIAGNOSTIC TIPS 4. Press the selector button again, this time for 2 seconds. NOTE: It is a good practice to check for fault This will change the Mode to either Speed, RPM codes using B.U.D.S. -
Page 392
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) DIAGNOSTIC GUIDELINES BRAKE LIGHTS WILL NOT COME ON WHEN BRAKES APPLIED (GAUGE) 1. Defective brake relay. MULTIFUNCTION GAUGE WILL NOT — Test brake relay (R8), refer to POWER DISTRIBU- COME ON TION subsection. 1. Multifunction gauge not powered up. 2. -
Page 393
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) HORN WILL NOT FUNCTION (CE MODELS 6. Defective flasher module. ONLY) — Replace flasher module, refer to FLASHER MOD- ULE in this subsection. 1. Burnt Clock/Hazard fuse (F10) HAZARD LIGHTS COME ON WITHOUT — Check fuse BEING SELECTED (CE MODELS ONLY) 2. -
Page 394
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Multifunction Gauge Wire 4. If the 12-hour format was selected, choose Am Identification (A) or Pm (P) by pressing button. 5. Choose hour first digit by pressing button. FUNCTION COLOR 6. Choose hour second digit by pressing button. 12 volt input from fuse F4 17 ORANGE/YELLOW 7. -
Page 395
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Clock Setting In B.U.D.S., select the: – Setting page tab – Cluster page tab. To set clock to the 24-hour format, check the 24 H box. To set it to the 12-hour format, leave the box empty. -
Page 396
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Removing the Multifunction Gauge 2. Remove seat to access diagnostic link connec- tor (DB). 1. Remove console panel, refer to BODY subsec- 3. Remove diagnostic link connector from its tion. holder. 2. Pull gauge support from vehicle. vmr2016-410-004_a EXCEPT X MR MODEL vmr2012-023-003_a… -
Page 397: Volt Power Outlet
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) HEADLIGHTS Installing the Multifunction Gauge For the installation, reverse the removal proce- Headlight Wire Identification dure. HEADLIGHTS RELAY (R5) New Multifunction Gauge Registration FUNCTION COLOR (coding) Whenever the multifunction gauge is replaced, 12 volt input from fuse YELLOW/BLACK B.U.D.S.
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Page 398: Replacing The Headlight Bulb
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) POWER 4. Remove the JP1 jumper/fuse, refer to 2. Measure the distance from the center of each DISTRIBUTION subsection. headlight to the ground (high beam and low beam). 5. Measure the voltage on headlight connector as follows.
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Page 399
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Taillight Wire Identification CIRCUIT FUNCTION PROTECTION Supplied when Accessories relay R3 RED/VIOLET activated Ground from BK2 BLACK Taillight Circuit Protection CONDITION CIRCUIT PROTECTION Supplied when Fuse 14 (from Accessories relay R3 Accessories relay R3) vmo2012-012-060_a activated LOW AND HIGH BEAMS… -
Page 400
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) FLASHER MODULE HAZARD CIRCUIT FUNCTION COLOR CONDITION CIRCUIT PROTECTION 12 volt input from Battery power Fuse 10 MC1-5 RED/BLACK fuse F7 (continuous) RH turn 12 volt input MC1-1 BEIGE/BROWN Flasher Module Access from turn signal switch Remove multifunction gauge. -
Page 401
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) WINCH Winch Wire Identification WINCH RELAY FUNCTION COLOR 12 volt input from battery (winch power) Ground BLACK 12 volt input from GREEN/BLUE switch (IN) 12 volt input from LIGHT BLUE switch (OUT) Motor power (switches RED (with blue tmr2011-030-003_a polarity depending on… -
Page 402
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) vmr2016-410-003_a 6. Disconnect both winch power cables. NOTE: Note the position of the power cables for tsi2011-004-009_a reinstallation. 1. Hook 2. Hook pin 3. Cotter pin 3. Remove the winch cable fairlead. vmr2012-035-010_a 1. Winch power cables vmr2016-410-001_a 7. -
Page 403
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES) Installing the Winch For the installation, reverse the removal proce- dure, however pay attention to the following. Connect winch power cables as noted at removal. NOTE: If the winch power cables are not con- nected correctly, the winch motor will operate in the reverse direction of selection. -
Page 404
Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) FRONT DRIVE SERVICE TOOLS Description Part Number Page 529 035 665 ……… 469 BACKLASH MEASUREMENT TOOL……….529 036 120 ……… 467 CV BOOT CLAMP PLIER ………….. 529 036 005 ……… 467 CV JOINT EXTRACTOR…………..529 035 649 ……… -
Page 405
Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) FRONT DRIVE SHAFTS AND FRONT PROPELLER SHAFT 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) (M8) 61 ± 9 N•m (45 ± 7 lbf•ft) (M10) STEERING SYSTEM Loctite XPS Synthetic Synthetic grease grease 205 ±… -
Page 406
Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) FRONT DIFFERENTIAL XPS synthetic grease 37 ± 3 N•m (27 ± 2 lbf•ft) 33 ± 3 N•m (24 ± 2 lbf•ft) 22.5 ± 2.5 N•m (17 ± 2 lbf•ft) For backlash adjustment 180 ±… -
Page 407
Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) GENERAL The procedure explained below is the same for the RH and LH sides unless otherwise instructed. SYSTEM DESCRIPTION The Visco-Lok ® system constantly monitors front wheel speed and, if it detects one wheel spinning faster than its mate, it progressively sends more power to the wheel with the better traction. -
Page 408: Front Drive Shaft
Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) FRONT DRIVE SHAFT Front Drive Shaft Removal Lift and support vehicle. BODY Remove inner fender panel(s). Refer to subsection. Remove the KNUCKLE . Refer to STEERING SYS- subsection. Remove shock absorber lower bolt. Lift and attach the following parts to make room.
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Page 409
Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) 529036005 vmr2012-036-003_a FROM LH SIDE 1. Vent hose 4. Remove bolts securing front differential to frame. vmr2007-053-010_a TYPICAL — CV JOINT SHOWN 1. Joint extractor tool With an hammer, hit on the tool to separate joint from shaft. -
Page 410
Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) vmr2012-036-005_a vmr2006-023-015_a FRONT PROPELLER SHAFT MOVED REARWARD 1. Tab of backlash measurement tool 2. Mark on tab 7. Remove front differential by pulling it from RH A. 25.4 mm (1 in) side. Position the dial indicator tip against the tab at a NOTICE Be careful not to knock or to bend… -
Page 411
Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) BACKLASH ADJUSTMENT GUIDELINE BACKLASH WHAT TO DO MEASUREMENT Remove shim(s) and Below 0.1 mm (.004 in) recheck backlash Add shim(s) and recheck Above 0.25 mm (.01 in) backlash vmr2015-051-006_a PRELOAD SPECIFICATION Maximum 0.50 N•m (4 lbf•in) If preload is out of specification, split front differ- ential housing and check all bearings conditions. -
Page 412
Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) Visco-Lok Carrier/Ring Gear Remove Visco-Lok carrier/ring gear out of half housing. vmr2015-051-010_a 1. Visco-Lok unit 2. Ring gear Pinion Gear Remove screw retaining front propeller shaft vmr2015-051-002_a adapter. Remove screws securing ring gear to Visco-Lok unit. -
Page 413
Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) 529035649 vmr2008-142-010_a 1. O-ring 2. Pinion gear 3. Bearing Remove and discard the needle bearing. Front Differential Assembly vmr2012-036-011_a Adjustment is required when any of the following 1. Pinion nut part is changed. Remove bearing and pinion gear together. -
Page 414
Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) Visco-Lok Carrier/Ring Gear The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Tighten Visco-Lok / ring gear screws to specifica- tion. TIGHTENING TORQUE Visco-Lok / ring gear 37 N•m ±… -
Page 415: Front Propeller Shaft
Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) TIGHTENING TORQUE M8 nut securing front 24.5 N•m ± 3.5 N•m differential to frame (18 lbf•ft ± 3 lbf•ft) M10 nuts securing front 61 N•m ± 9 N•m differential to frame (45 lbf•ft ± 7 lbf•ft) Install NEW Oetiker clamps.
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Page 416
Section 06 DRIVE SYSTEM Subsection 01 (FRONT DRIVE) 9. Remove front propeller shaft adapters from en- gine and from front differential. Front Propeller Shaft Inspection Inspect if propeller shaft is not bent or twisted. Check propeller shaft splines for wear or damage. Check if propeller shaft bellows is pierced or brit- tle. -
Page 417: Rear Drive
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) REAR DRIVE SERVICE TOOLS Description Part Number Page 529 035 665 ……… 620 BACKLASH MEASUREMENT TOOL……….529 036 120 ……… 616 CV BOOT CLAMP PLIER ………….. 529 036 005 ……… 617 CV JOINT EXTRACTOR…………..529 035 649 ………
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Page 418
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) MODELS WITH 500 ENGINE XPS Synthetic grease MAX models XPS Synthetic Short models grease XPS Synthetic 205 ± 15 N•m grease (151 ± 11 lbf•ft) 90 ± 5 N•m (66 ± 4 lbf•ft) XPS Synthetic grease Synthetic… -
Page 419
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) MODELS WITH 450 ENGINE XPS Synthetic grease MAX models XPS Synthetic Short models grease XPS Synthetic 205 ± 15 N•m grease (151 ± 11 lbf•ft) 90 ± 5 N•m (66 ± 4 lbf•ft) XPS Synthetic grease Synthetic… -
Page 420
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) XPS synthetic grease For preload adjustment 32 ± 3 N•m (24 ± 2 lbf•ft) For backlash adjustment 22.5 ± 2.5 N•m (17 ± 2 lbf•ft) 180 ± 15 N•m (133 ± 11 lbf•ft) LH threads 5 ±… -
Page 421
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) PROCEDURES Wheel Hub Inspection Remove disk from RH wheel hub as necessary. WHEEL HUB Check wheel hub for cracks or other damages. Wheel Hub Removal Check inner splines for wear or other damages. If any damage is detected on wheel hub, replace Lift and support vehicle. -
Page 422
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) Drive Shaft Inspection TIGHTENING TORQUE Inspect the condition of boots. If there is any dam- 205 N•m ± 15 N•m Wheel hub nut age or evidence of leaking lubricant, replace them. (151 lbf•ft ± 11 lbf•ft) Refer to DRIVE SHAFT BOOT NOTE: If required, tighten castellated nut further… -
Page 423: Propeller Shaft
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) PROPELLER SHAFT Remove and discard the circlip. A new one is in- cluded in the boot kit. Propeller Shaft Removal With the Special Tool Place drive shaft in vice with the joint downward. Install the CV JOINT EXTRACTOR (P/N 529 036 005) on bearing.
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Page 424: Propeller Shaft Inspection
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) 7. Remove rear final drive retaining bolts. Refer to REAR FINAL DRIVE in this subsection. 8. Remove bolts from rear retaining plate. Refer REAR FINAL DRIVE in this subsection. 9. Move the rear final drive rearward to allow dis- lodging the propeller shaft.
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Page 425
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) Support U-joint in vice and drive inner yoke down PARTS TORQUE to remove remaining bearing caps. 75 N•m ± 5 N•m Remove U-joint cross. (55 lbf•ft ± 4 lbf•ft) Propeller shaft screw (rear final drive side) Propeller Shaft U-Joint Installation LOCTITE 648 (GREEN) -
Page 426
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) V01H12A vmr2015-052-003_a Unplug the vent hose from final drive. Install snap ring. Complete installation for the other bearing caps. PERIODIC MAINTE- Grease U-joint. Refer to NANCE PROCEDURES subsection. REAR FINAL DRIVE Rear Final Drive Removal PERIODIC MAINTENANCE Drain oil. -
Page 427
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) BACKLASH ADJUSTMENT GUIDELINE BACKLASH WHAT TO DO MEASUREMENT Add shim(s) and recheck Below 0.1 mm (.004 in) backlash Remove shim(s) and Above 0.35 mm (.014 in) recheck backlash vmr2006-023-015_a 1. Tab of backlash measurement tool 2. -
Page 428
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) vmr2015-052-006_a PRELOAD SPECIFICATION vmr2015-052-007_a 0.06 N•m (.5 lbf•in) to 0.50 N•m (4 lbf•in) Split final drive housings. NOTE: Be careful to keep track of shims on ring If preload is out of specification, split final drive gear. -
Page 429
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) Unscrew the pinion nut. Use the SPANNER SOCKET (P/N 529 035 649) 529035649 vmr2015-052-011_a 1. O-ring 2. Ball bearing 3. Pinion gear shim 4. Pinion gear The pinion gear and bearing can be easily removed using the following suggested tool: PART Pipe: 83 mm (3-1/4 in) diameter x 127 mm… -
Page 430
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) RECOMMENDED SHIM THICKNESS See procedure for pinion gear PINION GEAR shim thickness BACKLASH 0.5 mm (.02 in) (as a preliminary adjustment) PRELOAD Procedure for pinion gear shim thickness: 1. Remove the old pinion gear and install the new one without the ball bearing. -
Page 431
Section 07 DRIVE SYSTEM Subsection 03 (REAR DRIVE) – Check backlash. Install the shim(s) then a NEW ball bearing. – Check preload. install a NEW O-ring. Apply to pinion nut. Ring Gear LOCTITE 277 (P/N 293 800 073) Install and tighten the pinion nut as per specifica- The installation is the reverse of the removal pro- tion. -
Page 432
Section 08 CHASSIS Subsection 01 (WHEELS AND TIRES) WHEELS AND TIRES SERVICE PRODUCTS Description Part Number Page 293 800 070 ……… 627 LOCTITE 767 (ANTISEIZE LUBRICANT) ……..PROCEDURES TIRES WARNING Do not rotate tires. The front and rear tires have a different size. Respect direction of ro- tation when applicable. -
Page 433
Section 08 CHASSIS Subsection 01 (WHEELS AND TIRES) tmr2011-033-002_a TYPICAL 1. Direction of rotation Install wheel with the tire in the right direction of rotation. Install lug nuts with the taper towards the wheel. Tighten wheel lug nuts to the specified torque us- ing the illustrated sequence. -
Page 434
Subsection 01 (STEERING SYSTEM) STEERING SYSTEM SERVICE TOOLS Description Part Number Page 529 036 059 ……….3 STEERING ALIGNMENT TOOL…………. SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page 16 ga ……….4 SMOOTHFLOW™ TAPERED TIP……….#511 rtt-b SERVICE PRODUCTS Description Part Number Page… -
Page 435
Subsection 01 (STEERING SYSTEM) 31.5 ± 3.5 N•m (23 ± 3 lbf•ft) X mr Loctite Europe Loctite 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) Synthetic grease 31.5 ± 3.5 N•m (23 ± 3 lbf•ft) 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) Loctite 767 Antiseize 24.5 ±… -
Page 436
Subsection 01 (STEERING SYSTEM) GENERAL 10. Rotate the front wheel to position the align- ment tool level with the rope. Ensure rope The procedures described below are the same for passes over the spacer blocks on the align- the RH and LH sides, unless otherwise instructed. ment tool. -
Page 437: Handlebar Grip
Subsection 01 (STEERING SYSTEM) 13. Measure the distance between the rope and the rim, at the front and at the rear of the wheel rim. tmr2011-034-107_a A. Maximum tie-rod end length 15.3 Tighten tie-rod end lock nuts to specifica- tion. TIGHTENING TORQUE Tie-rod end 34 N•m ±…
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Page 438: Multifunction Switch
Subsection 01 (STEERING SYSTEM) STEERING CONNECTORS TIGHTENING TORQUE Steering Connector Access 0.4 N•m ± 0.1 N•m Grip cap screw (4 lbf•in ± 1 lbf•in) REMOVING 1. Remove gauge support, refer to THE MULTIFUNCTION GAUGE LIGHTS, HANDLEBAR GAUGE AND ACCESSORIES subsection. Removing the Handlebar Steering Connector Identification 1.
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Page 439: Throttle Lever
Subsection 01 (STEERING SYSTEM) THROTTLE LEVER Removing the Throttle Lever 1. Disconnect the BD connector (2/4WD switch), WIRING HARNESS AND CONNEC- refer to TORS subsection. 2. Remove throttle lever housing retaining screws. V07I0HA 1. Inner housing protector 7. Slide cable in clip slot and remove the end of the cable from clip.
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Page 440: Steering Column Bearing
Subsection 01 (STEERING SYSTEM) BRAKES REMOVING THE 2. Disconnect brake hose, refer to sub- 4. Remove handlebar, refer to HANDLEBAR section. in this subsection. Also remove locking ties and separate wiring harnesses and Removing the Brake Lever (At hoses from the steering column. Handlebar) 5.
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Page 441: Installing The Steering Column
Subsection 01 (STEERING SYSTEM) 6. Remove upper half bushing retaining bolts and pull retainer off of half bushings. vmr2012-039-010_a TYPICAL 1. Upper steering column support 2. Half bushings 3. Half bushing retainer vmr2012-039-010_a 4. Retainer mounting screws (2) TYPICAL 1. Upper steering column support 8.
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Page 442
Subsection 01 (STEERING SYSTEM) PRODUCT O-rings, half XPS SYNTHETIC GREASE bushings and DPS (P/N 293 550 010) input shaft splines DPS output shaft LOCTITE 767 (ANTISEIZE splines LUBRICANT) (P/N 293 800 070) Install NEW cotter pins (as applicable per model). Both ends of cotter pins must be folded. -
Page 443
Subsection 01 (STEERING SYSTEM) rmr2008-028-015_a NOMINAL LENGTH 1. Pitman arm side 2. Knuckle side A. 416.4 mm (16.394 in) TIE-ROD MAXIMUM UNENGAGED LENGTH Dimension «A» — Shoulder 32 mm (1.26 in) to tie rod end face vmr2015-141-003 WARNING 6. Detach upper suspension arm from knuckle, re- Maximum tie-rod unengaged length must FRONT SUSPENSION fer to… -
Page 444
Subsection 01 (STEERING SYSTEM) 5. Remove bearing from knuckle using an appro- priate bearing remover. tmr2011-034-109 NOTE: It may be necessary to heat the knuckle to V07I0RA remove bearing. TYPICAL WARNING 3. Remove the circlip. Clean all grease from outside and inside of knuckle before heating it. -
Page 445
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) DYNAMIC POWER STEERING (DPS) SERVICE TOOLS Description Part Number Page 529 035 868 ……… 520 FLUKE 115 MULTIMETER …………529 036 225 ……… 532, 534 PITMAN ARM JIG …………….. 529 036 227 ……… 533 PITMAN ARM PULLER ………….. -
Page 446
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) DPS MED provides normal (medium) steering as- sist for general all purpose riding. DPS MIN provides less steering assist for in- creased feedback and aggressive trail riding. A fourth mode of operation is available as an ac- cessory to adjust the steering assist level for op- eration with an approved BRP track kit. -
Page 447
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Steering Torque Sensor PART ADJUSTED OR WHAT TO DO REPLACED – DPS unit – Steering column half bushings – Steering column – Tie rod – Tie rod end Reset Torque Offset –… -
Page 448
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) DPS ASSIST MODE TROUBLESHOOTING 1. To view the active DPS ASSIST mode, momen- TROUBLESHOOTING FLOW tarily press and release the OVERRIDE/DPS CHARTS button on the LH multifunction switch assem- bly. Use the troubleshooting flow charts to diagnose a problem. -
Page 449
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart A vbs2014-009-001_aen vmr2015-142… -
Page 450
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart B vbs2014-009-002_aen vmr2015-142… -
Page 451
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart C vbs2014-009-003_aen vmr2015-142… -
Page 452
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart D vbs2014-009-004_aen vmr2015-142… -
Page 453
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) Flow Chart E vbs2014-009-006_aen vmr2015-142… -
Page 454
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) PROCEDURES DPS UNIT DPS Unit Fuse Test A 40 A DPS fuse located in a fuse holder, on the RH side of the frame, under the battery support, provides power for the DPS motor. vmr2012-029-002_a TYPICAL 1. -
Page 455
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) MULTIMETER PROBE POSITIONS VOLTAGE MULTIMETER PROBE VOLTAGE POSITIONS DPS2 power connector pin A DPS control connector (pin A) Battery ground and battery ground DPS2 power connector pin B Battery voltage Battery voltage rmr2008-028-093_a rmr2008-028-091_a… -
Page 456
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) If resistance measured is out of specification, MULTIMETER PROBE READING check wires and connector pins. Carry out re- POSITIONS pairs as required and reset fault codes using DPS GDN B.U.D.S software. connector pin A Continuity Battery ground… -
Page 457
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-007 If the electrical system cannot sustain at least mmr2009-023-027_e 12 Vdc, check the following: 1. MIN function selected – Battery 7. Turn the handlebar momentarily against the – Battery connections steering frame stops to each side. -
Page 458
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) 5. With the vehicle engine running in PARK, turn – Steering column shim adjustment at half bush- DPS UNIT INSTALLA- the handlebar side to side, momentarily against ings as described in the TION each stop and observe the indications on the procedure detailed in this section. -
Page 459
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) 6. Remove the steering column pinch bolt and re- taining nut. Discard the retaining nut. vmr2010-003-023 TYPICAL — TIE ROD ENDS (HARDWARE REMOVED) vmr2010-003-017_a TYPICAL 9. Pull up on the steering column to partly disen- 1. -
Page 460
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2012-039-014_a DPS REMOVAL — RH SIDE 1. DPS vmr2012-039-016_a 2. RH DPS support bracket TYPICAL — LH DPS SUPPORT BRACKET 3. Remove these screws (2) 1. DPS unit 2. DPS support bracket NOTE: Discard the conical spring washers on the 3. -
Page 461
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) NOTE: Important: Install the retaining screws to the DPS support bracket loosely at this time. This is required to ensure proper DPS alignment at a later step when all steering and DPS fasteners are tightened to specified torque. -
Page 462
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2012-039-018_a vmr2010-003-031 A. XPS synthetic grease (P/N 293 550 010) here TYPICAL — STEERING COLUMN INDEXED TO DPS SHAFT SPLINES 5. Insert the steering column onto the DPS input shaft 7. Ensure the following are properly positioned on the lower steering shaft and lower steering 6. -
Page 463
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-023_a TYPICAL 1. Pitman arm 2. Tie rod ends inserted in pitman arm 3. Hardened steel washer on tie rod end 9. Install the lower half bushing retainer loosely using NEW fasteners. vmr2012-039-100_a DPS AND STEERING TORQUE SEQUENCE (1 OF 3) vmr2012-039-021_a… -
Page 464
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) NOTE: Ensure the locking tie is on the tube part of the steering column, not on the forged end. Bel- lows should cover end of ring flange on DPS unit but not cover the drainage hole at the bottom of the ring flange. -
Page 465: Pitman Arm
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2010-003-040 DPS SOFTWARE UPDATE 4. Once the correct DPS software file is installed, vmr2010-003-039_a TYPICAL — LH ILLUSTRATED go to the Faults page and clear the fault codes. 1. Pitman arm 2.
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Page 466
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) REQUIRED TOOLS REQUIRED TOOL POSITIONING ADAPTOR PITMAN ARM JIG (P/N 529 036 230) (P/N 529 036 225) 4. Insert the DPS input shaft in the Pitman arm jig receptacle with the Pitman arm facing up. vmr2012-039-024_a 1. -
Page 467
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) vmr2012-039-026_b vbs2011-015-008_a 1. Extractor nut 1. Jig upper bar 2. No space here 2. Positioning screw 3. Lock nut 8. Install the universal Pitman arm puller over the Pitman arm and the extractor thrust bearing. 10. -
Page 468
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) REQUIRED TOOL PITMAN ARM JIG (P/N 529 036 225) 2. Apply antizeize lubricant on DPS output shaft splines; completely cover all the splines with a light coat. PRODUCT vmr2012-039-030_a LOCTITE 767 1. -
Page 469
Section 07 CHASSIS Subsection 03 (DYNAMIC POWER STEERING (DPS)) 9. Carry out a steering alignment as described in this subsection. vmr2012-039-032_a vmr2012-039-033_a 1. Ensure proper contact here 7. Unscrew positioning screw and remove pusher adapter and pull out DPS unit. 8. -
Page 470: Front Suspension
Subsection XX (FRONT SUSPENSION) FRONT SUSPENSION SERVICE TOOLS Description Part Number Page 529 036 310 ……….. 7 BALL JOINT REMOVAL TOOL…………vmr2015-056…
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Page 471
Subsection XX (FRONT SUSPENSION) UPPER SUSPENSION ARMS AND COMPONENTS 61 ± 9 N•m (45 ± 7 lbf•ft) 3 ± 0.5 N•m (27 ± 4 lbf•in) 73 ± 7 N•m Suspension (54 ± 5 lbf•ft) Grease 90° from arm axis Suspension Grease 3 ±… -
Page 472
Subsection XX (FRONT SUSPENSION) LOWER SUSPENSION ARMS AND COMPONENTS 48 ± 6 N•m (35 ± 4 lbf•ft) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 3.0 ± 0.5 N•m (27 ± 4 lbf•in) Suspension Grease 3.0 ± 0.5 N•m (27 ± 4 lbf•in) Suspension Grease 90°… -
Page 473
Subsection XX (FRONT SUSPENSION) GENERAL Extend and compress the piston several times over its entire stroke. Check that it moves The procedure explained below is the same for smoothly and with uniform resistance with its the RH and LH sides unless otherwise noted. rod upward. -
Page 474
Subsection XX (FRONT SUSPENSION) PERIODIC Lubricate suspension arm. Refer to MAINTENANCE PROCEDURES subsection. Tighten ball joint nut to specification. TIGHTENING TORQUE Nut securing ball joint 48 N•m ± 6 N•m to knuckle (35 lbf•ft ± 4 lbf•ft) Perform steering alignment procedure. Refer to STEERING ALIGNMENT subsection. -
Page 475
Subsection XX (FRONT SUSPENSION) 9. Remove screws and nuts securing suspension arm to frame. vsi2015-143-006 6. Carefully move brake hose aside. 7. Using a plastic hammer, carefully hit on the vsi2015-143-008 knuckle side to separate ball joint from knuckle. 10. Remove suspension arm. NOTE: A ball joint remover can be used if the ball joint is jammed into knuckle. -
Page 476
Subsection XX (FRONT SUSPENSION) vmr2015-056-010 vsi2015-143-009_a LOWER BALL JOINT UPPER SUSPENSION ARM 1. Wear plates 2. Bushings 3. Sleeves vsi2015-143-010_a vmr2015-056-009_a UPPER BALL JOINT LOWER SUSPENSION ARM 1. Wear plates 2. Bushings 3. Install suspension arm on a press. 3. Sleeves NOTICE Pressing on the center or on the lip Suspension Arm Bushings Installation… -
Page 477
Subsection XX (FRONT SUSPENSION) 529036310 vmr2015-056-013 vmr2015-056-014_a CONTACT BETWEEN TOOL AND BALL JOINT ON THE OUTSIDE EDGE ONLY 4. Remove ball joint from suspension arm. NOTICE Make sure that suspension arm is properly supported on the press during ball joint removal. Ball Joint Installation The installation is the reverse of the removal pro- cedure. -
Page 478: Rear Suspension
Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) REAR SUSPENSION SERVICE TOOLS Description Part Number Page 529 036 184 ……… 681 SPRING COMPRESSOR …………… SERVICE PRODUCTS Description Part Number Page 293 550 033 ……… 684 SUSPENSION GREASE …………..vmr2015-057…
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Page 479
Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) TRAILING ARMS AND SWAY BAR 255 ± 10 N•m (188 ± 7 lbf•ft) 3.0 ± 0.5 N•m (27 ± 4 lbf•in) Suspension Grease 90° from arm axis Suspension Grease Suspension Grease 3.0 ± 0.5 N•m (27 ±… -
Page 480: Shock Absorbers
Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) SHOCK ABSORBERS 61 ± 9 N•m (45 ± 7 lbf•ft) = Components must be replaced when removed vmr2015-057-101 vmr2015-057…
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Page 481
Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) GENERAL Check the following conditions that will denote a defective shock: The procedure described below is the same for – A skip or a hang back when reversing stroke at the RH and LH sides, unless otherwise instructed. mid travel –… -
Page 482: Sway Bar
Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) vmr2015-057-018_a tmr2011-036-020 CAP OPENING AT 180° TYPICAL SWAY BAR 5. Install a NEW bushing as the reverse of re- moval. Sway Bar Removal 6. Install shock absorber on vehicle. 1. Safely lift and support the vehicle off the ground.
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Page 483
Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) PERIODIC MAINTE- Lubricate sway bar. Refer to NANCE PROCEDURES subsection. TRAILING ARM Trailing Arm Removal 1. Safely lift and support the vehicle off the ground. REAR DRIVE 2. Remove wheel hub, refer to sub- section. -
Page 484
Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) 4. Remove drive shaft bearing from trailing arm. Link Arm Inner Bushing Removal Remove both bushings and sleeve from trailing arm. vmr2015-057-008 6. Firmly hold trailing arm then remove: – Shock absorber lower screw –… -
Page 485
Section 08 CHASSIS Subsection 05 (REAR SUSPENSION) Trailing Arm Inspection Check trailing arms for: – Cracks – Bending. Check seals condition. Check inner race of each pivot bearing with your finger. Bearings should turn smoothly and quietly. Replace all damaged parts. Trailing Arm Assembly and Installation The installation is the reverse of the removal pro- vmr2015-057-017_a… -
Page 486
Subsection 07 (BRAKES) BRAKES SERVICE TOOLS Description Part Number Page 529 036 166 ……….. 9 ECM ADAPTER TOOL…………..SERVICE PRODUCTS Description Part Number Page 219 701 705 ……….. 12 XPS BRAKES AND PARTS CLEANER (USA) ……… 219 701 776 ……….. 12 XPS BRAKES AND PARTS CLEANER ……….. -
Page 487
Subsection 07 (BRAKES) FRONT CIRCUIT All Except CE Models 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) To rear circuit 5.5 ± 1.5 N•m (49 ± 13 lbf•in) 28.5 ± 1.5 N•m (21 ±… -
Page 488
Subsection 07 (BRAKES) REAR CIRCUIT All Except CE Models 0.7 ± 0.1 N•m (6 ± 1 lbf•in) 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) To front circuit 27.5 ± 2.5 N•m (20 ±… -
Page 489
Subsection 07 (BRAKES) FRONT CIRCUIT CE Models 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) To rear RH caliper 28.5 ± 1.5 N•m (21 ± 1 lbf•ft) To brake pedal cylinder 28.5 ± 1.5 N•m (21 ±… -
Page 490
Subsection 07 (BRAKES) REAR CIRCUIT CE Models To front 61 ± 9 N•m RH splitter (45 ± 7 lbf•ft) 33.5 ± 3.5 N•m (25 ± 3 lbf•ft) 0.7 ± 0.1 N•m (6 ± 1 lbf•in) To front RH splitter 27.5 ± 2.5 N•m (20 ±… -
Page 491
Subsection 07 (BRAKES) CALIPERS AND BRAKE LEVERS All Models REAR FRONT Brake caliper 8.5 ± 1.5 N•m synthetic grease (75 ± 13 lbf•in) Brake caliper synthetic grease 8.5 ± 1.5 N•m (75 ± 13 lbf•in) LH SIDE 1.3 ± 0.1 N•m (12 ±… -
Page 492
Subsection 07 (BRAKES) GENERAL WARNING Always check brake system operation after removing or servicing a brake component. NOTICE Avoid spilling brake fluid on plastic, rubber or painted parts. Protect these parts with a rag when servicing brake system. NOTICE Sealing washers must be discarded and replaced with new ones every time a Banjo bolt is unscrewed. -
Page 493: Brake Light Switches
Subsection 07 (BRAKES) PROCEDURES 6. If load reading is not in accordance with the specification: BRAKE LIGHT SWITCHES 6.1 Perform a brake system inspection and cleaning. Brake Light Switch Location 6.2 Bleed brake system. BRAKE SWITCH LOCATIONS PERIODIC MAINTENANCE NOTE: Refer to PROCEDURES subsection.
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Page 494
Subsection 07 (BRAKES) Brake Light Switch Located on Master Cylinder or Manifold 1. Disconnect brake light switch connector. 2. Drain brake line. 3. Remove brake light switch. NOTE: Use shop rags to catch any spilled brake fluid. 4. Install NEW sealing washers. 5. -
Page 495: Master Cylinder
Subsection 07 (BRAKES) vmr2015-058-007_a vmr2015-058-005_a TIGHTENING SEQUENCE 6. Remove brake pedal. Step 1: Tighten bolt Step 2: Hold bolt then tighten nut MASTER CYLINDER Master Cylinder Removal BRAKE PEDAL 1. Remove . See procedure in this subsection. 2. Remove master cylinder from support. vmr2015-058-006_a Brake Pedal Installation The installation is the reverse of the removal pro-…
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Page 496: Brake Pads
Subsection 07 (BRAKES) TIGHTENING TORQUE Brake hose screw 28.5 N•m ± 1.5 N•m (banjo fitting) (21 lbf•ft ± 1 lbf•ft) 8.5 N•m ± 1.5 N•m Bleeder (75 lbf•in ± 13 lbf•in) Install NEW sealing washers. PERIODIC Refill and bleed brake system, refer to MAINTENANCE PROCEDURES subsection.
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Page 497
Subsection 07 (BRAKES) vmr2012-042-009_a vmr2012-042-011_a 1. Pin retainer BRAKE PAD SPRING 3. Remove brake pad pin from caliper. 8. Ensure pad stopper is properly aligned with caliper support protrusion. vmr2012-042-010_a TYPICAL vmr2012-042-012_a 1. Brake pad pin 1. Pad stopper 2. Caliper support protrusion 4. -
Page 498: Brake Disc
Subsection 07 (BRAKES) vmr2012-042-013_a vmr2012-042-014_a 1. Brake disc screw 1. Caliper support 4. Replace brake disc. 13. Install caliper, refer to CALIPER INSTALLA- TION in this subsection. 5. Install NEW brake disc screws. 6. Tighten brake disc screws to specification. BRAKE DISC TIGHTENING TORQUE Brake Disc Inspection…
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Page 499
Subsection 08 (BODY (EXCEPT X MR)) BODY (EXCEPT X MR) SERVICE TOOLS Description Part Number Page 295 000 070 ……….. 9 OETIKER PLIERS…………….vmr2016-416… -
Page 500
Subsection 08 (BODY (EXCEPT X MR)) BODY PARTS NOMENCLATURE Front Body Module Rear Body Module vmr2016-416-001_a REAR BODY MODULE — FRONT BODY MODULE 7. Inner fender panel 1. Gauge support 8. Headlight trim 2. Console 9. Front bumper 3. Rear fender 10. -
Page 501
Subsection 08 (BODY (EXCEPT X MR)) BODY PARTS (REAR) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 2.5 ± 0.5 N•m 4.5 ± 0.5 N•m = Component must be replaced when removed. -
Page 502
Subsection 08 (BODY (EXCEPT X MR)) BODY PARTS (FRONT) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 1.6 ± 0.4 N•m (14 ± 4 lbf•in) 1.6 ± 0.4 N•m (14 ± 4 lbf•in) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 2.5 ±… -
Page 503
Subsection 08 (BODY (EXCEPT X MR)) BODY PARTS (CENTRAL) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 10 ± 2 N•m (89 ± 18 lbf•in) 2.5 ± 0.5 N•m (22 ± 4 lbf•in) 3.5 ± 0.5 N•m (31 ± 4 lbf•in) 3.5 ±… -
Page 504
Subsection 08 (BODY (EXCEPT X MR)) REAR BUMPER 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) 10 ± 2 N•m 48 ± 6 N•m (89 ± 18 lbf•in) (35 ± 4 lbf•ft) 24.5 ±… -
Page 505: Front Bumper
Subsection 08 (BODY (EXCEPT X MR)) FRONT BUMPER 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 10 ± 2 N•m (89 ± 18 lbf•in) 24.5 ±…
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Page 506: Skid Plates
Subsection 08 (BODY (EXCEPT X MR)) SKID PLATES 4.5 ± 0.5 N•m (40 ± 4 lbf•in) Renegade STD 4.5 ± 0.5 N•m (40 ± 4 lbf•in) 10 ± 2 N•m (89 ± 18 lbf•in) 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) 4.5 ±…
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Page 507
Subsection 08 (BODY (EXCEPT X MR)) PROCEDURES FRONT BODY MODULE Removing the Front Body Module PLASTIC RIVET CONSOLE 1. Remove . See procedure in this sub- Plastic rivets are used in the riveting of the vari- section. ous body parts. Plastic rivets can be reused many GAUGE SUPPORT LIGHTS, 2. -
Page 508
Subsection 08 (BODY (EXCEPT X MR)) vmr2012-047-005_a SOME PARTS REMOVED FOR CLARITY vmr2012-047-003_a 1. Bolt securing front body module to bumper FROM UNDERNEATH LH FRONT FENDER 1. Ignition switch connector 10. Remove front fuse box from its support. 8. Remove screws securing front fender to footrest panel (on both sides). -
Page 509
Subsection 08 (BODY (EXCEPT X MR)) 12. Remove front body module by pulling it for- wards. 13. Install front body module on an appropriate support. Installing the Front Body Module The installation is the reverse of the removal pro- cedure. However, pay attention to the following. Tighten front body module fasteners to specifica- tion. -
Page 510
Subsection 08 (BODY (EXCEPT X MR)) 8. Place a clean rag into fuel tank filler tube. 5. Remove console by pulling it rearwards. 9. Remove rear body module by pulling it rear- wards. 10. Install rear body module on an appropriate support. -
Page 511
Subsection 08 (BODY (EXCEPT X MR)) vmr2012-047-015_a RH SIDE PANEL SHOWN vmr2012-047-013_a 1. Lower tab SOME PARTS REMOVED FOR CLARITY 1. Plastic rivets (3 on LH side) 4. Remove side panel by pulling it outwards. Installing the Inner Fender Panel Installing the Side Panel The installation is the reverse of the removal pro- The installation is the reverse of the removal pro-… -
Page 512
Subsection 08 (BODY (EXCEPT X MR)) vmr2012-047-004_a TYPICAL 1. Screw securing front fender 4. Remove screw securing rear fender to footrest panel. vmr2012-047-009_a TYPICAL 1. Screw securing rear fender 5. Remove footrest panel from vehicle. Installing the Footrest Panel The installation is the reverse of the removal pro- cedure. -
Page 513
Subsection XX (FRAME) FRAME SERVICE TOOLS – OTHER SUPPLIER Description Part Number Page model 9600 ……….. 3 BLIND THREADED INSERT INSTALLER……..vmr2013-047… -
Page 514
Subsection XX (FRAME) 24.5 ± 3.5 N•m (18 ± 3 lbf•ft) Models Rear frame 24.5 ± 3.5 N•m extension (18 ± 3 lbf•ft) 24.5 ± 3.5 N•m 61 ± 9 N•m (18 ± 3 lbf•ft) (45 ± 7 lbf•ft) 61 ± 9 N•m (45 ±… -
Page 515
Subsection XX (FRAME) PROCEDURES Frame Replacement Blind threaded inserts are not installed on replace- FRAME ment frames. Make sure to order enough inserts when replacing frame. Refer to ELECTRONIC Frame Inspection PARTS CATALOG Check frame for bending, cracks, weld damages or any other damage. -
Page 516
Subsection 01 (RENEGADE SERIES) RENEGADE SERIES ENGINE ® ROTAX 549, 4-stroke, 2 cylinders (V-twin), liquid cooled ROTAX 850, 4-stroke, 2 cylinders Engine type (V-twin), liquid cooled ROTAX 1010HO, 4-stroke, 2 cylinders 1000R (V-twin), liquid cooled 4 valves/cylinder (mechanical adjustment), Valve train single over head camshaft (SOHC) with timing chain 84 mm (3.31 in) -
Page 517
Subsection 01 (RENEGADE SERIES) ENGINE 4.966 mm to 4.980 mm (.1955 in to .1961 in) Service limit 4.930 mm (.1941 in) Intake 5.472 mm to 5.486 mm (.2154 in to .216 in) 1000R Service limit 5.450 mm (.2146 in) Valve stem diameter 4.956 mm to 4.970 mm (.1951 in to .1957 in) Service limit… -
Page 518
Subsection 01 (RENEGADE SERIES) ENGINE Upper compression ring, rectangular Lower compression ring, tapered face Piston ring type Oil scraper ring 0.10 mm to 0.30 mm (.004 in to .012 in) Service limit 0.50 mm (.02 in) 0.20 mm to 0.35 mm (.008 in to .014 in) Rectangular Service limit 0.60 mm (.024 in) -
Page 519
Subsection 01 (RENEGADE SERIES) ENGINE 31.830 mm to 32.030 mm (1.2531 in to 1.261 in) Service limit 31.810 mm (1.2524 in) 32.890 mm to 33.090 mm Intake (1.2949 in to 1.3028 in) valve Service limit 32.870 mm (1.2941 in) 32.960 mm to 33.160 mm (1.2976 in to 1.3055 in) 1000R Service limit… -
Page 520
Subsection 01 (RENEGADE SERIES) ENGINE 20.010 mm to 20.020 mm (.7878 in to .7882 in) Service limit 20.060 mm (.7898 in) Connecting rod small end diameter 22.010 mm to 22.020 mm (.8665 in to .8669 in) 1000R Service limit 22.050 mm (.8681 in) 19.996 mm to 20.000 mm (.7872 in to .7874 in) Service limit… -
Page 521
Subsection 01 (RENEGADE SERIES) TRANSMISSION 6.078 mm to 6.100 mm (.239 in to .24 in) Centrifugal lever pivot bolt diameter 6.000 mm (.236 in) Service limit 6.035 mm to 6.078 mm (.2376 in to .2393 in) Centrifugal lever bore diameter Service limit 6.200 mm (.244 in) 6.113 mm to 6.171 mm (.241 in to .243 in) -
Page 522
Subsection 01 (RENEGADE SERIES) GEARBOX WITH EXTERNAL SWITCHES High 3.341 5.662 Reverse 5,451 Overall gear ratios High 2,886 5.662 5.451 Reverse Capacity 400 ml (13.5 U.S. oz) XPS SYNTHETIC GEAR OIL (75W 140) Gearbox oil Recommended (P/N 293 600 140) or a 75W140 API GL-5 synthetic gear oil 0.10 mm to 0.20 mm (.004 in to .008 in) Output shaft backlash… -
Page 523
Subsection 01 (RENEGADE SERIES) GEARBOX WITH GBPS Dual range (HI-LO) with park, neutral Type and reverse Angle drive 37/15 = 2.467 sub-transmission Intermediate 45/44 = 1.023 Gear ratios High 37/33 = 1.121 46/17 = 2.706 Reverse 34/12 = 2.833 High 2.829 Overall gear ratios 6.826… -
Page 524
Subsection 01 (RENEGADE SERIES) ELECTRICAL SYSTEM Without DPS 400 W @ 6000 RPM Magneto generator output With DPS 625 W @ 6000 RPM Stator resistance (20°C (68°F)) 0.15 to 0.30 Ignition system type IDI (Inductive Discharge Ignition) Ignition timing Not adjustable Quantity Make and type NGK DCPR8E… -
Page 525
Subsection 01 (RENEGADE SERIES) ELECTRICAL SYSTEM Accessory relay control Brake lights relay control Communication connector (DB4) Gauge Brake relay DPS control Ignition coils Fuel injectors Vehicle speed sensor Engine control module power (ECM) Fan relay control Position lights (Europe) Winch control 2W/4W control Fuses in fuse box 1 ECM (wake up signal) -
Page 526
Subsection 01 (RENEGADE SERIES) DRIVE SYSTEM Rear drive ratio 3.6:1 500 ml (17 U.S. oz) Capacity XPS SYNTHETIC GEAR OIL Front differential oil Type (75W 90) (P/N 293 600 043) or synthetic gear oil 75W90 API GL-5 Capacity 250 ml (8.45 U.S. oz) XPS SYNTHETIC GEAR OIL Rear final drive oil Type… -
Page 527
Subsection 01 (RENEGADE SERIES) REAR SUSPENSION STD 570 355.7 mm (14 in) Spring free length STD 850 and 1000R 311 mm (12.24 in) X xc 321.6 mm (12.66 in) STD 570 5 position cam Preload adjustment type All other models Variable positions BRAKES Front brake… -
Page 528
Subsection 01 (RENEGADE SERIES) Front 96.5 cm (38 in) Wheel track Rear 91.4 cm (36 in) Ground clearance 26.7 cm (11 in) WEIGHT AND LOADING CAPACITY 570 engine 279 kg (615 lb) Dry weight 850 engine 303 kg (668 lb) 1000R engine 314 kg (692 lb) Rear cargo area capacity… -
Page 529
Subsection 01 (WIRING DIAGRAM INFORMATION) WIRING DIAGRAM INFORMATION GENERAL WIRING DIAGRAM LOCATION WIRING DIA- Wiring diagrams are found in the GRAM BOOKLET WIRING DIAGRAM WITH COLORED LINES KNOWLEDGE CENTER The wiring diagram on the is in color. mmr2015-147-004_a WIRING DIAGRAM INDEX WIRING DIAGRAM CODES Connector Code The wiring diagrams use the following codes. -
Page 530
Subsection 01 (WIRING DIAGRAM INFORMATION) WIRE COLORS AND SIZES 2. If an electrical issue can not be found with the usual tests, locate the main harness splice that is involved in the faulty circuit and repair it as SPLICES REPAIR PROCEDURE per the 3. -
Page 531
Subsection 01 (WIRING DIAGRAM INFORMATION) CASE 2: Wire Broken from Splice 1. Locate splice. Refer to splices location dia- grams. 2. Remove wires from protector tube. 3. Locate the shrink tube protecting the defective splice. mmr2010-043-003 4.3 Remove the shrink tube with long nose pli- ers. -
Page 532
Subsection 01 (WIRING DIAGRAM INFORMATION) mbg2008-021-118_a 1. Broken wire 2. Splice 6. Strip wire insulation at the end of broken wire. 7. Strip wire insulation below the splice. mbg2008-021-119_a 1. Broken wire stripped 2. Splice wire stripped 8. Twist wire around stripped wire. mbg2008-021-120_a 1. -
Page 533
GENERAL SYSTEM OUTLANDER RENEGADE 2016. Key switch FUSE INJ/ IGN FUSE CLOCK/HAZARD FUSE FAN RELAY FUEL PMP RELAY HEADLAMP FUSE JT-RD/GN Main RELAY ECM FUSE FAN FUSE FUEL PMP FUSE RELAY/SPEEDO FUSE Winch /4WD FUSE ACC2 FUSE DC outlet FUSE BRAKE RELAY HEADLAMP RELAY RD/GN-14… -
Page 534
SPECIFIC HARNESS MAIN HARNESS SIDE CE HARNESS SIDE INTERCONNECT JT RD/BK FROM ACC RELAY/HOT AT KEY ON HIC2_m RD/BK GEARBOX POSITION SENSOR TPS PIN LAYOUT MG3-3 +12V VSS, COIL,INJ VT/BU-16 JT BE FLASHER HORN HAZARD HANDLEBAR SW RD/BK ECU2_OF_4 ECU_3_OF_4 HIC1_m BE/RD FUEL INJ…
This Service Manual covers all 2020 Renegade Series models:
- 2020 Can-Am RENEGADE 570
- 2020 Can-Am RENEGADE XXc 650
- 2020 Can-Am RENEGADE 850
- 2020 Can-Am RENEGADE XXc 850
- 2020 Can-Am RENEGADE XXc 1000
- 2020 Can-Am RENEGADE XMR 570
- 2020 Can-Am RENEGADE XMR 1000
This is a digital product — downloadable PDF file.
File data:
Format: PDF (not scanned, high definition factory OEM manual).
Keyword Searchable.
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Language: English.
Pages: 993 (Flat Rate included).
Size: 106 MB.
Contact me if you would like to receive a few pages to review the quality.
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