Atv 2023 Renegade Series - Shop Manual - Sm51y023 - en

Vehicle Service Manual
2023 Renegade Series
Version A
WARNING
Disregarding any of the safety precautions and instructions contained in this service manual
could cause injury including the possibility of death.
CALIFORNIA PROPOSITION 65 WARNING
WARNING
Operating, servicing and maintaining an off-road vehicle can expose you to chemicals including
engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of Cali-
fornia to cause cancer and birth defects or other reproductive harm. To minimize exposure,
avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a
well-ventilated area and wear gloves or wash your hands frequently when servicing your ve-
hicle. For more information go to
www.p65warnings.ca.gov/products/passenger-vehicle.
All rights reserved. No parts of this Manual may be reproduced in any form without the prior written per-
mission of Bombardier Recreational Products Inc.
©Bombardier Recreational Products Inc. (BRP) 2023.
™®Trademarks of BRP or its affiliates.

This document contains the trademarks of the following companies:
TABLE OF CONTENTS
01 S A F E T Y N O T I C E ....................................................................................................................... 1
I M P O R T A N T S A F E T Y P R E C A U T I O N S .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . . 2
02 I N T R O D U C T I O N ........................................................................................................................ 5
V E H I C L E I N F O R M A T I O N . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . . 6
VEHICLE IDENTIFICATION NUMBER (VIN).......................................................................... 6
VIN DECAL DESCRIPTION........................................................................................................ 6
ENGINE IDENTIFICATION NUMBER (EIN) ........................................................................... 6
COMPLIANCE LABEL ............................................................................................................. 6
REGULATION (EU) 2016/1628 APPLICABLE FOR NON-ROAD MOBILE MACHINERIES ...................... 6
E N G I N E E M I S S I O N S I N F O R M A T I O N . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . . 8
MANUFACTURER'S RESPONSIBILITY................................................................................. 8
DEALER RESPONSIBILITY.................................................................................................... 8
OWNER RESPONSIBILITY .................................................................................................... 8
EMISSION REGULATIONS .................................................................................................... 8
M A N U A L I N F O R M A T I O N . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . . 9
MANUAL PROCEDURES........................................................................................................ 9
MANUAL LAYOUT................................................................................................................... 9
TIGHTENING TORQUE ........................................................................................................ 12
F A S T E N E R I N F O R M A T I O N . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 1 4
SELF-LOCKING FASTENER PROCEDURE ........................................................................ 14
LOCTITE® THREADLOCKER APPLICATION PROCEDURE.............................................. 14
THREADLOCKER APPLICATION FOR UNCOVERED HOLES (BOLTS AND NUTS) ........................... 14
THREADLOCKER APPLICATION FOR BLIND HOLES .................................................................. 14
THREADLOCKER APPLICATION FOR STUD INSTALLATION IN BLIND HOLES ............................... 15
THREADLOCKER APPLICATION FOR PRE-ASSEMBLED PARTS ................................................. 15
THREADLOCKER APPLICATION FOR AN ADJUSTMENT SCREW................................................. 15
THREADLOCKER APPLICATION FOR MOUNTING ON A SHAFT................................................... 15
THREADLOCKER APPLICATION FOR CASE-IN COMPONENTS (METALLIC GASKETS) ................... 16
APPLICATION FOR STRIPPED THREAD REPAIR............................................................. 16
GASKET COMPOUND APPLICATION................................................................................. 17
03 M A I N T E N A N C E ....................................................................................................................... 1 9
P E R I O D I C M A I N T E N A N C E S C H E D U L E . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 2 0
GENERAL .............................................................................................................................. 20
EPA REGULATION - CANADIAN AND USA VEHICLES ................................................................. 20
SEVERE DUSTY CONDITIONS ................................................................................................ 21
MAINTENANCE SCHEDULE LEGEND....................................................................................... 21
MAINTENANCE SCHEDULE (EXCEPT 6X6) ............................................................................... 21
P E R I O D I C M A I N T E N A N C E P R O C E D U R E S . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 2 9
GENERAL .............................................................................................................................. 29
PROCEDURES...................................................................................................................... 29
AIR INTAKE SYSTEM ............................................................................................................. 29
EXHAUST SYSTEM................................................................................................................ 31
COOLING SYSTEM ................................................................................................................ 33
FUEL SYSTEM ...................................................................................................................... 36
ELECTRICAL SYSTEM ........................................................................................................... 39
DRIVE SYSTEM..................................................................................................................... 39
STEERING SYSTEM .............................................................................................................. 41
SUSPENSION ....................................................................................................................... 41
BRAKES............................................................................................................................... 42
BODY .................................................................................................................................. 45
III
TABLE OF CONTENTS
FRAME ................................................................................................................................ 45
S T O R A G E P R O C E D U R E .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 4 6
GENERAL .............................................................................................................................. 46
PROCEDURES...................................................................................................................... 46
FUEL SYSTEM ...................................................................................................................... 46
ENGINE ............................................................................................................................... 46
ELECTRICAL SYSTEM ........................................................................................................... 47
DRIVE SYSTEM..................................................................................................................... 47
CHASSIS.............................................................................................................................. 47
P R E S E A S O N P R E P A R A T I O N . . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 4 9
S P E C I A L P R O C E D U R E S .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 5 0
GENERAL .............................................................................................................................. 50
WHAT TO DO IF WATER IS IN THE CVT .................................................................................... 50
WHAT TO DO IF WATER IS IN THE AIR FILTER HOUSING ........................................................... 50
WHAT TO DO IF VEHICLE IS TURNED OVER............................................................................. 50
WHAT TO DO IF VEHICLE IS IMMERSED IN WATER ................................................................... 51
0 4 E N G I N E ..................................................................................................................................... 5 3
E N G I N E R E M O V A L A N D I N S T A L L A T I O N . . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 5 4
PROCEDURES...................................................................................................................... 57
ENGINE REMOVAL (TWIN CYLINDERS).................................................................................... 57
ENGINE LIFTING (TWIN CYLINDERS)....................................................................................... 60
ENGINE INSTALLATION ......................................................................................................... 62
ENGINE MOUNT REPLACEMENT ............................................................................................ 62
A I R I N T A K E S Y S T E M . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 6 3
GENERAL .............................................................................................................................. 64
PROCEDURES...................................................................................................................... 64
AIR FILTER........................................................................................................................... 64
AIR FILTER HOUSING ............................................................................................................ 64
E X H A U S T S Y S T E M .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1
GENERAL .............................................................................................................................. 74
PROCEDURES...................................................................................................................... 74
HEATED OXYGEN SENSOR (HO2S)......................................................................................... 74
SPARK ARRESTER................................................................................................................ 76
MUFFLER............................................................................................................................. 76
HEAT SHIELD ....................................................................................................................... 76
Y-PIPE ................................................................................................................................. 78
HEAD PIPE (FRONT CYLINDER) .............................................................................................. 78
C O O L I N G S Y S T E M - V E H I C L E C O M P O N E N T S . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 8 0
GENERAL .............................................................................................................................. 83
PROCEDURES...................................................................................................................... 83
THERMOSTAT (ON CYLINDER HEAD) ...................................................................................... 83
THERMOSTAT (EXTERNAL OF ENGINE ................................................................................... 83
RADIATOR ........................................................................................................................... 83
RADIATOR COOLING FAN ...................................................................................................... 84
RADIATOR COOLING FAN RELAY (RY1)................................................................................... 86
S H I F T E R .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 8 8
PROCEDURES...................................................................................................................... 89
HANDLE............................................................................................................................... 89
SHIFT LEVER........................................................................................................................ 89
SHIFT ROD........................................................................................................................... 90
SHIFT PLATE ........................................................................................................................ 91
0 5 E L E C T R O N I C M A N A G E M E N T S Y S T E M S .......................................................................... 9 5
IV
TABLE OF CONTENTS
E N G I N E M A N A G E M E N T S Y S T E M ( E M S ) . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 9 6
GENERAL .............................................................................................................................. 98
SYSTEM DESCRIPTION ......................................................................................................... 98
C O N T R O L L E R A R E A N E T W O R K ( C A N ) .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 0 0
GENERAL ............................................................................................................................ 100
SYSTEM DESCRIPTION ....................................................................................................... 100
C O M M U N I C A T I O N T O O L S .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 0 1
GENERAL ............................................................................................................................ 101
REQUIRED TOOLS .............................................................................................................. 101
TROUBLESHOOTING......................................................................................................... 101
DIAGNOSTIC TIPS............................................................................................................... 101
PROCEDURES.................................................................................................................... 102
MULTI-PURPOSE INTERFACE CARD (MPI-2 OR MPI-3) ............................................................ 102
D I A G N O S T I C A N D F A U L T C O D E S . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 0 3
GENERAL ............................................................................................................................ 103
MONITORING SYSTEM ........................................................................................................ 103
FAULT CODES .................................................................................................................... 104
FAULT CODE DIAGNOSTIC .................................................................................................. 105
SPECIFIC FAULTS............................................................................................................... 108
06 F U E L S Y S T E M ....................................................................................................................... 1 0 9
I N T E L L I G E N T T H R O T T L E C O N T R O L ( I T C ) . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 1 0
GENERAL ............................................................................................................................ 110
PROCEDURES.................................................................................................................... 110
THROTTLE ACCELERATOR SENSOR (TAS)............................................................................ 110
DRIVE MODE SWITCH (IF EQUIPPED).................................................................................... 112
2WD/4WD/6WD SWITCHES................................................................................................... 113
ELECTRONIC THROTTLE ACTUATOR (ETA) ........................................................................... 114
F U E L T A N K A N D F U E L P U M P . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 1 5
GENERAL ............................................................................................................................ 117
INSPECTION ....................................................................................................................... 118
FUEL SYSTEM PRESSURE TEST .......................................................................................... 118
FUEL TANK LEAK TEST........................................................................................................ 119
TEST CONCLUSION ............................................................................................................ 119
FUEL SYSTEM DIAGNOSTIC FLOW CHART ............................................................................ 120
PROCEDURES.................................................................................................................... 121
FUEL HOSE AND OETIKER CLAMPS...................................................................................... 121
FUEL TANK ........................................................................................................................ 121
FUEL PUMP........................................................................................................................ 126
FUEL PUMP PRE-FILTER (STRAINER).................................................................................... 129
FUEL LEVEL SENDER.......................................................................................................... 129
FUEL TANK VENT VALVES ................................................................................................... 131
07 E L E C T R I C A L S Y S T E M ......................................................................................................... 1 3 3
P O W E R D I S T R I B U T I O N A N D G R O U N D S . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 3 4
GENERAL ............................................................................................................................ 134
OVERVIEW......................................................................................................................... 134
FUSES............................................................................................................................... 134
RELAYS ............................................................................................................................. 135
GROUNDS ......................................................................................................................... 135
PROCEDURES.................................................................................................................... 136
V
TABLE OF CONTENTS
TESTING A FUSE LINK ......................................................................................................... 136

REPLACING A FUSE LINK..................................................................................................... 136
W I R I N G H A R N E S S A N D C O N N E C T O R S .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 3 7
GENERAL ............................................................................................................................ 137
MAIN HARNESS .................................................................................................................. 137
MAIN HARNESS SPLICE LOCATION ...................................................................................... 139
CONNECTOR ABBREVIATION DESCRIPTION ......................................................................... 142
PROCEDURES.................................................................................................................... 142
DEUTSCH CONNECTORS .................................................................................................... 142
PACKARD CONNECTORS .................................................................................................... 144
PACKARD CONNECTOR (MULTIFUNCTION GAUGE) ............................................................... 144
MOLEX CONNECTOR .......................................................................................................... 145
FURUKAWA CONNECTOR.................................................................................................... 148
BATTERY AND STARTER CABLE TERMINALS......................................................................... 148
SPLICES REPAIR PROCEDURE ............................................................................................ 149
C H A R G I N G S Y S T E M . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 5 2
GENERAL ............................................................................................................................ 152
INSPECTION ....................................................................................................................... 152
CHARGING SYSTEM OUTPUT .............................................................................................. 152
TROUBLESHOOTING........................................................................................................... 153
PROCEDURES.................................................................................................................... 153
LOAD TESTING THE BATTERY.............................................................................................. 153
LOAD TESTING THE CHARGING SYSTEM .............................................................................. 153
VOLTAGE REGULATOR (RD) ................................................................................................ 154
BATTERY ........................................................................................................................... 156
I G N I T I O N S Y S T E M . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 5 7
GENERAL ............................................................................................................................ 157
DIAGNOSTIC GUIDELINES ................................................................................................... 157
PROCEDURES.................................................................................................................... 158
IGNITION SWITCH ............................................................................................................... 158
EMERGENCY ENGINE STOP SWITCH.................................................................................... 158
IGNITION COIL.................................................................................................................... 159
SPARK PLUG...................................................................................................................... 161
S T A R T I N G S Y S T E M .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 6 2
GENERAL ............................................................................................................................ 162
STARTING SYSTEM OPERATION .......................................................................................... 162
ENGINE WILL NOT TURN ..................................................................................................... 162
ENGINE TURNS .................................................................................................................. 162
PROCEDURES.................................................................................................................... 162
STARTING SYSTEM TESTS .................................................................................................. 162
R A D I O F R E Q U E N C Y D I G I T A L L Y E N C O D E D S E C U R I T Y S Y S T E M ( R F D . E . S . S . ) . .. . . .. . .. . . .. . .. . . .. . . .. . 1 6 8
GENERAL ............................................................................................................................ 168
RF D.E.S.S. KEY.................................................................................................................. 168
RF D.E.S.S. MODULE / CUT-OFF SWITCH / D.E.S.S. POST ........................................................ 169
PROCEDURES.................................................................................................................... 169
RF D.E.S.S. KEY.................................................................................................................. 169
RF D.E.S.S. / ENGINE CUT-OFF OPERATION .......................................................................... 170
L I G H T S . . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 1 7 2
GENERAL ............................................................................................................................ 172
VI
TABLE OF CONTENTS
DIAGNOSTIC TIPS............................................................................................................... 172
PROCEDURES.................................................................................................................... 173
ACTIVATING THE ELECTRICAL SYSTEM USING AN IGNITION SWITCH ...................................... 173
ACTIVATING THE ELECTRICAL SYSTEM USING A RF D.E.S.S. KEY ........................................... 173
HEADLIGHTS...................................................................................................................... 174
HEADLAMP BEAM AIMING (ALL MODELS) .............................................................................. 174
TAILLIGHTS/BRAKE LIGHTS ................................................................................................. 175
TRAILER PLUG ................................................................................................................... 175
C O M P A C T D I G I T A L G A U G E . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 7 7
GENERAL ............................................................................................................................ 177
COMPACT DIGITAL MULTIFUNCTION GAUGE......................................................................... 177
DIAGNOSTIC TIPS............................................................................................................... 180
PROCEDURES.................................................................................................................... 181
MULTIFUNCTION GAUGE..................................................................................................... 181
4 . 5 " D I G I T A L D I S P L A Y G A U G E .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 8 5
GENERAL ............................................................................................................................ 185
INDICATOR LAMPS DESCRIPTION ........................................................................................ 185
DIAGNOSTIC TIPS............................................................................................................... 186
MULTIFUNCTION GAUGE TROUBLESHOOTING...................................................................... 186
PROCEDURES.................................................................................................................... 187
7 . 6 " D I G I T A L D I S P L A Y G A U G E .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 8 9
GENERAL ............................................................................................................................ 189
INDICATOR LAMPS DESCRIPTION ........................................................................................ 189
DIAGNOSTIC TIPS............................................................................................................... 190
MULTIFUNCTION GAUGE TROUBLESHOOTING...................................................................... 190
PROCEDURES.................................................................................................................... 190
CLUSTER SWITCH .............................................................................................................. 192
A C C E S S O R I E S .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 1 9 4
GENERAL ............................................................................................................................ 194
DIAGNOSTIC TIPS............................................................................................................... 194
PROCEDURES.................................................................................................................... 194
ACTIVATING THE ELECTRICAL SYSTEM................................................................................ 194
12 VOLT POWER OUTLET .................................................................................................... 194
HEATED VISOR CONNECTORS ............................................................................................ 194
HEATED THROTTLE LEVER ................................................................................................. 196
HEATED HANDLEBAR GRIPS ............................................................................................... 197
HEATED PASSENGER GRIPS ............................................................................................... 198
WINCH (IF EQUIPPED) ......................................................................................................... 199
08 D R I V E S Y S T E M ..................................................................................................................... 2 0 3
W H E E L S A N D T I R E S . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 2 0 4
PROCEDURES.................................................................................................................... 204
TIRES ................................................................................................................................ 204
WHEELS ............................................................................................................................ 206
F R O N T D R I V E . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 2 0 8
GENERAL ............................................................................................................................ 212
VII
TABLE OF CONTENTS
VISCO-LOK SYSTEM DESCRIPTION ...................................................................................... 212

PROCEDURES.................................................................................................................... 212
WHEEL HUB ....................................................................................................................... 212
FRONT DRIVE SHAFT .......................................................................................................... 213
DRIVE SHAFT BELLOWS...................................................................................................... 213
FRONT DIFFERENTIAL ........................................................................................................ 214
FRONT PROPELLER SHAFT ................................................................................................. 220
PROPELLER SHAFT U-JOINTS.............................................................................................. 221
F R O N T D R I V E - M O D E L S W I T H A B S . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 2 2 3
GENERAL ............................................................................................................................ 226
PROCEDURES.................................................................................................................... 226
WHEEL HUB ....................................................................................................................... 226
F R O N T D R I V E W I T H V I S C O - 4 L O K . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 2 3 6
GENERAL ............................................................................................................................ 239
PROCEDURES.................................................................................................................... 239
WHEEL HUB ....................................................................................................................... 239
DRIVE SHAFT BELLOW........................................................................................................ 240
FRONT DIFFERENTIAL ACTUATOR ....................................................................................... 241
R E A R D R I V E . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 2 4 9
PROCEDURES.................................................................................................................... 252
WHEEL HUB ....................................................................................................................... 252
DRIVE SHAFT ..................................................................................................................... 253
PROPELLER SHAFT ............................................................................................................ 254
REAR FINAL DRIVE ............................................................................................................. 257
0 9 C H A S S I S ................................................................................................................................. 2 6 5
S T E E R I N G S Y S T E M .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 2 6 6
GENERAL ............................................................................................................................ 270
ALIGNING THE WHEELS ................................................................................................... 270
PROCEDURES.................................................................................................................... 271
HANDLEBAR GRIP .............................................................................................................. 271
HANDLEBAR COVER ........................................................................................................... 272
HANDLEBAR ...................................................................................................................... 272
STEERING CONNECTORS ................................................................................................... 273
MULTIFUNCTION SWITCH.................................................................................................... 273
INTELLIGENT THROTTLE CONTROL (ITC) HOUSING ............................................................... 278
BRAKE LEVER .................................................................................................................... 278
STEERING COLUMN BEARING ............................................................................................. 278
STEERING COLUMN............................................................................................................ 278
TIE-ROD ............................................................................................................................ 281
KNUCKLE........................................................................................................................... 282
WHEEL BEARINGS .............................................................................................................. 282
PITMAN ARM (WITHOUT DPS) .............................................................................................. 283
VIII
TABLE OF CONTENTS
PITMAN ARM (WITH DPS)..................................................................................................... 284

D Y N A M I C P O W E R S T E E R I N G ( D P S ) .. .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 2 8 6
GENERAL ............................................................................................................................ 288
SYSTEM DESCRIPTION (FEATURES) .................................................................................... 288
DPS SYSTEM DESCRIPTION (COMPONENTS) ........................................................................ 288
RESETTING THE TORQUE OFFSET ................................................................................ 289
PROCEDURES.................................................................................................................... 290
DPS UNIT ........................................................................................................................... 290
S U S P E N S I O N A D J U S T M E N T S .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 2 9 9
GENERAL ............................................................................................................................ 299
SPRING PRELOAD ............................................................................................................. 299
SHOCK DAMPING ADJUSTMENTS (IF EQUIPPED) ........................................................ 299
ADJUSTING THE COMPRESSION DAMPING (WITH SINGLE ADJUSTMENT) ................................ 299
ADJUSTING THE COMPRESSION DAMPING (WITH DUAL ADJUSTMENTS) ................................. 300
REBOUND DAMPING ........................................................................................................... 301
F R O N T S U S P E N S I O N .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 3 0 2
GENERAL ............................................................................................................................ 303
PROCEDURES.................................................................................................................... 303
SHOCK ABSORBER............................................................................................................. 303
SHOCK ABSORBER BUSHINGS ............................................................................................ 303
SPRINGS ........................................................................................................................... 303
LOWER SUSPENSION ARM .................................................................................................. 303
UPPER SUSPENSION ARM................................................................................................... 304
SUSPENSION ARM BUSHINGS ............................................................................................. 305
BALL JOINTS ...................................................................................................................... 306
R E A R S U S P E N S I O N . . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 3 0 8
GENERAL ............................................................................................................................ 312
PROCEDURES.................................................................................................................... 312
SHOCK ABSORBERS........................................................................................................... 312
SHOCK ABSORBER BUSHINGS ............................................................................................ 312
SPRINGS ........................................................................................................................... 313
STABILIZER BAR................................................................................................................. 313
TRAILING ARM.................................................................................................................... 314
B R A K E S .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 3 1 7
GENERAL ............................................................................................................................ 321
INSPECTION ....................................................................................................................... 321
BRAKE SYSTEM PRESSURE VALIDATION.............................................................................. 321
PROCEDURES.................................................................................................................... 322
BRAKE LIGHT SWITCH ........................................................................................................ 322
BRAKE PEDAL .................................................................................................................... 322
MASTER CYLINDER ............................................................................................................ 323
CALIPER ............................................................................................................................ 324
BRAKE PADS...................................................................................................................... 324
BRAKE DISC....................................................................................................................... 326
B R A K E S ( A B S ) . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . 3 2 7
GENERAL ............................................................................................................................ 330
FAULT CODES .................................................................................................................... 330
SYSTEM COMPONENTS DESCRIPTION ................................................................................. 330
MAINTENANCE ................................................................................................................... 332
BLEEDING THE BRAKE FLUID............................................................................................... 332
INSPECTION ....................................................................................................................... 332
VERIFYING THE COMPRESSION FORCE ............................................................................... 332
TROUBLESHOOTING TIPS ................................................................................................... 333
IX
TABLE OF CONTENTS
PROCEDURES.................................................................................................................... 333
BRAKE LIGHT SWITCHES .................................................................................................... 333
BRAKE PEDAL .................................................................................................................... 334
MASTER CYLINDER ............................................................................................................ 335
CALIPER ............................................................................................................................ 335
BRAKE PADS...................................................................................................................... 336
BRAKE DISC....................................................................................................................... 337
WHEEL SPEED SENSOR (WSS) ............................................................................................ 338
ABS MODULE ..................................................................................................................... 339
BRAKE SYSTEM PRESSURE SENSOR ................................................................................... 343
B O D Y . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 3 4 5
PROCEDURES.................................................................................................................... 357
PLASTIC RIVET................................................................................................................... 357
DECALS............................................................................................................................. 357
FRONT BODY MODULE........................................................................................................ 357
REAR BODY MODULE.......................................................................................................... 360
CONSOLE .......................................................................................................................... 362
GAUGE SUPPORT............................................................................................................... 363
INNER FENDER PANELS...................................................................................................... 363
SIDE PANELS ..................................................................................................................... 363
PANEL EXTENSIONS ........................................................................................................... 364
REAR TOP PANEL ............................................................................................................... 364
FOOTREST PANELS ............................................................................................................ 365
RACK (FRONT AND REAR) ................................................................................................... 368
REAR STORAGE COMPARTMENT......................................................................................... 369
REAR FENDERS ................................................................................................................. 372
F R A M E . . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 3 7 3
PROCEDURES.................................................................................................................... 373
HUCK RIVET REMOVAL ....................................................................................................... 373
FRAME .............................................................................................................................. 373
1 0 T E C H N I C A L S P E C I F I C A T I O N S .......................................................................................... 3 7 5
R E N E G A D E . . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 3 7 6
R E N E G A D E - T C A T E G O R Y . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 3 8 4
1 1 W I R I N G D I A G R A M ................................................................................................................ 3 9 1
W I R I N G D I A G R A M I N F O R M A T I O N . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . 3 9 2
GENERAL ............................................................................................................................ 392
WIRING DIAGRAM LOCATION............................................................................................... 392
DIAGNOSTIC TIPS............................................................................................................... 393
SIMPLIFYING ELECTRICAL SYSTEM TESTS ........................................................................... 393
X
SERVICE TOOLS INDEX
Backlash measurement tool Differential nut socket 65mm Fuel hose adapter
(P/N 529 035 665) (P/N 529036302) (P/N 529 036 396)
Page:118
Page:215, 229, 242

Fuel pump nut tool
Page:260 (P/N 529 036 427)
Backlash measurement tool
(P/N 529035665)
ECM adapter tool
(P/N 529 036 166)
Page:127
Page:257
Page:75, 160 Pressure gauge
(P/N 529 036 395)
Bellows clamp pliers
(P/N 529 036 120)
ECM terminal remover 2.25
(P/N 529 036 175)
Page:213, 227, 240, 253

Page:118
Page:147
CV joint extractor
(P/N 529 036 005) Small hose pincher
ECM terminal remover 3.36 (P/N 295 000 076)
(P/N 529 036 174)
Page:214, 227, 241, 253

Page:131
D.E.S.S. Post Remover Page:147
(P/N 529035943) Spanner socket
(P/N 529 035 649)
Engine lifting tool
(P/N 529036022)
Page:218, 231
Page:60
Page:170–171
Spring compressor
(P/N 529036184)
Differential nut socket 65mm Fluke 115 multimeter
(P/N 529 036 302) (P/N 529 035 868)
Page:313
Steering alignment tool

Page:74–75, 182 (P/N 529036059)
Page:218, 245 Page:270
1
SERVICE TOOLS INDEX
Test cap
(P/N 529 035 991)
Page:35
Vacuum/pressure pump
(P/N 529 021 800)
Page:35, 119, 131
2
SERVICE PRODUCTS INDEX
Brake Caliper Synthetic Grease XPS Synthetic suspension

Page:44 grease
Page:316
BRP heavy duty cleaner
Page:47
Cleaner and degreaser PRO C1

Page:47
Clutch and pulley flange cleaner

PRO S1
Page:271
Dielectric grease
Page:297
Loctite 271 (red)

Page:220, 246, 262–263, 316
Loctite 406 (glue)

Page:271
Loctite 648 (green)

Page:221, 233–234, 248, 255
Loctite 767 (anti-seize lubricant)

Page:75, 206, 280, 284–285,
295
Lubricant and anti-corrosive

Page:48
Oil storage
Page:46
XPS ATV wash

Page:47
XPS Brakes and Parts cleaner

Page:325, 336
XPS Fuel stabilizer

Page:46
XPS Synthetic grease

Page:213, 219–221, 227, 232–
234, 240, 246–247, 252, 255,
280, 285, 323, 335
3
01
SAFETY NOTICE
1
Safety Notice
Important Safety Precautions
01 Safety Notice
This manual has been prepared as a guide to cor-
rectly service and repair the Can-Am® ATV.
NOTICE
Indicates an instruction which, if not followed,
This edition was primarily published to be used by could result in severe damage to vehicle
mechanics and technicians who are already famili- components or other property.
ar with all service procedures relating to BRP
products. Technicians should attend training N O T E : Indicates supplementary information re-
courses given by BRPTI. quired to fully complete an instruction.
Please note that the instructions in this manual will
apply only if proper hand tools and special service Although the mere reading of such information
tools are used. does not eliminate the hazard, your understanding
of the information will promote its correct use.
The contents of this manual depicts parts and pro-
cedures applicable to the particular product at the Unless otherwise noted, the engine must be
time of writing. Service and warranty bulletins may stopped and the key must be removed prior to per-
be published to update the content of this manual. forming any services.
Dealer modifications that were carried out after Torque wrench tightening specifications must be
manufacturing of the product, whether or not au- strictly adhered to. Use the torque values and
thorized by BRP, are not included. service products as in the exploded views or in the
In addition, the sole purpose of the illustrations procedures when noted.
throughout the manual, is to assist identification of Locking devices when removed must be replaced
the general configuration of the parts. They are (e. g.: locking tabs, elastic stop nuts, self-locking
not to be interpreted as technical drawings or ex- fasteners, cotter pins, etc.).
act replicas of the parts.
Hoses, cables and locking ties removed during a
The use of BRP parts is most strongly recom- procedure must be reinstalled as per factory
mended when considering replacement of any standards.
component. Dealer and/or distributor assistance
should be sought in case of doubt. When ordering parts always refer to the specific
model Parts Catalogs.
The engines and the corresponding components
identified in this document should not be utilized We strongly recommend that any services be car-
on product (s) other than those mentioned in this ried out and/or verified by a highly skilled profes-
document. sional mechanic.
It is understood that certain modifications may ren- It is understood that this manual may be translated
der use of the vehicle illegal under existing federal, into another language. In the event of any discrep-
provincial and state regulations. ancy, the English version shall prevail.
This manual emphasizes particular information BRP disclaims liability for all damages and/or inju-
denoted by the following wording and symbols: ries resulting from the improper use of the con-
tents of this publication.
WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or Important Safety
death.
Precautions
CAUTION We do not provide warnings about many basic
Indicates a hazardous situation which, if not shop safety practices (e.g.: Use Grinding Wheel –
avoided, could result in minor or moderate wear safety glasses). If you have not received
injury. shop safety training or do not feel confident about
your knowledge of safe servicing practices, we
2
Safety Notice
Important Safety Precautions
recommend that you do not attempt to perform the

procedures described in BRP shop manuals. 01
You should have a clear understanding of all basic
shop safety practices. You should be wearing the
appropriate clothing, using appropriate safety
equipment and taking all necessary safety precau-
tions. Please be especially careful of the following:
– Read and understand all instructions before
you begin a procedure or repair.
– Ensure you have the proper tools, any neces-
sary replacement parts and the skills to per-
form the tasks safely and completely.
– Protect your eyes by using approved and prop-
erly fitted safety glasses.
– Use other protective wear when necessary, for
example safety shoes and gloves.
– Unless the service procedure requires that the
engine remain running, make sure the engine
is off b e f o r e beginning service.
– Be sure there is adequate ventilation whenever
you run the engine, to avoid the risk of Carbon
Monoxide poisoning.
– To avoid injury from moving parts, make sure
your hands, fingers and clothing are out of the
way when the engine is running.
– Gasoline vapors and hydrogen gases from bat-
teries are explosive. Keep all cigarettes, sparks
and flames away from the battery, fuel-related
components and other enclosed
compartments.
– Never use gasoline to clean parts, always use
an approved nonflammable solvent.
– Never drain or store gasoline in an open
container.
WARNING
The foregoing list represents general safety
practices. For details on workplace health
and safety requirements in your area, consult
your local workplace health and safety
agency or association.
We have provided you with some of the most im-

portant general service safety precautions, above.
We cannot, however, warn you of every conceiv-
able hazard that can arise in performing the serv-
ice and repair procedures depicted in BRP
manuals. Only you can decide whether or not you
should perform a given task.
3
Notes
Notes Notes
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
4
02
INTRODUCTION
5
Introduction
Vehicle Information
02 Introduction
The information and component/system descrip-
tions contained in this manual are correct at time
of publication. BRP however, maintains a policy of
continuous improvement of its products without
imposing upon itself any obligation to install them
on products previously manufactured.
Due to late changes, it may have some differences
between the manufactured product and the de- TYPICAL — VEHICL E SERIAL NUMBER DECAL ON RH SIDE
scription and/or specifications in this document. OF FRAME
1. VIN (Vehicle Identification Number)
2. Vehicle manufacturing date and model number
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod- Engine Identification Number (EIN)
els or equipment without incurring obligation.
Vehicle Information
Vehicle Identification Number (VIN)
1
1. Engine Identification Number (EIN)
Compliance Label
Regulation (EU) 2016/1628 applicable for
2 3 Non-Road Mobile Machineries
VIN LOCATIONS Vehicles who comply to Regulation (EU) 2016/
1. VIN decal under seat 1628 (NRMM) are identified on the engine valve
2. VIN decal on lower frame member, RH side cover.
3. VIN stamped on lower frame member, RH side
VIN Decal Description

MANUFACTURED BY :
FABRIQUÉ PAR:
MFD. DATE FAB : 12/2003 MODEL: 1234 2
VIN / NIV: 2BPS1234X2V000123 1
3
MADE IN/FABRIQUÉ AU: TYPE: ATV / VTT
XXXXX
TYPICAL — VEHICLE SERIAL NUMBER DECAL UNDER SEAT

1. VIN (Vehicle Identification Number)
2. Vehicle manufacturing date and model number
3. VIN bar code
6
Introduction
Vehicle Information
02
TYPICAL
Rotax
# M#######
Production date: MM-YYYY
Family type: ######
7469 e13 AT1/P V-####
TYPICAL NRMM IDENTIFICATION
NOTE: Any tampering with the engine or its

components will void the EU type-approval of the
vehicle.
7
Introduction
Engine Emissions Information
Engine Emissions When servicing any vehicle; adjustments must be

kept within published factory specifications. Re-
Information placement or repair of any emission related com-
ponent must be executed in a manner that
Manufacturer's Responsibility maintains emission levels within the applicable
Manufacturers of engines must determine the ex- certification standards. Nobody is allowed to modi-
haust emission levels for each engine horsepower fy the engine in any manner that would alter the
family and certify these engines with the United horsepower or allow emission levels to exceed
States of America Environmental Protection their predetermined factory specifications. Excep-
Agency (EPA). An emissions control information tions include manufacturer’s prescribed changes.
label, showing emission levels and engine specifi- The owner/operator is required to have engine
cations, must be placed on each vehicle at the maintenance performed to maintain emission lev-
time of manufacture. els within the prescribed certification standards.
The owner/operator is allowed and should not al-
Dealer Responsibility low anyone else to modify the engine in any man-
When servicing any vehicle that carry an emis- ner that would alter the horsepower or allow
sions control information label, adjustments must emissions levels to exceed their predetermined
be kept within published factory specifications. factory specifications.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sion levels to exceed their predetermined factory
specifications.
Exceptions include manufacturer's prescribed
changes.
Owner Responsibility
The owner/operator is required to have engine
maintenance performed to maintain emission lev-
els within prescribed certification standards.
The owner/operator is not to, and should not allow
anyone else to modify the engine in any manner
that would alter the horsepower or allow emissions
levels to exceed their predetermined factory
specifications.
Emission Regulations
The vehicle you are servicing may have been cer-
tified to applicable emission regulations in your
country or state. Not as an exhaustive list; this
may include standards for engine exhaust emis-
sions, crankcase emissions, permeation emis-
sions and evaporative emissions. Servicing
procedures in this manual must be strictly followed
in order to keep the vehicle within the factory spec-
ifications. Failure to follow servicing procedures in
this manual may lead a vehicle to be out of compli-
ance with applicable emission regulations.
8
Introduction
Manual Information
Manual Information This manual uses technical terms which may be

different from the ones of the parts catalogs.
Manual Procedures When ordering parts always refer to the specific
Many of the procedures in this manual are interre- model Parts Catalogs.
lated. Before undertaking any task, you should
read and thoroughly understand the entire section NOTICE 02
or subsection in which the procedure is contained. Most fasteners are metric, and most compo-
nents are built with parts dimensioned using
WARNING the metric system. Consult the appropriate
Unless otherwise specified, the engine parts catalog to obtain and use the correct
should be turned OFF and cold for all mainte- parts and fasteners. Mismatched or incorrect
nance and repair procedures. fasteners could cause damage to the vehicle.
A number of procedures throughout the book re- Manual Layout

quire the use of special tools. Before starting any This manual is divided into many major sections
procedure, be sure that you have on hand all re- as can be seen in the main table of contents at the
quired tools, or their approved equivalents. beginning of the manual.
The use of RIGHT and LEFT indications in the text Each section is divided into various subsections,
are always referenced to the driving position (sit- and again, each subsection has one or more
ting on the vehicle). divisions.
Illustrations and photos show the typical construc-
tion of various assemblies and, in all cases, may
not reproduce the full detail or exact shape of the
parts used in a particular model vehicle. However,
they represent parts which have the same or a
similar function.
TYPICAL
1. Left
2. Right
9
Introduction
Manual Information
10
Introduction
Manual Information
02
11
Introduction
Manual Information
Tightening Torque
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When a
torque is not specified, refer to the following table.
WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices must be replaced when removed (e.g.: locking tabs, elastic stop nuts, self-lock-
ing fasteners, cotter pins, etc.).
In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following
procedure:
1. Manually screw in all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
3. Tighten fastener to the recommended torque value.
NOTICE
Be sure to use the recommended tightening torque for the specified fastener used.
Whenever possible, always apply torque on the nut.

Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are used
to secure a part (eg. a cylinder head). Some parts must be torqued according to a specific sequence
and torque pattern as detailed in the installation procedure.
12
Introduction
Manual Information
FASTENER FASTENER GRADE/TORQUE

SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
1.5 – 2 N∙m (13 – 18 2.5 – 3 N∙m (22 – 27 3.5 - 4 N∙m (31 - 35

M4 4 - 5 N∙m (35 - 44 lbf∙in)
lbf∙in) lbf∙in) lbf∙in)
02
3 - 3.5 N∙m (27 - 31 4.5 - 5.5 N∙m (40 - 49 7 - 8.5 N∙m (62 - 75
M5 8 - 10 N∙m (71 - 89 lbf∙in)
6.5 - 8.5 N∙m (58 - 75 8 - 12 N∙m (71 - 106 10.5 – 15 N∙m (93 – 133
M6 16 N∙m (142 lbf∙in)
M8 15 N∙m (133 lbf∙in) 25 N∙m (18 lbf∙ft) 32 N∙m (24 lbf∙ft) 40 N∙m (30 lbf∙ft)
M10 29 N∙m (21 lbf∙ft) 48 N∙m (35 lbf∙ft) 61 N∙m (45 lbf∙ft) 73 N∙m (54 lbf∙ft)
13
Introduction
Fastener Information
Threadlocker Application for Uncovered Holes

Fastener Information (Bolts and Nuts)
NOTICE
Most components in the vehicles are built
with parts dimensioned in the metric system.
Most fasteners are metric and must not be re-
placed by customary fasteners or vice-versa.
Mismatched or incorrect fasteners could
cause damage to the vehicle or possible per-
sonal injury.
Self-Locking Fastener Procedure
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.

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

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

Procedure
The following describes common procedures used
when working with Loctite products.
1. On fastener threads
N O T E : Always use proper strength Loctite prod- 2. On threads and at the bottom of hole
uct as recommended in this Shop Manual.
1. Clean threads (bolt and hole) with solvent.
2. Apply Loctite 7649 (Primer) on threads (bolt
and nut) and allow to dry for 30 seconds.
3. Choose proper strength Loctite threadlocker.
4. Apply several drops along the threaded hole
and at the bottom of the hole.
5. Apply several drops on bolt threads.
6. Tighten as required.
14
Introduction
Threadlocker Application for Stud Installation 5. Avoid touching metal with tip of flask.
in Blind Holes
N O T E : For preventive maintenance on existing
equipment, retighten nuts and apply proper
strength Loctite on bolt/nut contact surfaces.
Threadlocker Application for an Adjustment 02
Screw
1. On stud threads
2. On threads and in the hole
3. On retaining nut threads
1. Clean threads (stud and hole) with solvent.

2. Apply Loctite 7649 (Primer) on threads and al-
low to dry.
3. Apply 2 or 3 drops of proper strength Loctite
threadlocker on female threads and in hole.
1. Apply here
N O T E : To avoid a hydro lock situation, do not 2. Plunger
apply too much Loctite. 1. Adjust screw to proper setting.
2. Apply a few drops of proper strength Loctite
4. Apply several drops of proper strength Loctite
threadlocker on screw/body contact surfaces.
on stud threads.
3. Avoid touching metal with tip of flask.
5. Install stud.
6. Install cover, part, etc. N O T E : If it is difficult to readjust, heat screw with
7. Apply a few drops of proper strength Loctite on a soldering iron (232 °C (450 °F)).
uncovered stud threads.
8. Install and tighten retaining nut(s) as required. Threadlocker Application for Mounting on a
Shaft
Threadlocker Application for Pre-Assembled
Parts Mounting with a Press
1. Bearing
2. Proper strength Loctite
2 3. Shaft
A00A3OA
1. Clean shaft external contact surface.
1. Apply here
2. Do not apply 2. Clean internal contact surface of part to be in-
stalled on shaft.
1. Clean bolts and nuts with solvent.
2. Assemble components.
3. Tighten nuts.
4. Apply a few drops of proper strength Loctite on
bolt/nut contact surfaces.
15
Introduction
3. Apply a strip of proper strength Loctite on cir- Application for Stripped Thread Repair
cumference of shaft contact surface at inser-
tion or engagement point.
N O T E : Retaining compound is always forced out

when applied on shaft. DO NOT use Loctite anti-
seize or any similar product. No curing period is
required.
Mounting in Tandem
1. Apply retaining compound on internal contact
surface (bore) of parts to be installed.
2. Continue parts assembly in the prescribed
order. 1. Release agent
2. Stripped threads
Threadlocker Application for Case-In 3. Form-A-Thread
Components (Metallic Gaskets) 4. Tape
5. Cleaned bolt
6. Plate
7. New threads
8. Threadlocker
Standard Thread Repair

Follow instructions on Loctite FORM-A-THREAD
81668 package.
If a plate is used to align bolt:
1. Apply release agent on mating surfaces.
2. Put waxed paper or similar film on the
1. Proper strength Loctite surfaces.
3. Twist bolt when inserting it to improve thread
1. Clean inner housing diameter and outer gasket conformation.
diameter.
2. Spray housing and gasket with Loctite 7649 N O T E : NOT intended for engine stud repairs.
(Primer).
3. Apply a strip of proper strength Loctite on lead- Repair of Small Holes/Fine Threads
ing edge of outer metallic gasket diameter.
Option 1: Enlarge damaged hole, then follow
N O T E : Any Loctite product can be used here. A Standard Thread Repair procedure.
low strength liquid is recommended as normal
Option 2: Apply FORM-A-THREAD on the screw
strength and gap are required.
and insert in damaged hole.
4. Install according to standard procedure. Permanent Stud Installation (Light Duty)
5. Wipe off excess product.
6. Allow 30 minutes for product to cure. 1. Use a stud of the desired thread length.
N O T E : Normally used on worn-out housings to N O T E : DO NOT apply release agent on stud.

prevent leaking or sliding.
2. Follow Standard Thread Repair procedure.
It is generally not necessary to remove gasket 3. Allow 30 minutes for Loctite FORM-A-
compound applied on outer gasket diameter. THREAD to cure.
4. Complete part assembly.
16
Introduction
Gasket Compound Application
02
1. Proper strength Loctite

2. Loctite Primer and Gasket Eliminator 518 on both sides of gasket
3. Loctite Primer N only
1. Remove old gasket and other contaminants

using Loctite chisel (gasket remover). Use a
mechanical means only if necessary.
N O T E : Avoid grinding.
2. Clean both mating surfaces with solvent.
3. Spray Loctite Primer N on both mating surfa-
ces and on both sides of gasket and allow to
dry 1 or 2 minutes.
4. Apply Loctite 518 on both sides of gasket, us-
ing a clean applicator.
5. Place gasket on mating surfaces and assem-
ble parts immediately.
N O T E : If the cover is bolted to blind holes, apply

proper strength Loctite in the hole and on threads.
Tighten fastener.
NOTE: If holes are sunken, apply proper
strength Loctite on bolt threads.
6. Tighten as usual.
17
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
18
03
MAINTENANCE
19
Maintenance
Periodic Maintenance Schedule
03 Maintenance
General
Maintenance is very important for keeping your vehicle in safe operating condition. The vehicle should
be serviced as per the maintenance schedule.
WARNING
Failure to properly maintain the vehicle according to the maintenance schedule and procedures
can make it unsafe to operate.
EPA Regulation - Canadian and USA Vehicles

A r e p a i r s h o p o r p e r s o n o f t h e o w n e r ' s c h o o s i n g m a y m a i n t a i n , r e p l a c e , o r r e p a i r emission control
devices and systems. These instructions do not require components or service by BRP or authorized
Can-Am Off-Road dealers.
Although an authorized Can-Am Off-Road dealer has an in-depth technical knowledge and tools to serv-
ice your vehicle, the emission-related warranty is not conditioned on the use of an authorized Can-Am
Off-Road dealer or any other establishment with which BRP has a commercial relationship.
Proper maintenance is the owner’s responsibility. A warranty claim may be denied if, among other things,
the owner or operator caused the problem through improper maintenance or use.
You must follow the instructions for fuel requirements in the fueling section of this manual. Even if gaso-
line containing greater than ten volume percent ethanol is readily available, the US EPA issued a prohibi-
tion against the use of gasoline containing greater than 10 vol% ethanol that applies to this vehicle. The
use of gasoline containing greater than 10 vol% ethanol with this engine may harm the emission control
system.
EPA Regulation - Canadian and USA Vehicles
A r e p a i r s h o p o r p e r s o n o f t h e o w n e r ' s c h o o s i n g m a y m a i n t a i n , r e p l a c e , o r r e p a i r emission control
devices and systems. These instructions do not require components or service by BRP or authorized
Can-Am Off-road dealers.
Although an authorized Can-Am Off-road dealer has an in-depth technical knowledge and tools to serv-
ice your vehicle, the emission-related warranty is not conditioned on the use of an authorized Can-Am
Offroad dealer or any other establishment with which BRP has a commercial relationship.
Proper maintenance is the owner’s responsibility. A warranty claim may be denied if, among other things,
the owner or operator caused the problem through improper maintenance or use.
For emission-related warranty claims, BRP is limiting the diagnosis and repair of emission-related parts
to the authorized Can-Am Offroad dealers. For more information, please refer to the US EPA Emission-
Related Warranty contained in the Warranty section.
You must follow the instructions for fuel requirements in the fueling section of this manual. Even if gaso-
line containing greater than ten volume percent ethanol is readily available, the US EPA issued a prohibi-
tion against the use of gasoline containing greater than 10 vol% ethanol that applies to this vehicle. The
use of gasoline containing greater than 10 vol% ethanol with this engine may harm the emission control
system.
20
Maintenance
Severe Dusty Conditions

Engine Air Filter Maintenance Guideline
Air filter maintenance should be adjusted according to riding conditions.
Air filter maintenance must be increased in frequency in the following dusty conditions:
– Riding on dry sand
– Riding on dry dirt covered surfaces
– Riding on dry gravel roads or similar conditions.
N O T E : Riding in a group in these conditions would increase the frequency of air filter maintenance
03
even more.
Maintenance Schedule Legend
Operation in trail riding conditions

Operation in severe riding conditions (dusty or muddy) or carrying heavy loads condition
Maintenance Schedule (except 6x6)

Make sure to perform proper maintenance at recommended intervals as indicated in the tables.
The maintenance chart intervals are based on 3 factors:
– Calendar time
– Vehicle hours
– Odometer reading.
Take in account whichever comes first to determine the maintenance threshold.
Your driving habits determines the factors you shall adhere too. For example:
– Someone who uses their vehicle every other weekend trail riding with friends would most likely follow
the o d o m e t e r r e a d i n g to determine the maintenance interval.
– Someone who uses their vehicle seldomly over the year or only on a few occasions (hunting, camp-
ing) would most likely follow the c a l e n d a r t i m e to determine the maintenance interval.
– Someone who uses their vehicle daily / weekly for long periods of time such as agricultural / work
would most likely follow the v e h i c l e h o u r s to determine the maintenance interval.
I M P O R T A N T : The following tables show the appropriate maintenance application for the first 3 years.
For subsequent years, repeat the same pattern alternatively.
Regular Maintenance Overview

Calendar Years Vehicle Hours Odometer Regular Duty
1 100 3000 km (2000 mi) A
2 200 6000 km (4000 mi) A and B
3 300 9000 km (5500 mi) A
21
Maintenance
Severe Duty and Mud/Water Maintenance Overview

Severe Duty and Deep
Calendar Years Vehicle Hours Odometer
Mud / Water
0.5 50 1500 km (1000 mi) A+
1 100 3000 km (2000 mi) A + and A
1.5 150 4500 km (3000 mi) A+
2 200 6000 km (4000 mi) A + and A and B
2.5 250 7500 km (5700 mi) A+
3 300 9000 km (5500 mi) A + and A
22
Maintenance
REGULAR DUTY A B
A = Adjust Every year Every 2 years
C = Clean or or
I = Inspect 100 hours 200 hours
L = Lubricate or or
R = Replace 3000 km 6000 km
T = Torque (2000 mi) (4000 mi)
Air and Fuel Delivery
Engine air filter C, L or R
03
Air delivery components and function (filters, throttle body, ducts,
I, C
clamps)
Fuel components and function I
Fuel pump pressure I
Engine and Cooling
Engine oil and filter R
Engine seals and gaskets I
R
Spark plugs Every 200 hours or 6000
km (4000 mi)
I, A
Valve clearance Every 100 hours or 3000
km (2000 mi)
Engine cooling components (coolant concentration, coolant level,
I, A
hose condition, clamps, leaks)
R
Coolant
Every 5 years or 12 000 km (8000 mi)
Radiator C
Exhaust and Emissions
Fuel tank vent breather filter (Non-EVAP models) R
Canister vent pre-filter (CARB and EVAP models) R
Debris around exhaust pipe and muffler area C
Muffler spark arrester C
Brake
Brake components and function I, L
R
Brake fluid
Every 2 years
Drive
Drive components and function I, L
R
Replace at first 3000 km
Gearbox oil (2000 mi) and at 6000 km R
(4000 mi), then follow the
regular schedule
Gearbox oil level I
Front differential oil I R
23
Maintenance
REGULAR DUTY A B
A = Adjust Every year Every 2 years
C = Clean or or
I = Inspect 100 hours 200 hours
L = Lubricate or or
R = Replace 3000 km 6000 km
T = Torque (2000 mi) (4000 mi)
Rear final drive oil I R
Tires I, A
Wheel beadlock bolts T
Wheel lug nuts T
Continuously Variable Transmission (CVT)
CVT components and function I, C, L
Electrical
Battery connections and condition I
Electrical harness routing I
Modules and applicable software updates I
Operation of control switches and lighting I
C
Clean at first 3000 km
Vehicle speed sensor (2000 mi) and at 6000 km C
(4000 mi), then follow the
regular schedule
Steering
Steering components and function I
Steering column half bushings C, L
Controls
Gearbox position lever operation I, A
Throttle cable (If equipped) I, A, L
Throttle operation I
Suspension
Suspension components and function I, L
24
Maintenance
SEVERE DUTY A+ A B
A = Adjust
Every 6 months Every year Every 2 years
C = Clean
or or or
I = Inspect
50 hours 100 hours 200 hours
L = Lubricate
or or or
R = Replace
1500 km (1000 mi) 3000 km (2000 mi) 6000 km (4000 mi)
T = Torque
03
Air delivery components and function (filters, throttle
I, C
body, ducts, clamps)
Engine and Cooling
R
Spark plugs Every 200 hours or
6000 km (4000 mi)
I, A
Valve clearance Every 100 hours or
3000 km (2000 mi)
Engine cooling components (coolant concentration,
I, A
coolant level, hose condition, clamps, leaks)
R
Coolant
Radiator C
Brake
Brake components and function I I, L
R
Brake fluid
Every 2 years
Drive
R
Replace at first 1500
km (1000 mi) and at
Gearbox oil R
3000 km (2000 mi),
then follow the
regular schedule
Gearbox oil level I
25
Maintenance
SEVERE DUTY A+ A B
A = Adjust
C = Clean
or or or
I = Inspect
L = Lubricate
or or or
R = Replace
1500 km (1000 mi) 3000 km (2000 mi) 6000 km (4000 mi)
T = Torque
Tires I, A I, A
Wheel lug nuts T
Electrical
C
Clean at first 3000
km (2000 mi) and at
Vehicle speed sensor C
6000 km (4000 mi),
then follow the
regular schedule
Steering
Controls
Suspension
26
Maintenance
DEEP MUD / WATER A+ A B

A = Adjust
C = Clean
or or or
I = Inspect
L = Lubricate
or or or
R = Replace
1500 km (1000 mi) 3000 km (2000 mi) 6000 km (4000 mi)
T = Torque
03
Air delivery components and function (filters, throttle
I, C
body, ducts, clamps)
Engine and Cooling
Engine oil level I
R
Spark plugs Every 200 hours or
6000 km (4000 mi)
I, A
Valve clearance Every 100 hours or
3000 km (2000 mi)
Engine cooling components (coolant concentration,
I, A I
coolant level, hose condition, clamps, leaks)
R
Coolant
Radiator C
Brake
Brake components and function I I, L
R
Brake fluid
Every 2 years
Drive
R
Replace at first 3000
km (2000 mi) and at
Gearbox oil R
6000 km (4000 mi),
then follow the
regular schedule
27
Maintenance
DEEP MUD / WATER A+ A B

A = Adjust
C = Clean
or or or
I = Inspect
L = Lubricate
or or or
R = Replace
1500 km (1000 mi) 3000 km (2000 mi) 6000 km (4000 mi)
T = Torque
Gearbox oil level I
Tires I, A
Wheel lug nuts T
Electrical
C
Clean at first 3000
km (2000 mi) and at
Vehicle speed sensor C
6000 km (4000 mi),
then follow the
regular schedule
Steering
Controls
Suspension
28
Maintenance
Periodic Maintenance Procedures

SERVICE TOOLS
Description Part Number Page
TEST CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529 035 991)

VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . (P/N 529 021 800)
. . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . 35
03
SERVICE PRODUCTS
BRAKE CALIPER SYNTHETIC GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 44

BRP HEAVY DUTY CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 47
CLEANER AND DEGREASER PRO C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 47
LUBRICANT AND ANTI-CORROSIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 48
OIL STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 46
XPS ATV WASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 47
XPS FUEL STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 46
General Air Intake Prefilter (X mr)

This subsection provides: See Cleaning the CVT Air Filter in this subsection.
– Fluid level verifications Removing the Engine Air Filter
– Maintenance procedures.
NOTICE
The following systems should be serviced accord- Never remove or modify any component in
ing to the appropriate Periodic Maintenance the air filter housing. Otherwise, engine per-
Schedule. formance degradation or damage can occur.
The engine is calibrated to operate specifi-
Procedures cally with these components.
Air Intake System
Engine Air Filter Maintenance Guideline 1. Remove seat.
1. As with any ATV, air filter maintenance is crit- 2. Remove console. Refer to BODY subsection.
ical to ensure proper engine performance and 3. Rotate air filter cover counterclockwise to re-
life span. move it.
2. Air filter maintenance should be adjusted ac- N O T E : A socket wrench may be used to ease re-
cording to riding conditions. moval of the air filter cover.
3. Air filter maintenance must be increased in fre-
quency and oil must be added to the foam filter
for the following dusty conditions:
– Riding on dry sand
– Riding on dry dirt covered surfaces
– Riding on dry gravel trails or similar
conditions.
N O T E : Riding in a group in these conditions

would increase the frequency of air filter mainte-
nance even more.
29
Maintenance
– If any debris or water are found, clean air fil-

ter chamber using a vacuum cleaner.
NOTICE
Do not blow compressed air into air filter
chamber.
4. Check air filter housing drain tube (clean

chamber).
– If any debris or water are found, refer to
Special Procedures subsection.
1. Air filter cover
– Investigate for contamination source.
4. Remove air filter.
TYPICAL - SOME PARTS REMOVED FOR CLARITY

1. Air filter drain tube
AIR FIL TER REMOVAL
Cleaning the Paper Filter
Inspecting and Draining the Engine Air Filter 1. Ensure that the foam filter is removed from pa-
Housing
per filter.
1. Remove LH side panel and extension. Refer to 2. Tap out heavy dust from the paper filter.
Body subsection.
2. Drain air filter housing drain tube. This will allow dirt and dust to get out of the pa-
per filter.
N O T E : Paper filters have a limited life span; re-
place filter if too dirty or clogged.
NOTICE
It is not recommended to blow compressed
air on the paper filter; this could damage the
paper fibers and reduce its filtration ability
when used in dusty environments.
NOTICE
Do not wash the paper filter with any cleaning
solution.
1. Air filter housing drain tube
Cleaning the Foam Filter
3. Check air filter dirty chamber for cleanliness. 1. Spray the foam filter inside and out with air fil-
ter cleaner and follow manufacturer's
instructions.
30
Maintenance
2. Dry the foam filter completely.
03
TYPICAL - DRY
N O T E : A second application may be necessary 1. Cover position arrow

2. Locked
for heavily soiled elements. 3. Unlocked
Oiling the Foam Filter 4. Reinstall the console.

1. Spray the recommended air filter oil on the
foam filter previously cleaned and dried. Follow Exhaust System
manufacturer's directions.. Cleaning and Inspecting the Muffler Spark
Arrester
The muffler must be periodically purged of accu-
mulated carbon.
WARNING
Never run engine in an enclosed area. Never
perform this operation immediately after the
engine has been run because exhaust sys-
tem is very hot. Make sure that there are no
combustible materials in the area. Wear eye
protection and gloves. Never stand behind
the vehicle while purging exhaust system.
Respect all applicable laws and regulations.
TYPICAL - OIL THE FOAM FILTER
Select a well-ventilated area and make sure the
2. Reinstall oiled foam filter over the paper filter. muffler is cool.
Installing the Engine Air Filter
CAUTION
1. Slightly grease O-ring seal and plastic body of
air filter. Refer to Air Intake System exploded Never perform this operation immediately
view. after the engine has been running as exhaust
2. Install filter assembly in air filter housing. system is very hot.
3. Ensure air filter cover is properly locked onto
the air filter housing. See indications on filter Muffler (Transversal Mounting)
cover and housing.
1. Place transmission on PARK position.
2. Remove the clean out plug of the muffler.
31
Maintenance
TYPICAL
1. Muffler
2. Clean out plug
3. Block the end of the muffler with a shop rag

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

er using a brush.
TYPICAL
1. Remove and discard screws NOTICE
2. Cover
Use a soft brush and be careful to avoid dam-
2. Remove and discard the tail pipe retaining aging spark arrester mesh.
screws.
32
Maintenance
Do not use tap water, straight antifreeze or straight

water in the system. Tap water contains minerals
and impurities which build up in the system. Dur-
ing cold weather, straight water causes the system
to freeze while straight antifreeze thickens and
does not have the same efficiency.
Verifying the Engine Coolant Level
WARNING
In order to avoid potential burns, check cool-
03
ant level with engine cold. Do not remove the
radiator cap if the engine is hot.
1. Place vehicle on a level surface.

1. Clean spark arrester 2. Remove gauge support. Refer to Body
5. Inspect mesh of spark arrester for any dam- subsection.
age. Replace as required. With the vehicle on a level surface, coolant lev-
6. Inspect spark arrester chamber in muffler. el should be between the MIN. and MAX.
Clean as required. marks of the reservoir.
7. The installation is the reverse of the removal
procedure. However, pay attention to the
following.
8. Install new gasket and new retaining screws.
Tightening Torque
Tail pipe retaining 11 ± 1 Nm

screws (97 ± 9 lbf-in)
Cooling System
Recommended Engine Coolant
XPS RECOMMENDED COOLANT

TYPICAL
Extended life pre-mixed coolant 1. Engine coolant reservoir
IF THE RECOMMENDED XPS COOLANT IS NOT

AVAILABLE N O T E : When checking level at temperature low-
er than 20 °C (68 °F), it may be slightly lower than
Use distilled water and antifreeze solution (50% MIN. mark.
distilled water, 50% antifreeze)
3. Add coolant up to MAX. mark if required.
NOTICE 4. Use a funnel to avoid spillage. D o n o t o v e r f i l l .
5. Properly reinstall and tighten reservoir cap.
Always use ethylene-glycol antifreeze con- 6. Reinstall gauge support.
taining corrosion inhibitors specifically formu-
lated for internal combustion aluminum NOTICE
engines. Do not store any objects under the gauge
support.
To prevent antifreeze deterioration, always use
the same brand. Never mix different brands or Checking the Engine Coolant Specific Gravity
type of antifreeze. Always use the same antifreeze 1. Remove gauge support, refer to Body
unless cooling system is completely flushed and subsection.
refilled. 2. Remove pressure cap.
33
Maintenance
WARNING
To avoid potential burns, do not remove the
pressure cap if the engine is hot.
3. Using an antifreeze tester, test coolant

strength.
Minimum recommended coolant strength

-30 °C (-22 °F)
Inspecting the Engine Cooling System

1. Check general condition of hoses and clamps
TYPICAL
for tightness. 1. Leak indicator hole
2. Check the leak indicator hose for oil or coolant. 2. PTO cover
3. Crankcase PTO, front side
Leaking coolant indicates a defective rotary
seal. Leaking oil indicates a defective oil seal. 3. Ensure vent hose on coolant expansion tank is
If either seal is leaking, both seals must be re- not obstructed.
placed at the same time. Refer to Water Pump
Testing the Engine Cooling System Pressure
Shaft and Seals in the appropriate Engine Cap
Service Manual.
1. Remove gauge support. Refer to Body
subsection.
2. Remove pressure cap.
WARNING
3. Test the pressure cap using a cooling system

tester.
4. Replace the cap if it does not hold the pres-
sure, or if it opens at a relief pressure that is
too low or too high.
1. Leak indicator hose
2. Water pump Pressure Cap Relief Pressure
Another leak indicator hole is visible on the Approximately 110 kPa (16 lbf/in²)
PTO side. It provides an indication of the PTO
gasket condition. If a liquid leaks from this hole, Testing the Engine Cooling System Leak
PTO gasket replacement is necessary.
1. Remove gauge support. Refer to Body
subsection.
2. Remove pressure cap.
WARNING
3. Pressurize cooling system as follows.
34
Maintenance
Test cap (P/N 529 N O T E : Coolant drain plug is accessible from

035 991) underneath RH footrest panel.
Vacuum/pressure
pump (P/N 529 021
800) 03
Cooling System Leak Test

110 kPa (16 lbf/in²)
If there is no pressure drop after 10 minutes, 1. Coolant drain plug
there is no leak in the cooling system. 4. Drain cooling system into a suitable container.
If the pressure drops, check all hoses, radiator, 5. Disconnect the lower radiator hose and drain
cylinders and engine base for coolant leaks or the remaining coolant.
air bubbles.
N O T E : Take note of the hose clamp position be-
Replacing the Engine Coolant fore it is loosened for hose removal.
Draining the Engine Cooling System
6. Reinstall coolant drain plug with a N E W seal-
CAUTION ing washer.
Engine coolant can be very hot. Coolant 7. Tighten coolant drain plug to specification.
draining should be carried out on a cold
engine. Tightening Torque
10 ± 1 Nm
1. Remove gauge support. Refer to Body Coolant drain plug
(89 ± 9 lbf-in)
subsection.
2. Remove cooling system pressure cap.
8. Fill cooling system with recommended coolant,
refer to Filling and Bleeding the Cooling Sys-
tem procedure.
Filling and Bleeding the Engine Cooling
System
1. Remove cooling system pressure cap.
2. Remove RH and LH side panels.
3. On LH side of engine, remove outer exhaust
heat shield.
TYPICAL
1. Cooling system pressure cap
3. Unscrew coolant drain plug.
35
Maintenance
1. Outer exhaust heat shield

LH SIDE
4. Remove CVT duct outlet. 1. Rear cylinder bleed screw
6. Fill cooling system until coolant comes out of

bleed screws.
7. Squeeze the top of the coolant hose between
the radiator and coolant pump several times to
bleed all air from the highest point of the hose.
8. Tighten bleed screws.
NOTICE
In the case of the screws were removed com-
pletely, make sure to replace the gasket rings
with new ones.
Tightening Torque
1. CVT duct outlet 3.5 ± 0.4 Nm

Bleed screws (31 ± 4 lbf-in)
5. Loosen bleed screws on thermostat housing
covers of both front and rear cylinders. 9. Refill coolant tank up to MAX level mark.
No need to remove screws completely for bleed- 10. Install cooling system pressure cap.
ing the system. 11. Run engine at idle until the cooling fan cycles
on for a second time.
12. Stop the engine and let it cool down.
WARNING
Do not remove the pressure cap if the engine
is hot.
13. Check coolant level in the coolant tank. Refer

to Verifying the Engine Coolant Level in this
subsection.
14. Add coolant if required.
Fuel System
Inspecting and Cleaning the Throttle Body
1. Remove the air intake housing, refer to Air In-
take System subsection.
RH SIDE
1. Front cylinder bleed screw
36
Maintenance
2. Visually inspect throttle plate and throttle body

venturi for cleanliness.
3. Clean inside throttle body if necessary, refer to
Electronic Fuel Injection (EFI) in appropriate
engine service manual.
Lubricating the Throttle Cable
1. The throttle cable must be lubricated with a sili-
cone based lubricant.
WARNING
03
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.
1. Cable protector
2. Throttle cable adjuster
2. Open the throttle lever housing. 3. Lock nut
4. Throttle lever housing
5. Screw in the throttle cable adjuster.

6. Remove inner housing protector.
1. Remove these screws
3. Separate the housing.

4. Slide rubber protector back to expose throttle 1. Inner housing protector
cable adjuster.
7. Remove the cable from the throttle lever
housing.
N O T E : Slide cable in clip slot and remove the

end of cable from clip.
37
Maintenance
TYPICAL
8. Remove the throttle body side cover. N O T E : Place a rag around the throttle cable ad-
juster to prevent the lubricant from splashing.
10. Add lubricant until it runs out at throttle body

end of the throttle cable.
11. Reinstall and adjust the cable, refer to Elec-
tronic Fuel Injection (EFI) subsection.
Replacing the Fuel Tank Vent Breather Filter
1. Ensure breather filter is installed with the flow
arrow pointing towards the vent inlet check
valve.
1. Throttle body
2. Side cover screws
9. Insert the needle of the lubricant can in the end

of throttle cable adjuster.
1. Vent breather filter

2. Vent inlet check valve
Inspecting the Fuel System

1. Visually inspect fuel tank for cracks, wear
marks, signs of leakage or any other damages.
2. Visually inspect fuel system hoses for proper
rooting, cracking, wear marks, signs of leakage
or any other damages.
38
Maintenance
3. Carry out a Fuel Tank Leak Test, refer to Fuel 5. Remove filler plug.
Tank and Fuel Pump subsection. 6. Remove drain plug.
WARNING
All fuel system leaks must be repaired. Dam-
aged, worn or leaking fuel system compo-
nents should be replaced to ensure fuel
system tightness.
Electrical System 03
Inspecting the Battery
1. Visually inspect battery casing for cracks or
other damage. If casing is damaged, replace
battery and thoroughly clean battery rack with
water and sodium bicarbonate (baking soda).
BOTTOM VIEW OF VEHICL E
2. Inspect battery posts condition and battery re-
tainer plate.
3. For battery testing, refer to Charging System N O T E : Allow enough time for oil to flow out.
subsection.
7. Install and tighten drain plug to specification.
Drive System
Verifying the Front Differential Oil Level Tightening Torque
1. Clean filler plug prior to checking oil level. 7.5 ± 0.5 Nm
Drain plug
(66 ± 4 lbf-in)
8. Refill front differential with recommended oil.

XPS Recommended Differential Oil
75W90 Synthetic gear oil
IF THE RECOMMENDED XPS DIFFERENTIAL OIL
IS NOT AVAILABLE
Use a 75W90 gearbox oil that meets the API
GL-5 specification
9. Reinstall filler plug with a N E W sealing

RH SIDE OF VEHICLE
washer.
2. With vehicle on a level surface, check oil level 10. Tighten filler plug to specification.
by removing filler plug. Oil level must reach the
lower edge. Tightening Torque
3. Reinstall filler plug with a N E W sealing
washer. 22.5 ± 2.5 Nm
Filler plug
(17 ± 2 lbf-ft)
Tightening Torque
Inspecting the Front Differential Oil Seals
22.5 ± 2.5 Nm
Filler plug Visually inspect oil seals for leak. Replace if
(17 ± 2 lbf-ft)
required.
Replacing the Front Differential Oil Verifying the Rear Final Drive Oil Level
1. Place vehicle on a level surface. 1. Ensure vehicle is on a level surface.
2. Set transmission in park position. 2. Clean filler plug area.
3. Clean filler and drain plug areas. 3. Remove filler plug.
4. Place a drain pan under the front differential.
39
Maintenance
LH REAR SIDE OF VEHICL E LH REAR SIDE OF VEHICLE

1. Filler plug 1. Filler plug
2. Drain plug
4. Verify the oil level by inserting a wire with a 90°
bend through the oil filler hole.
5. Oil level must be within the following specifica- N O T E : Allow enough time for oil to flow out.
tion from the bottom of oil filler hole. 6. Install drain plug.
Oil Level
Tightening Torque
20 ± 5 mm (9/16 ± 3/16 in)
7.5 ± 0.5 Nm
Drain plug
6. Reinstall filler plug with a N E W sealing (66 ± 4 lbf-in)
washer.
7. Refill the rear final drive.
Tightening Torque
XPS RECOMMENDED Final Drive Oil
22.5 ± 2.5 Nm
Filler plug 75W140 Synthetic gear oil
(17 ± 2 lbf-ft)
IF THE RECOMMENDED XPS FINAL DRIVE OIL IS
Replacing the Rear Final Drive Oil NOT AVAILABLE
1. Ensure vehicle is on a level surface.
Use a 75W140 gearbox oil that meets the API
2. Clean filler and drain plug areas.
GL-5 specification
3. Place a drain pan under rear final drive.
4. Unscrew filler plug.
5. Remove drain plug. 8. Reinstall filler plug with a N E W sealing
washer.
Tightening Torque
22.5 ± 2.5 Nm
Filler plug
(17 ± 2 lbf-ft)
Inspecting the Rear Final Drive Oil Seals

Visually inspect final drive oil seals for leaks. Re-
place if required.
Inspecting Drive Shaft Bellows and Protector
1. Visually inspect each drive shaft bellows for
grease leak, cracks or opening.
2. Check if the drive shaft bellow protectors are
fixed firmly, not torn or otherwise damaged.
3. Replace if necessary.
40
Maintenance
Inspecting Drive Shaft Joint – Up and down.

Turn and move drive shaft back and forth to detect 3. If any play is detected, replace shock absorber
excessive play. bushings. Refer to Rear Suspension
subsection.
Inspecting Rear Propeller Shaft U-Joint
Check yoke U-joints for wear, backlash or axial Lubricating Front Suspension Arm
play. Replace if necessary. Lubricate suspension arm at grease fittings.
Lubricating Rear Propeller Shaft U-Joint Service Product
Recommended Propeller Shaft U-Joint XPS Synthetic suspension grease
03
Grease
Propeller shaft grease
If the Recommended Propeller Shaft U-joint
Grease is not Available
Hi-temp bearing grease NLGI-2 or an equivalent
Steering System
Inspecting the Steering System
Steering Column
1. Turn and move steering column back and forth
to detect any abnormal play.
2. If abnormal play is detected, inspect upper and TYPICAL
1. Grease fittings
lower steering column half bushings. Replace
halve bushings and O-rings as necessary, re-
fer to Steering System subsection.
3. If steering column feels stiff, refer to Steering
Column Half Bushing Cleaning and Lubrication
in this subsection.
Tie-Rod End
Check tie-rod end ball joint for:
– Damage
– Pitting
– Abnormal play.
Replace if necessary.
Cleaning and Lubricating Steering Column TYPICAL
Half Bushing 1. Grease fittings
Clean, inspect and lubricate upper and lower
steering column half bushings and O-rings. Refer Inspecting Front Suspension Arm
to Steering System subsection. 1. Check suspension arm for:
Suspension – Cracks
Inspecting Shock Absorber – Pitting
– Bending
1. Check shock absorber for any leaks, replace if – Distortion.
necessary.
2. Check suspension arm for abnormal play:
HPG Shock Absorber (without Remote
Reservoir) – Side to side
2. Check shock absorber for abnormal play: – Up and down.
3. If any play is detected, inspect:
– Front to back
41
Maintenance
– Wear plates
– Bushings
– Sleeves.
4. Check ball joint for:
– Damage
– Pitting
– Play.
5. Check ball joint bellows for:
– Damage
– Cracks.
Inspecting Rear Suspension Trailing Arm
1. Check trailing arms for: TYPICAL
1. Grease fittings
– Cracks
– Pitting Brakes
– Bending
– Distortion. Recommended Brake Fluid
2. Check trailing arm for abnormal play: Always use brake fluid meeting the specification
DOT 4 only.
– Side to side
– Up and down. Service Product
3. If any play is detected, inspect: Brake fluid DOT 4
– Spacers
– Bearings NOTICE
– Inner spacers. To avoid damage to the braking system, do
Inspecting and Lubricating Rear Stabilizer Bar not use other brake fluid types.
Bushing
Rear Stabilizer Bar Bushing Inspection Verifying the Brake Fluid Reservoir Level
Inspect bushings for: With vehicle on a level surface, check brake fluid
in reservoirs for proper level.
– Cracks
– Damage N O T E : A low level may indicate leaks or worn
– Abnormal wear. brake pads.
Lubricating Rear Stabilizer Bar Bushing Front Brake Reservoir
Lubricate bushings at grease fittings. 1. Turn steering in the straight-ahead position to
ensure reservoir is level.
Service Product 2. Check the brake fluid level, the reservoir is full
XPS Synthetic suspension grease when the fluid reaches of the top of window.
3. Visually inspect lever bellow condition.
4. Check for cracks, tears, etc. Replace if
damaged.
42
Maintenance
N O T E : Ensure filler cap diaphragm is pushed in-

side the cap before closing the brake fluid
reservoir.
Inspecting and Cleaning Brake System
NOTICE
Do not clean brake components in petroleum
based solvent. Use brake system cleaner on-
ly. Soiled brake pads must be replaced with
new ones.
03
To clean parts from the brake system, use the fol-
lowing recommended products or an equivalent.
TYPICAL Service Product

Rear Brake Reservoir XPS Brakes and Parts cleaner
Remove the seat.
Brake Pads
With vehicle on a level surface, liquid should be 1. Measure brake pad lining thickness.
between MIN. and MAX. level marks of brake ped-
al fluid reservoir. Brake Pad Minimum Thickness
1 mm (1/32 in)
NOTE: The brake pad grooves are wear

indicators.
1. Rear brake fluid reservoir

BRAKE PAD GROOVE
Adding Brake Fluid
NOTICE
1. Clean filler cap.
Brake pads must always be replaced in pairs.
WARNING
Clean filler cap before removing. Brake Caliper
1. Remove caliper then check the following
2. Remove screws retaining the reservoir cap. components:
3. Remove reservoir cap. – Check brake pad pin
4. Add fluid as required using a clean funnel. D o – Check caliper boots for cracks
not overfill. – Check caliper movement on its support
– Check pistons movement
NOTICE
– Check pistons for scratches, rust or other
Brake fluid can damage plastic and painted damages.
surface. Wipe off and clean any spillage.
2. Clean the following components using the rec-
ommended product or an equivalent:
5. Reinstall reservoir cap and tighten screws.
– Brake pads
– Caliper support and slider
43
Maintenance
– Caliper pistons and pin. Replacing the Brake Fluid

Draining the Brake Fluid
N O T E : Do not remove pistons from caliper for
1. Clean and remove reservoir cover with its
cleaning them.
diaphragm.
3. Lubricate caliper slider. 2. Connect a clear hose onto bleeder.
Brake Caliper Synthetic Grease
Brake Disc
1. Check brake disc as follows:
– Check disc thickness
– Check disc surfaces
– Check disc warpage.
Refer to Brake Disc Inspection for details.
2. Clean brake disc using the recommended
product or an equivalent.
Master Cylinder TYPICAL
1. Check master cylinder as follows: 1. Caliper bleeder
– Leaks or damages. 3. Loosen bleeder.

– Brake fluid level. 4. Pump brake lever (s) and/or brake pedal until
– Check cleanliness of master cylinder rod no more fluid flows out.
and bellows. 5. Repeat draining procedure for the other
– Check master cylinder boot for cracks or bleeders.
damage. Replace as necessary. Filling the Brake Fluid
Hand Lever 1. Add recommended brake fluid to MAX. mark.
Check hand lever as follows: Do not overfill.
– Lever pivot bolt cleanliness
– Lever pivot bolt movement.
Brake Pedal
1. Check brake pedal as follows:
– Brake pedal pivot movement
– Brake pedal pivot cleanliness.
2. If required, clean then lubricate brake pedal
pivot using a recommended grease.
Service Product
Synthetic grease
Brake Hoses TYPICAL - BRAKE FLUID RESERVOIR

1. Check hoses for leaks, crushed, deformations,
cracking or scrapes.
N O T E : Any deformation can restrict the proper

flow of fluid and cause braking problems.
44
Maintenance
Inspecting the Tow Hitch

1. Ensure tow hitch receptacle module is solidly
mounted.
2. Inspect hitch for cracks and other damages.
3. Repair or replace if necessary.
03
TYPICAL - UNDER THE SEAT

1. Brake fluid reservoir
N O T E : If applicable, ensure filler cap diaphragm

is fully retracted before closing the cap.
WARNING
Use only DOT 4 brake fluid from a sealed
container.
Do not use brake fluid from an old or already
opened container.
Bleed the brake system. Refer to the Brake

subsection.
Body
Inspecting Seat Latch Operation
Ensure seat latch functions properly and that seat
is properly secured when latched.
Frame
Inspecting the Frame
Inspect frame for damages such as:
– Cracks
– Dents
– Twisting
– Deformation
– Corrosion
– Loose fasteners.
Pay particular attention to:
– Front and rear frame extensions (body
modules)
– Underside of frame
– Suspension attachment points
– Engine attachment points.
45
Maintenance
Storage Procedure
Storage Procedure
SERVICE PRODUCTS
BRAKE CALIPER SYNTHETIC GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 44

BRP HEAVY DUTY CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 47
CLEANER AND DEGREASER PRO C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 47
LUBRICANT AND ANTI-CORROSIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 48
OIL STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 46
XPS ATV WASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 47
XPS FUEL STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 46
General 1. Remove side body panels.

If the ATV is not used or is to be stored for an ex- 2. Remove spark plugs.
tended period of time, more than 4 months, be 3. Spray storage oil into each cylinder (see fol-
sure to perform the storage procedures described lowing table).
below.
Oil storage
Where applicable, refer to the appropriate subsec-
tions in this manual for details of the required tasks NOTE: Use the storage oil as per country
as outlined in these procedures. availability.
Procedures 4. Press start button, 1 or 2 seconds maximum,
To facilitate the inspection and ensure adequate to lubricate cylinders.
lubrication of components, it is recommended to 5. Reinstall spark plugs.
clean the entire vehicle. Refer to Cleaning the Ve-
hicle . N O T E : Do not run engine during storage period.
Fuel System Engine Air Intake System
Remove parts required for access to engine air in-
Fuel System Protection
let hose, refer to Air Intake System subsection.
1. Pour fuel stabilizer in fuel tank and fill up fuel
tank. Block engine air inlet hose using a rag to prevent
2. Start vehicle to allow for fuel stabilizer to intrusion of small animals.
spread through the fuel system. CVT Protection
XPS Fuel stabilizer 1. Remove drive belt. Refer to Continuously Vari-
able Transmission (CVT).
3. Follow the manufacturer's instructions for prop- 2. Inspect and clean pulleys.
er use. 3. Protect pulleys by spraying Lubricant and anti-
corrosive on pulley faces.
NOTICE
N O T E : Do not reinstall drive belt.
Fuel stabilizer should be added prior to en-
gine lubrication to ensure fuel system compo- 4. Close CVT cover.
nents protection against varnish deposits. 5. Remove CVT outlet from exhaust system heat
shield and from CVT outlet hose.
Engine
Engine Internal Lubrication
Engine internal parts must be lubricated to protect
them from rust formation during the storage
period.
Proceed as follows:
46
Maintenance
Storage Procedure
Electrical System
Removing the Battery
Remove battery from the vehicle.
Store and charge battery as per battery manufac-
turer's recommendations.
Drive System
Lubricate rear propeller shaft U-joints.
03
Chassis
Lubrication
TYPICAL Lubricate front and rear suspension.
1. CVT cover
2. Exhaust system heat shield Tire Pressure
3. CVT outlet
Inflate tires to recommended pressure.
6. Block CVT outlet hose using a rag.
Cleaning the Vehicle
1. Wash and dry the vehicle.
NOTICE
Never use a high pressure washer to clean
the vehicle. USE LOW PRESSURE ONLY
(such as a garden hose). The high pressure
may damage electrical or mechanical
components.
2. Remove any dirt or rust.

3. To clean plastic parts, use only flannel cloths
and XPS ATV wash or soapy water.
TYPICAL XPS ATV wash
1. CVT outlet hose
4. To clean vinyl parts, use only flannel cloths

Exhaust System and a mild non abrasive multipurpose cleaner.
Block muffler outlet using a rag to avoid intrusion
of small animals. Cleaner and degreaser PRO C1
NOTICE
It is necessary to use flannel cloths on plastic
parts to avoid damaging surfaces. Never
clean plastic parts with strong detergent, de-
greasing agent, paint thinner, acetone, prod-
ucts containing chlorine, etc. To avoid
damaging the glossy finish on Polypropylene
body parts, never use:
– Petroleum based cleaning products
– XPS ATV finishing spray
– XPS ATV cleaning kit
TYPICAL - RENEGADE MODEL ILLUSTRATED

5. To clean heavily soiled parts of the vehicle, in-
1. Muffler cluding metallic parts use the following.
2. Block with rag here
BRP heavy duty cleaner
47
Maintenance
Storage Procedure
6. Inspect the vehicle and repair any damage.

Touch up all metal spots where paint has been
scratched off.
7. Spray all metal parts with an appropriate lubri-
cant for rust protection.
Lubricant and anti-corrosive
Vehicle Protection
Protect the vehicle with a cover to prevent dust ac-
cumulation during storage.
NOTICE
The vehicle has to be stored in a cool and dry
place, and covered with an opaque tarpaulin.
This will prevent sun rays and grime from af-
fecting plastic components and vehicle finish.
48
Maintenance
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.
03
Clean drive and driven pulleys to remove storage
protective lubricant, then reinstall drive belt. Refer
to Continuously Variable Transmission (CVT).
Remove parts required to allow inspection of en-
tire engine air inlet system. Check for animal nests
and other foreign material. Reinstall removed
parts.
Drain fuel tank and fill with fresh fuel if a fuel stabil-
izer was not used for storage.
Reinstall battery. Refer to Charging System
subsection.
Inflate tires to the recommended pressure.
Do each items indicated in the table entitled:
Every 3 000 km (2,000 mi) or 100 hours
(whichever comes first)
EVERY 1 500 KM (1,000 MI) OR 50 HOURS
(whichever comes first)
N O T E : If the EVERY 6 000 km (4,000 mi) OR

200 HOURS OF OPERATION maintenance serv-
ice is due, also perform the related items as per
the maintenance schedule.
Test drive vehicle.
49
Maintenance
Special Procedures
Special Procedures
General
N O T E : Component failures resulting from these
events are not warrantable.
Refer to the appropriate subsections in this man- TYPICAL

ual for details of the required tasks as outlined in 1. Air filter housing drain reservoir
these procedures.
If water is present, press clamp and remove reser-
What To Do If Water Is In The CVT voir to drain water from air filter housing.
The CVT drain plug is located on the rear portion
If one of the following conditions is met, refer to
of the CVT cover. It is accessible from the rear LH
What to Do if vehicle is Immersed in Water:
fender.
– If more than 50 ml (2 fl oz(US)) of water (ap-
Inspect the CVT drain plug to validate if water is proximately 5 drain reservoirs) is found in the
present. air filter housing.
– If any deposits are present in the drain
reservoir.
NOTICE
Failure to service vehicle properly may lead
to component permanent damage.
What to Do if Vehicle is Turned Over

In the event the vehicle was rolled over tilted on it's
side; put the vehicle back on its wheel, wait 3 to 5
1. Drain plug minutes, then check the following:
2. Spring clamp – Inspect air filter housing for oil accumulation, if
any oil is found, clean air filter and air filter
NOTICE housing.
If water is present in the CVT, it could result – Check engine oil level and refill if necessary.
in belt slippage. The engine will accelerate – Check engine coolant level and refill if
but the vehicle will remain still. necessary.
– Check gearbox oil level and refill if necessary.
If water is present, remove CVT drain plug to expel – Check rear final drive oil level and refill if
water. necessary.
Reinstall the drain plug and secure it using the – Inspect suspension components and steering
spring clamp. system components.
– Inspect body and chassis for any damages.
N O T E : Make sure hose is properly inserted on – Start engine. If the oil pressure light stays on,
CVT cover nipple. stop engine immediately and investigate the
problem.
If an appreciable amount of water is drained from – After restarting engine, check for indicator
the CVT cover, remove the cover and properly lights or messages displayed in the multifunc-
service the CVT. tion gauge. Correct as required.
What to Do if Water is in the Air Filter Housing L i m i t e d m o d e l : Inspect ACS intake hose for any
Inspect the drain reservoir underneath the air filter trace of oil. Clean thoroughly if oil is found in hose.
housing to validate if water is present. If oil reached compressor, disassemble compres-
sor and clean thoroughly.
50
Maintenance
Special Procedures
Inspect all lights for water intrusion. Dry as

WARNING
required.
Do not use vehicle if any of the controls,
steering, suspension or brakes are damaged Inspect multifunction switch for water intrusion.
or inoperative. Dry as required.
Remove spark plugs. Crank engine in drowned
What to Do if Vehicle is Immersed in Water mode to expel any water.
In the event the vehicle was immersed, proceed
with the following. CAUTION
Keep away from spark plug holes to avoid
03
NOTICE being splashed when cranking engine.
A vehicle that was immersed may be dam-
aged or prone to malfunctions (short and long Add a small quantity of engine oil in cylinders (ap-
term) if not serviced promptly and appropri- proximately 2 teaspoonfuls).
ately. Do not crank or start engine.
Install spark plugs (replace if required).
Drain the entire air intake system. Inspect the
throttle body. Remove parts as required. WARNING
Before starting engine, use B.U.D.S. and
Inspect and clean air box as needed. Remove check vehicle for fault codes.
parts as required.
Replace the air filter. Start the engine and allow it to run at idle speed
until the engine reaches its operating temperature.
Drain, inspect and clean the CVT.
Stop the engine.
L i m i t e d m o d e l : Inspect ACS hose. If water is
present, disassemble and dry compressor. Change engine oil and filter.
Inspect front differential and rear final drive vents. N O T E : Change oil as many times as necessary,
Clean or replace as necessary. until there is no whitish appearance in engine oil.
Drain muffler and exhaust pipes (removal Replace front differential oil.
required).
Replace rear final drive oil.
Clean muffler spark arrester.
Lubricate front and rear suspensions and propeller
Remove fuse box covers. Check for presence of shaft joints.
water. Dry as necessary.
Spray all metal parts with (P/N 293 600 016).
Disconnect, clean and dry the following electrical
connectors: Test drive to confirm proper operation.
– ECM
– Multifunction gauge
– DPS.
Replace the engine oil (without starting the
engine).
Replace gearbox oil.
Inspect fuel tank for water intrusion. If in doubt,
flush fuel tank and refill with new fuel.
Inspect fuel tank vent system for water intrusion.
Clean as required. Replace breather filter. Carry
out a fuel pump pressure test.
Inspect brake system for water intrusion. Replace
brake fluid as required.
51
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
52
04
ENGINE
53
ENGINE
Engine Removal and Installation
04 ENGINE
Engine Removal and
Installation
SERVICE TOOLS
ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529 036 166) . . . . . . . . . . . . . . . . . . . . . . . . 75

ENGINE LIFTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036022) . . . . . . . . . . . . . . . . . . . . . . . . 60
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529 035 868) . . . . . . . . . . . . . . . . . . . . . 74–75
54
ENGINE
Outlander models
13 ± 2 N•m
(115 ± 18 lbf•in)
7 ± 1 N•m
(62 ± 9 lbf• in)
04
NEW
4 ± 1 N•m
(35 ± 9 lbf•in)
4.9 ± 0.4 N•m
(43 ± 4 lbf•in)
1000
1000
62.5 ± 7.5 N•m
(46 ± 6 lbf•ft)
62.5 ± 7.5 N•m
(46 ± 6 lbf•ft)
NEW = Component must be replaced when removed.
55
ENGINE
NEW
5 ± 1 N•m
(44 ± 9 lbf•in)
NEW
4 ± 1 N•m
(35 ± 9 lbf•in)
NEW
NEW
4.9 ± 0.4 N•m
(43 ± 4 lbf•in)
NEW
NEW
62.5 ± 7.5 N•m

(46 ± 6 lbf•ft) NEW = Component must be replaced when removed.
56
ENGINE
Procedures
Engine Removal (Twin Cylinders)
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
table.
References
Operations
(Subsection)
Safely lift and support
Introduction
the vehicle
TYPICAL 04
Fuel Tank and Fuel 1. RH footrest support
Release fuel pressure
Pump 5. Move throttle body aside to make room.
Periodic
Drain engine coolant Maintenance
Procedures
Remove front body
module
Body
Remove RH footrest
panel
Remove air filter housing Air Intake System
Remove muffler
Exhaust System
Remove exhaust pipes
TYPICAL
Remove CVT air inlet Continuously
Variable 6. Move master cylinder aside to make room.
Transmission (CVT)
Remove CVT air outlet in appropriate
Engine Service
Manual
Disconnect positive (+) Starting System
starter cable
Disconnect TPS
connector Electronic Fuel
Disconnect MAPTS Injection (EFI)
connector
Remove intake manifold Intake Manifold
Remove spark plug Ignition System TYPICAL
cables
7. Move crankcase vent hose as illustrated.
4. Remove RH footrest support.
57
ENGINE
TYPICAL TYPICAL - FROM LH SI DE

1. Crankcase vent hose 1. Ignition coil connector
8. Disconnect both engine harness connectors 12. Remove the following locking ties.
(HIC).
TYPICAL
TYPICAL 1. Locking ties
1. Engine harness connectors (HIC)
13. Remove plastic cover from engine.
9. Move ECM as illustrated.
TYPICAL TYPICAL
1. Plastic cover
10. Cut locking ties from ignition coil harness.
11. Disconnect ignition coil connector. 14. Remove harnesses support from engine.
58
ENGINE
TYPICAL
MAGNETO HARNESS
04
1. Harnesses support
15. Disconnect magneto connector from voltage 17. Disconnect vent hose from gearbox.
regulator rectifier.
TYPICAL
1. Vent hose
TYPICAL 18. Disconnect coolant hoses as illustrated.

1. Magneto connector
16. Remove magneto harness from its location

along vehicle and gather it in a bundle near
engine.
N O T E : It may be necessary to slightly lift the rear

body module to ease magneto harness removal.
Refer to BODY subsection.
WITHOUT EXTERNAL THERMOSTAT

1. Disconnect the following coolant hoses
59
ENGINE
2. Attach hoist to engine lifting tool and pick up

some of the engine weight with the hoist.
3. Remove retaining screws from upper engine
mount.
WITH EXTERNAL THERMOSTAT

1. Disconnect the following coolant hoses
19. Remove main ground wire from engine.

TYPICAL - LH SIDE
1. Upper retaining screws
4. Remove retaining bolt from rear engine mount.
TYPICAL
1. Main ground wire
Engine Lifting (Twin Cylinders)

1. Install the engine lifting tool on engine. TYPICAL - LH SIDE
1. Rear engine mount retaining bolt
Engine lifting tool
5. Remove retaining bolt from front engine
(P/N 529036022)
mount.
TYPICAL TYPICAL - LH SIDE

1. Front engine mount retaining bolt
60
ENGINE
6. At forward RH end of engine, remove engine

support plate from frame.
NOTICE
Heat screws in order to release threadlocker
prior to attempting to unscrew them. If not
done, the welded nuts may break away from
the frame bracket.
04
RH SIDE
1. Front propeller shaft bellows
9. Remove rear propeller shaft screw from gear-

box output shaft.
RH SIDE
1. Engine support plate screws
7. Remove the following Oetiker clamps from

front propeller shaft.
TYPICAL - RH SIDE
1. Rear propeller shaft screw
10. Slightly lift engine and move it forward to dis-

connect rear propeller shaft from engine.
11. Move rear propeller shaft yoke downwards to
make room.
RH SIDE
1. Oetiker clamps
8. Move front propeller shaft bellows forward.
TYPICAL
61
ENGINE
12. Move engine rearward to disconnect front pro-

peller shaft from engine.
13. Remove engine from RH side of vehicle.
TYPICAL
Engine Mount Installation (Twin Cylinders)

The installation is the reverse of the removal
procedure.
TYPICAL
Engine Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
1. Inspect condition of engine mounts.
2. Install engine on vehicle.
3. Install all engine retaining bolts loosely.
4. Install and tighten propeller shaft screw, refer
to Rear Drive subsection.
5. Tighten engine retaining bolts to specification.
Tightening Torque
62.5 ± 7.5 Nm
Engine retaining bolts
(46 ± 6 lbf-ft)
6. If applicable, fill engine as per specification.

Refer to Lubrication System in the appropriate
Engine Service Manual.
7. Fill and bleed cooling system, refer to Periodic
Maintenance Procedures subsection.
8. Check for any leaks.
9. Reinstall all the remaining parts as the reverse
of removal procedure. Refer to exploded views
and proper subsections.
10. Test drive vehicle to confirm proper operation.
Engine Mount Replacement
N O T E : Use the same procedure for the front and
rear engine mounts.
Engine Mount Removal
Insert a punch into engine mount bushing and
push the opposite engine mount out.
62
ENGINE
Air Intake System
Air Intake System

1.6 ± 0.4 N•m
(14 ± 4 lbf•in)
Loctite 5150
(silicone sealant)
6 ± 1 N•m
(53 ± 9 lbf•in)
04
Suspension
grease
6 ± 1 N•m
(53 ± 9 lbf•in)
Loctite 5150
(silicone sealant)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
To throttle body
To engine
63
ENGINE
Air Intake System
GENERAL 4. Remove screws securing CVT air inlet to air fil-

ter housing.
NOTICE
Never modify the air intake system. Other-
wise, 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 Mainte-
nance Procedures subsection.
Air Filter Housing
Air Filter Housing Removal TYPICAL
1. Remove front body module. Refer to Body 1. CVT air inlet screws
subsection.
5. Remove ECM retaining screws.
2. On applicable models, remove the following
plastic rivets.
1. ECM retaining screws
TYPICAL 6. Disconnect both engine harness connectors

1. Plastic rivets (HIC).
7. Move ECM aside.
3. On applicable models, move dashboard sup-
port toward front.
TYPICAL
TYPICAL
1. Dashboard support
8. Remove air intake tube retaining screw.
64
ENGINE
Air Intake System
04
1. Air intake tube retaining screw
TYPICAL - OUTLANDER SHOWN
9. Move air intake tube to gain access to coolant 1. Link rod retaining bolt
tank LH screw. 12. Carefully move link rod downward.
10. Remove coolant tank retaining screws.

AIR INTAKE TUBE MOVED TO GAIN ACCESS
1. Coolant tank LH retaining screw 13. Remove the following locking ties.

1. Locking tie to remove - location shown
1. Coolant tank RH retaining screw
11. Detach link rod from shift lever.
65
ENGINE
Air Intake System
TYPICAL - OUTLANDER SHOWN SCREWS LOCATED NEAR SEAT ANCHORAGE

1. Locking ties to remove 1. Air filter housing retaining screws
14. Detach gearbox vent hose from air filter
housing.
SCREW LOCATED UNDER COOL ANT TANK

1. Air filter housing retaining screw
TYPICAL
1. Gearbox vent hose
15. Detach crankcase vent hose from air filter

housing.
SCREW LOCATED ON L H SIDE - ACCESS FROM UNDER

SHI FT L EVER
17. Detach throttle body from intake adapters.

TYPICAL 18. Slightly lift air filter housing upward.
1. Crankcase vent hose 19. Move throttle body aside to make room.
16. Remove air filter housing retaining screws.
66
ENGINE
Air Intake System
04
TYPICAL
TYPICAL — OUTLANDER SHOWN 1. Plastic rivets
1. Throttle body
3. On applicable models, move dashboard sup-
20. Remove air filter housing by pulling it towards port toward front.
rear.
TYPICAL
AIR FILTER HOUSING REMOVAL 1. Dashboard support
21. Remove remaining components from air filter 4. Cut locking ties and move electrical connector
housing. away.
Removing the Air Filter Housing
1. Remove front body module. Refer to Body
subsection.
2. On applicable models, remove the following
plastic rivets.
1. Locking ties
5. Remove screws securing CVT air inlet to air fil-

ter housing.
67
ENGINE
Air Intake System
TYPICAL
1. CVT air inlet screws 1. Air intake tube retaining screw
6. Remove ECM retaining screws. 10. Move air intake tube to gain access to coolant
tank LH screw.
11. Remove coolant tank retaining screws.
1. ECM retaining screws
7. Disconnect both engine harness connectors

(HIC).
8. Move ECM aside. AIR INTAKE TUBE MOVED TO GAIN ACCESS
1. Coolant tank LH retaining screw
TYPICAL 1. Coolant tank RH retaining screw

12. Detach link rod from shift lever.
9. Remove air intake tube retaining screw.
68
ENGINE
Air Intake System
TYPICAL - OUTL ANDER SHOWN

1. Link rod retaining bolt
04
TYPICAL
13. Carefully move link rod downward. 1. Crankcase vent hose
16. Remove air filter housing retaining screws.
14. Remove the following locking tie.

SCREWS LOCATED NEAR SEAT ANCHORAGE
1. Air filter housing retaining screws

1. Locking tie to remove - location shown
15. Detach crankcase vent hose from air filter

housing.
SCREW LO CATED UNDER COOLANT TANK
69
ENGINE
Air Intake System
21. Remove remaining components from air filter

housing.
Air Filter Housing Inspection
Check air filter housing for cracks or other dam-
age. Replace if necessary.
Air Filter Housing Installation
Refer to applicable exploded views for tightening
torque.
SCREW L OCATED ON LH SIDE - ACCESS FROM UNDER

SHIFT LEVER
17. Detach throttle body from intake adapters.

18. Slightly lift air filter housing upward.
19. Move throttle body aside to make room.

1. Throttle body
20. Remove air filter housing by pulling it towards

rear.
AIR FIL TER HO USING REMOVALL
70
ENGINE
Exhaust System
Exhaust System
SERVICE TOOLS
ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529 036 166) . . . . . . . . . . . . . . . . . . . . . . . . 75

ENGINE LIFTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036022) . . . . . . . . . . . . . . . . . . . . . . . . 60
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529 035 868) . . . . . . . . . . . . . . . . . . . . . 74–75
SERVICE PRODUCTS 04
LOCTITE 767 (ANTI-SEIZE LUBRICANT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Single Cylinder Models
71
ENGINE
Exhaust System
Max Models
10 ± 2 N•m
(89 ± 18 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
NEW
Bolt down,
nut facing outwards
40 ± 1 N•m NEW
(30 ± 1 lbf•ft) 13 ± 1 N•m
(115 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
See tightening
sequence
72
ENGINE
Exhaust System
Twin Cylinder Models
Max Models
9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
04
13 ± 1 N•m
(115 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
NEW
Bolt down,
nut facing outwards
40 ± 1 N•m
(30 ± 1 lbf•ft)
10 ± 2 N•m
(89 ± 18 lbf•in) See tightening
sequence
9 ± 1 N•m
(80 ± 9 lbf•in) 9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in)
See tightening PRO series

sequence
73
ENGINE
Exhaust System
General Oxygen Sensor Voltage in BUDS2

WARNING
Voltage Reading Condition
Never touch exhaust system components im-
mediately after the engine has run. Indicates fuel mixture
too lean,
Procedures possible oxygen
Constant low voltage sensor fault,
Heated Oxygen Sensor (HO2S) possible fuel system
Oxygen Sensor Location fault,
The sensor is located on the exhaust pipe, be- possible air leak
tween the rear cylinder and the muffler. Indicates fuel mixture
Oxygen Sensor General Precautions too rich,
Take the following precautions to avoid sensor possible fuel system
Constant high voltage
malfunction: fault,
possible fuel canister
– Do not use any product on sensor probe. problem
– Do not expose sensor to water, oil, windshield
cleaner, anticorrosion oil, grease, terminal
Testing the Oxygen Sensor
cleaner, etc.
– Do not drop or use an oxygen sensor that has Testing for Oxygen Sensor Input Voltage
been dropped.
N O T E : This test validates the heater element
– Do not use any compound on sensor threads
circuit.
unless labeled as compatible with oxygen
sensor. 1. Ensure main power relay (R2) in installed in
– Do not use impact wrench or conventional fuse box 1.
socket type wrench to install sensor. 2. Disconnect the oxygen sensor connector.
– Do not allow sensor or wire to touch exhaust 3. Turn ignition switch ON.
system or any other hot component. 4. Using a multimeter set to Vdc, read the input
– Do not route sensor wires to create tension in voltage provided to the sensor heater.
the wires. This could cause faults or sensor
malfunction. Fluke 115 multimeter
Oxygen Sensor Troubleshooting (P/N 529 035 868)
Always use the BRP diagnostic software (BUDS2)
to check for fault codes. Carry out service actions.
In BUDS2, also check oxygen sensor voltage and Oxygen Sensor Connector
refer to following table. (Harness Side) Measurement
Oxygen Sensor Voltage in BUDS2 Pin
Voltage Reading C Battery ground Battery voltage

Condition
Normal oxygen sensor If Input voltage is good, refer to Testing the Re-
Varies 0.1 to 0.8 Volts operation in closed sistance of the Oxygen Sensor Heater and
loop Testing for Oxygen Sensor Circuit Continuity.
Oxygen sensor circuit If input voltage is not good, test the continuity
Constant 0.45 Volts open of the power circuit from the fuse in fuse box 1.
Refer to the applicable Wiring Diagram for
details.
If input voltage wire continuity is at fault, repair
or replace wiring or connector.
74
ENGINE
Exhaust System
Testing the Resistance of the Oxygen Sensor

Heater Oxygen Sensor Circuit Continuity Test
Test the resistance value of the oxygen sensor be-
Oxygen Resistance
tween the sensor pins as follows.
Sensor Pin @ 20 °C (68 °F)
Oxygen Resistance
Sensor Pin @ 20 °C (68 °F) A J1
Approximately B D2 Close to 0 Ω
C D
7 - 11 Ω D L2
If reading is not within specification, replace the If a resistance value is NOT as specified, repair
oxygen sensor. or replace the wiring and connectors.
Testing for Oxygen Sensor Circuit Continuity
04
Replacing the Oxygen Sensor
N O T E : This test validates the heater element cir- 1. Remove main power relay (R2) in fuse box 1.
cuit and the sensor circuits.
CAUTION
1. Remove main power relay (R2) in fuse box 1. Exhaust system and oxygen sensor may be
2. Disconnect ECM-B connector and install it on hot. To avoid possible injury, allow exhaust
the ECM adapter tool. system components time to cool before
3. Set the multimeter to "Ω". test for continuity be- proceeding.
tween the oxygen sensor harness connector
and the ECM adaptor as per following tables. 2. Disconnect oxygen sensor connector.
4. Test for continuity between the oxygen sensor 3. Cut locking tie securing oxygen sensor
harness connector and the ECM adaptor as harness.
per following tables. 4. Unscrew oxygen sensor from exhaust pipe.
Fluke 115 multimeter NOTICE
(P/N 529 035 868) Handle oxygen sensor with clean hands.
Oxygen sensor probe must remain free of oil,
grease, antiseize lubricant and any other for-
ECM adapter tool (P/ eign matter that could affect its operation.
N 529 036 166)
5. If a new oxygen sensor is installed, its threads
are already coated with an anti-seize product.
Sensor is ready for installation.
Oxygen Sensor Circuit Continuity Test 6. If the same oxygen sensor is installed, apply
Loctite 767 (anti-seize lubricant) on its first two
Oxygen Resistance threads.
Sensor Pin @ 20 °C (68 °F)
A C3
NOTICE
B G4 Always use a product that is oxygen sensor
Close to 0 Ω
C L1 safe.
D L2
75
ENGINE
Exhaust System
TYPICAL
1. Apply antiseize lubricant first two threads
2. Must be free of any product
NOTICE
Do not apply any antiseize lubricant to the 1. Muffler
sensor probe as it could affect its operation. 2. Remove bolts
3. Remove the muffler.

7. Screw sensor in exhaust pipe.
Inspecting the Muffler
Tightening Torque Check muffler and cover for cracks or other dam-
ages. Replace if necessary.
50 ± 10 Nm
Oxygen sensor Check if the rubber support is brittle, hard or other-
(37 ± 7 lbf-ft)
wise damaged. Replace if needed.
8. Install all other removed parts. Installing the Muffler
Spark Arrester For the installation, reverse the removal proce-
For spark arrester servicing, refer to Periodic dure. However, pay attention to the following.
Maintenance Procedures subsection. Install new exhaust gasket.
Muffler Heat Shield
Removing the Muffler Removing the Heat Shield
1. Loosen exhaust pipe clamp. 1. Refer to Body and remove following LH body
panels.
1. Muffler
2. Loosen clamp
LH SIDE
1. Side panel
2. Remove muffler retaining bolts. 2. Side panel extension
3. Rear panel extension (Max models)
2. Remove outer heat shield retaining bolts.
76
ENGINE
Exhaust System
NOTICE
Do not use impact tool to remove or install
heat shield bolts.
INNER HEAT SHIEL D

1. Inner heat shield
04
2. M6 x 16 bolts
4. 1 0 0 0 R m o d e l
5. Remove heat shield extension retaining bolts.
OUTER HEAT SHIELD
1. Heat shield bolts
3. Remove muffler for rear and inner heat shield

removal.
1. Outer heat shield extension

2. M6 x 16 bolts
REAR HEAT SHIEL D REMOVAL

1. Rear heat shield
2. M6 x 25 bolt
3. M6 elastic nut
4. M6 x 16 bolts with washers
1. Inner heat shield extension

2. M6 x 16 bolts
Installing the Heat Shield

FRONT INNER HEAT SHIEL D
77
ENGINE
Exhaust System
Refer to exploded view for torque specifications, Tightening Torque

and following illustration for rear heat shield tight-
ening sequence. 13 ± 1 Nm
Head pipe nuts
(115 ± 9 lbf-in)
Head Pipe (Front cylinder)

Removing the Front Head Pipe
1. Remove Y-pipe.
2. Refer to Body and remove rear part of RH in-
ner fender to reach head pipe screws (Out-
lander series only).
REAR HEAT SHIELD TIGHTENING SEQUENCE
Y-Pipe
Removing the Y-Pipe
1. Remove Muffler.
2. Remove Heat Shield.
3. Remove the following parts:
– Springs from head pipe
– Y-pipe retaining nuts on rear cylinder.
– Y-pipe from vehicle.
TYPICAL
1. Remove
3. From RH side of vehicle, remove head pipe re-

taining nuts.
TYPICAL LH SIDE
1. Y-pipe
2. Springs
Inspecting the Y-Pipe

Check Y-pipe for cracks, bending or other dam-
ages. Replace if needed.
Installing the Y-Pipe TYPICAL
1. Head pipe retaining nuts
procedure. However, pay attention to the 4. Remove front head pipe from vehicle.
following.
2. Install NEW exhaust gaskets and exhaust pipe
retaining nuts.
3. Properly position exhaust pipe before
tightening.
78
ENGINE
Exhaust System
570 - TIG HTENING SEQUENCE

04
TYPICAL
1. Head pipe
N O T E : The space to remove the front head pipe

is limited. Remove it without force.
Inspecting the Front Head Pipe
Check head pipe for cracks, bending or other ALL EXCEPT 570 - TIGHTENING SEQUENCE
damages. Replace if needed.
Check if the rubber support is brittle, hard or other-
wise damaged. Replace if needed.
Installing the Front Head Pipe
following.
2. Install NEW exhaust gaskets.
3. Refer to Exhaust System Tightening
Sequence.
Tightening Torque
13 ± 1 Nm
Head pipe nuts
(115 ± 9 lbf-in)
Exhaust System Tightening Sequence

1. Install all nuts and bolts loosely.
2. Install springs.
3. Tighten all fasteners as per following tightening
sequence. Refer to exploded view for torque
specifications.
79
ENGINE
Cooling System - Vehicle Components
Cooling System - Vehicle

Components
450 Engines
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
NEW
10 ± 2 N•m
(89 ± 18 lbf•ft)
Engine
10 ± 2 N•m
(89 ± 18 lbf•ft)
80
ENGINE
570 and 650 Engines
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
NEW
04
10 ± 2 N•m
(89 ± 18 lbf•ft)
10 ± 2 N•m
(89 ± 18 lbf•ft)
81
ENGINE
850, 1000 and 1000R Engines
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
NEW
NEW
10 ± 2 N•m
NEW (89 ± 18 lbf•ft) 1000R
850
NEW
82
ENGINE
General Start to Open Fully Open

NOTICE
65 °C 75 °C
Never start engine without coolant. Some en- (149 °F) (167 °F)
gine parts such as the rotary seal on the
water pump shaft can be damaged.
2. Replace the thermostat if it does not begin to
open at specified temperature.
Procedures 3. Check if the gasket is brittle, hard, or damaged.
Thermostat (on Cylinder Head) Replace as required.
Refer to appropriate Service Engine Manual. Installing the Thermostat
Thermostat (External of Engine The installation is the reverse of the removal pro-
Thermostat Location
cedure. However, pay attention to the following. 04
The thermostat is locate between the front cylinder 1. Install NEW Oetiker clamps.
head and the radiator, behind the RH front inner 2. Refill and bleed the cooling system.
fender. 3. Check cooling system for leaks.
Radiator
Inspecting the Radiator
Check radiator fins for clogging or damage.
Remove insects, mud or other obstructions with
compressed air or low pressure water.
Removing the Radiator
1. Drain engine coolant
2. Remove front body module. Refer to Body
subsection.
3. Disconnect radiator and fan assembly.
Removing the Thermostat

1. Drain the engine coolant.
2. Remove and discard the Oetiker clamps.
1. Radiator hoses
3. Remove the thermostat and its housing as a

unit.
Testing the Thermostat
1. Put the thermostat in water and heat the water.
83
ENGINE
Step 1. Remove upper retaining bolts

Step 1. Disconnect cooling fan connector Step 2. Remove radiator from bushings
Step 2. Remove the harness connector from the fan shroud
Installing the Radiator

following.
2. Ensure that rubber bushings are properly in-
stalled between frame and fan shroud.
3. Ensure that vent hose of the cooling fan motor
is properly rooted as prior to removal (if so
equipped).
NOTICE
If the vent hose of the cooling fan motor is not
properly rooted, the fan motor may be dam-
aged due to improper venting.
1. Remove fan motor vent hose (if equipped)
4. Tighten radiator upper retaining bolts to

N O T E : Take note of the rooting of vent hose on specification.
vehicle to ease reinstallation.
Tightening Torque
Radiator upper 10 ± 2 Nm
retaining bolts (89 ± 18 lbf-in)
5. Refill and bleed cooling system.

6. Check cooling system for leaks.
Radiator Cooling Fan
Troubleshooting the Radiator Cooling Fan
N O T E : The following troubleshooting chart as-
sumes that the engine is operating in the fan acti-
vation temperature range. Refer to Radiator
Cooling Fan Operation.
84
ENGINE
Cooling Fan Troubleshooting Chart

Is fan working? YES Everything is OK
NO
Check FAN fuse Replace fuse
Is fuse burnt? YES Is fan working?
NO
Bypass fan relay RY1
(refer to Relay Operation Test)
Fan turns? YES Replace relay 04

Is fan working?
NO
Apply 12 Vdc and a
ground to fan
connector
(refer to Radiator
Cooling Fan Test)
YES Replace fan

Fan turns?
Is fan working?
YES
Check CTS
(refer to Electronic
Fuel Injection (EFI) in
appropriate Engine
Service Manual)
Replace CTS
CTS works? ON Is fan working?
YES
Check wiring harness
and connectors
(refer to Wiring
Diagram)
Harness and Repair or replace

connectors good? ON defective part(s)
YES
Try a new ECM Is fan working?
Radiator Cooling Fan Operation

The ECM controls the radiator cooling fan via the
input of the coolant temperature sensor (CTS).
Refer to the following table.
85
ENGINE
Check –If cooling fan does not work, replace it.

Engine Cooling Gauge –If cooling fan works properly, refer to Radia-
Engine
Temp. Fan Message tor Cooling Fan Troubleshooting Chart.
Light
5. Reconnect radiator cooling fan connector.
95 °C
Turns ON __ __ Removing the Radiator Cooling Fan
(203 °F)
1. Remove the radiator.
93 °C 2. Remove radiator cooling fan retaining screws.
Turn OFF __ __
(199 °F)
Check
115 °C
ON Turns ON engine
(239 °F)
Hi Temp
118 °C Limp
(244 °F) ON Flashes
Home
Radiator Cooling Fan Fuse Location

The radiator cooling fan fuse is located in the front
fuse box, under the gauge support. Refer to fuse
box cover or Wiring Diagram.
F8 5A F11 30A F12 15A
START SWITCHCLOCK / HEADLAMPS DC OUTLET
R1 DEMARRAGE
HORLOGE PHARES SORTIE CC
FAN RELAY R3
RELAIS VENTILATEUR F15 5A
FUEL PUMP R5 ACCESSORIES RELAY 1. Cooling fan retaining screws
RELAIS ACCESSOIRES
POMPE ESSENCE HEADLAMPS RELAY R8
RELAIS PHARES BRAKE RELAY
F9 25A
RESETABLE COOLING FAN RELAIS FREINS
F14
ACC2
15A 3. Remove radiator cooling fan.
VENTILATEUR REDEMARRABLE TAIL LAMP
F5 5A
INJECTORS / IGNITION
F4 5A
SPEEDO / RELAY
Installing the Radiator Cooling Fan
R2 INJECTEUR / IGNITION RELAIS / CADRAN R4
MAIN RELAY
RELAIS PRINCIPAL F6 5A F7 5A
FUEL PUMP RELAY
RELAIS The installation is the reverse of the removal pro-
2X4WD POMPE ESSENCE
ECM
DESS 2X4RM
WINCH
TREUIL cedure. However, pay attention to the following.
Tighten cooling fan retaining screws to
Testing the Radiator Cooling Fan specification.
1. Disconnect radiator cooling fan connector.
Tightening Torque
Radiator cooling fan 10 ± 2 Nm

Radiator Cooling Fan Relay (RY1)

Relay Location (Radiator Cooling Fan)
The radiator cooling fan relay (RY1) is located in
the front fuse box, under the gauge support.
1. Cooling fan connector
2. Connect cooling fan connector pin B to a suit-

able 20 A fuse jumper and then directly to the
positive battery post.
3. Connect cooling fan connector pin A (BK wire)
directly to the negative battery post.
4. Check if cooling fan works properly.
86
ENGINE
F8 5A F11 30A F12 15A
START SWITCHCLOCK / HEADLAMPS DC OUTLET
R1 DEMARRAGE
HORLOGE PHARES SORTIE CC
FAN RELAY R3
RELAIS VENTILATEUR F15 5A ACCESSORIES RELAY
FUEL PUMP R5
RELAIS ACCESSOIRES
POMPE ESSENCE HEADLAMPS RELAY R8
RELAIS PHARES BRAKE RELAY
F9 25A RELAIS FREINS
F14 15A
RESETABLE COOLING FAN ACC2
VENTILATEUR REDEMARRABLE TAIL LAMP
F5 5A F4 5A
INJECTORS / IGNITION SPEEDO / RELAY
R2 INJECTEUR / IGNITION RELAIS / CADRAN R4
MAIN RELAY FUEL PUMP RELAY
RELAIS PRINCIPAL F6 5A F7 5A RELAIS
ECM 2X4WD WINCH POMPE ESSENCE
DESS 2X4RM TREUIL
Testing the Radiator Cooling Fan Relay

Relay Operation Test
1. Remove relay (RY1).
2. Bypass relay using a jumper. Refer to the ap- 04
propriate Wiring Diagram to locate proper
terminals.
3. If the radiator cooling fan is activated, replace
the relay.
Relay Continuity Test
Refer to Power Distribution and Grounds
subsection.
87
ENGINE
Shifter
Shifter
Loctite 243
NEW
5 ± 1 N•m
(44 ± 9 lbf•in) NEW
NEW
NEW
10 ± 2 N•m
(89 ± 18 lbf•in)
NEW
NEW
9 ± 1 N•m
NEW = Component must be replaced when removed. (80 ± 9 lbf•in)
88
ENGINE
Shifter
Procedures
Handle
Removing the Handle
04
1. Shift lever handle
Step 1. Loosen lock nut

Step 2. Unscrew shift lever handle
Installing the Handle

procedure.
Service Product
Shift lever threads Loctite 243 (blue)
Shift Lever
Removing the Shift Lever TYPICAL
1. Remove body parts as required. Refer to Body 1. Remove spring
subsection.
2. Secure vehicle using wheel chocks.
3. Place shift lever in N E U T R A L position.
TYPICAL
4. Remove parts as indicated in following

illustrations.
89
ENGINE
Shifter
1. Handle
TYPICAL 2. Ridge
A. Handle parallel with ridge
3. Check if shift lever works properly in all posi-

tions. Ensure throttle cable does not interfere
with shift lever in all positions.
N O T E : Shift lever must be perfectly centered
with the neutral position indicator when transmis-
sion is engaged in neutral.
TYPICAL
1. Locking tie to cut
5. Remove shift lever with shift lever support.

Inspecting the Shift Lever
1. Check shift lever for bending or cracks.
2. Check spring and bushing condition.
3. Check ball joint condition.
4. Replace all damaged parts.
Installing the Shift Lever 4. If adjustment is required, refer to Adjusting the
1. The installation is the reverse of the removal Shift Rod.
procedure. However, pay attention to the Shift Rod
following.
2. Adjust shift lever handle as per following Adjusting the Shift Rod
illustration. 1. Place shift lever in N E U T R A L position.
NOTICE
Move vehicle back and forth to ensure gear-
box is set in neutral position.

3. Remove body parts as required, refer to Body
subsection.
4. Loosen shift rod adjustment nuts.
N O T E : Be aware that a nut has LH threads.
90
ENGINE
Shifter

8. Check if shift lever is properly centered in neu-
tral notch. Readjust as required.
9. Hold adjuster steady and tighten lock nuts.
04
1. Adjustment nuts
5. Turn rod adjuster to center shift lever in neutral

notch.
1. Adjuster lock nuts tightened
10. Test the shifter to confirm that the system

works properly in all positions.
N O T E : Ensure shift rod ball joint is parallel with

shift plate. It may be necessary to realign shift rod
ball joint to ensure freedom of movement.
1. Shift rod adjuster
1. Shift rod ball joint

2. Shift plate
A. Parallel within +/- 5°
WARNING
After adjustment, make sure the PARK posi-
tion is also properly set.
Shift Plate
Removing the Shift Plate
A. Shift lever
B. Neutral notch
N O T E : Do not remove shift plate needlessly.
6. Move shift lever in R position then in H
position.
91
ENGINE
Shifter
1. Remove body parts as required, refer to Body

subsection.
4. Remove shift rod from shift plate.
1. Shift plate nut

2. Bolt
7. Remove shift plate.
1. Bolt
Inspecting the Shift Plate
2. Spacer Check shift plate for:
3. Nut
– Cracks
5. Trace an index mark on shift plate and shift – Bending
shaft. – Spline condition.
Installing the Shift Plate
procedure.
However, pay attention to the following.
1. Place gearbox in N E U T R A L position before
shift plate installation.
2. Position shift plate with the marking "ATV
OUT" visible outward.
3. Align shift plate using marks previously traced.
4. If there are no index marks, adjust shift plate
as per following illustrations.
1. Trace a mark on both parts
6. Remove shift plate nut and bolt.
92
ENGINE
Shifter
A
OU
T
ATV
3
4
04
1. "ATV OUT" marking this side
2. Forward edge of shift plate
3. Horizontal plane (top forward surface crankcase)
4. Center of bolt (secondary alignment reference)
A. 110° +/- 2.5°
5. Ensure that shift shaft protrudes shift plate as

per illustration.
1. Shift shaft end

2. Shift plate
A. 2.5 ± 1 mm (.1 ± .040 in)
6. Adjust shift rod, refer to Adjusting the Shift

Rod.
7. Tighten shift plate nut to specification.
Tightening Torque
9 ± 1 Nm
Shift plate nut
(80 ± 9 lbf-in)
93
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
94
05
ELECTRONIC MANAGEMENT SYSTEMS
95
Electronic Management Systems
Engine Management System (EMS)
05 Electronic Management Systems
Engine Management
System (EMS)
Single Cylinder
ECM
TPS/ETA
MAPTS IGN COIL

INJ
OPS CTS
GBPS
CPS
VSS
1. CPS = Crankshaft Position Sensor

2. CTS = Cooling Temperature Sensor
3. ECM = Engine Control Module
4. ETA = Electric Throttle Actuator
5. GBPS = Gearbox Position Sensor
6. IGN COIL = Ignition coil
7. INJ = Injector
8. MAPTS = Manifold Air Pressure and Temperature Sensor
9. OPS = Oil Pressure Switch
10. TPS = Throttle Position Sensor
11. VSS = Vehicle Speed Sensor
96
Twin Cylinders
ECM IGN COIL

TPS/ETA
MAPTS
INJ 2
CTS
INJ 1 05
KS
OPS
CPS
GBPS
4WD ACT
VSS
1. 4WD ACT = 4WD Actuator with 4WD Indicator Switch

2. CPS = Crankshaft Position Sensor
3. CTS = Cooling Temperature Sensor
4. ECM = Engine Control Module
5. ETA = Electric Throttle Actuator
6. GBPS = Gearbox position sensor
7. IGN COIL = Ignition coil
8. INJ 1= Injector 1
9. INJ 2 = Injector 2
10. KS = Knock Sensor
11. MAPTS = Manifold Air Pressure and Temperature Sensor
12. OPS = Oil Pressure Switch
13. TPS = Throttle Position Sensor
14. VSS = Vehicle Speed Sensor
97
General The ECM with single connector controls 5 main

System Description systems:
The ECM is located behind the LH panel. 1. Electronic Fuel Injection (EFI)
2. Cooling system (cooling fan)
3. Ignition system
4. Starting system
5. Fuel system
For the ECM with 2 connectors 7 main systems
that are controlled:
1. Electronic Fuel Injection (EFI)
2. Intelligent throttle control
3. Cooling system (cooling fan)
4. Ignition system
5. Starting system
6. Fuel system
TYPICAL
N O T E : For further information related to these
There are 2 types of ECM available on the ATV, systems, refer to the applicable subsection.
one with a single connector and the other with 2
connectors. The ECM reads input signals from various
switches, controls, and sensors, that it compares
ECM with single connector to predetermined parameters, makes computa-
tions, and provides control signal outputs required
for proper engine management.
The ECM also interacts through CAN bus with the
gauge module for various functions, information
exchange and display of messages. Refer to Con-
troller Area Network (CAN) and Gauge
subsections.
The ECM also features a permanent memory that
will store the information on the various ignition
keys programmed to the vehicle, fault codes, cus-
tomer information, and other engine information,
even when the battery is removed from the
vehicle.
Diagnostic Mode
ECM with 2 connectors The ECM features a self-diagnostic mode that is
activated on system power up (ignition key ON or
D. E. S. S. key installs) for certain systems and
components, and when the engine is running for
others.
Refer to Diagnostic and Fault Codes for more
information.
Monitoring System
The MONITORING SYSTEM monitors various
electrical and electronic components of the engine
The ECM ensures a high power output with clean control systems such as the:
combustion. – ETA (Electric Throttle Actuator)
The ECM is also the central point of the engine – TPS (Throttle Position Sensor)
management system. – TAS (Throttle Accelerator Sensor)
98
– ECM (Engine Control Module).

The engine management system provides for re-
dundancies in these components should a failure
or partial failure occur to which it will adjust system
operation to protect the vehicle and most of impor-
tantly, the driver.
Should the engine management system not re-
spond (or not respond correctly) to a failure, then
the monitoring system will react to ensure vehicle
and driver safety.
The monitoring system therefore ensures the en-
gine management system is functioning correctly.
Limp Home Mode
When a major component of the EMS is not oper-
ating properly, limp home mode will be set. 05
Engine RPM will be limited and/or engine behavior
and control may be modified depending on the
cause of the failure.
LIMP HOME will be displayed in the multifunction
gauge and the CHECK ENGINE light symbol will
be on in the gauge.
A failure of any of the following major components
will force the vehicle into LIMP HOME MODE:
– TPS / ETC / TAS
– Injectors
– Low oil pressure
– High engine coolant temp
– MAPTS signal fault.
99
Controller Area Network (CAN)
Controller Area Network

(CAN)
General
System Description
The CAN (Controller Area Network) protocol is an
ISO standard for serial data communication. The
CAN bus links the ECM, multifunction gauge and
DPS module together so that they can communi-
cate to each other and interact as required. The
components (modules) are connected together by
2 wires and are in constant communication at a
rate of about every 20 milliseconds. CAN lines
consist of a pair of wires (WHITE/BEIGE and
WHITE/BLACK).
If a component or system malfunction is detected,
a module (ECM, multifunction gauge or DPS) may
generate a fault code, which it transmits through
the CAN bus as a signal. The fault signal may be
used for various functions such as triggering the
display of an error message in the multifunction
gauge cluster, turning on a fault indicator light, lim-
iting or inhibiting vehicle or engine operation, or
viewed using the BRP diagnostic software
(BUDS2) for troubleshooting.
Using BUDS2, technicians may also communicate
through the diagnostic connector (DB) with elec-
tronic modules (ECM, Cluster, DPS, CCK) for vari-
ous reasons such as:
– Extracting data
– Programming a module
– Changing settings
– Viewing fault codes
– and for various other functions.
CAN-HI
WHITE/BEIGE
1 B-C1 19 J 1
CCK ECM CLUSTER DPS DB
2 B-C2 18 K 2
WHITE/BLACK
CAN-LO
1. CCK : Client Customization Kit (if applicable)
2. ECM: Engine Control Module
3. CLUSTER: Multifunction Gauge
4. DPS: Dynamic Power Steering
5. DB: Diagnostic Connector
6. WHITE/BEIGE: (wire color code)
7. WHITE/BLACK: (wire color code)
100
Communication Tools
Communication Tools Troubleshooting

Diagnostic Tips
General Refer to the BRP BUDS chart to ensure you are
Connect vehicle to the BRP Diagnostic Software using the appropriate hardware and tools.
BUDS2.
Troubleshooting the MPI Connection
Refer to the B.U.D.S. Directory on the Knowledge MPI Status Lights
Center for all B. U. D. S. related information, The MPI card includes 2 status lights that indicate
including: the connection condition: USB and CAN. Both
– Download link lights must be GREEN to function properly. Other-
– User manual (navigation through menus, pro- wise, refer to the following charts.
gramming keys, reading fault codes, writing
data to modules etc.)
– Installation instructions.
Refer to the BRP B.U.D.S. chart to ensure you are
using the appropriate hardware and tools. 05
Search keyword: "BUDS".
MPI-2 CARD
USB
Required Tools
CAN
Mandatory Tools
A personal computer (laptop or desktop)
MPI-2 interface card MPI-3 CARD
(P/N 529 036 018) Prerequisite for USB Communication:

– Computer turned on.
OR – MPI card connected to computer.
MPI-3 interface card Communication Problem (USB)

(P/N 529 036 353) Status What To Do
Check USB connection between
Diagnostic cable Light is MPI card and computer.
(P/N 710 000 851) OFF Check USB operation on computer
(hardware or USB drivers)
Optional Tool
Connections are GOOD.
Light is
Extension cable Communication can take place on
GREEN
available at electronic retail USB side
outlets.
Do not exceed 7.5 m (25 ft) Prerequisite for CAN Communication:
– MPI card connected to diagnostic connector
on vehicle.
– Computer turned ON
101
Communication Tools
– The D.E.S.S. key installed on the engine D.E.

S.S. post (if applicable).
– ECM is powered.
Communication Problem (CAN)

Status What To Do
– BUDS2 does not communicate

with
the vehicle.
– Check connections from computer
CAN
to vehicle.
Light is
– Check if BUDS2 is started. 1. Diagnostic connector
OFF
– Check if vehicle is powered: is
cluster turned ON? If it is not ON,
install the D.E.S.S. key on the
D.E.S.S. post (if apllicable).
This occurs when BUDS2 looses
communication with vehicle.
– Check connections from computer
CAN
to vehicle.
Light is
– Check if vehicle is powered: is
RED
cluster turned on ? If not, install the
D.E.S.S. key on the D.E.S.S. post
(if applicable).
CAN
Light is – Connections are GOOD.
GREE BUDS2 communicates normally
N with the vehicle.
Procedures
Multi-Purpose Interface Card (MPI-2 or MPI-3)
The MPI (Multi-Purpose Interface) in conjunction
with the diagnostic cable is used with BUDS2 to
communicate with the ECM (engine control mod-
ule) and other modules.
MPI Card Power
The MPI card uses the power from the computer's
USB port.
Diagnostic Connector Location
The 6-pin diagnostic connector is located under
the seat.
102
Diagnostic and Fault Codes

General
Monitoring System
The ECM features a monitoring system that self-diagnoses various electrical and electronic components.
This mode becomes active when the ignition key is turned ON.
NOTE: Some components require the engine to be running to be monitored (fuel injectors for
example).
The monitoring system continuously validates that the components (control modules, sensors and actua-
tors) are not faulty or defective. When a malfunction is detected, the related electronic module(s):
– Sets an active fault code.
– Adapts the proper protection strategy according to the failure.
– Sends out signals to the multifunction gauge to inform the rider of a particular condition.
If a minor fault occurs, the engine and vehicle will continue to operate without noticeable loss of 05
performance.
If a more important fault occurs, engine RPM may be limited. The engine/vehicle will continue to operate
with reduced performance.
If a major component of the Engine Management System (EMS) fails, engine RPM will be limited as well
as vehicle speed. Refer to Limp Home Mode in the Engine Management System subsection.
These strategies are used to protect engine and electrical system from damage and to maintain safe op-
eration of the vehicle. In extreme cases, the engine may also be completely shut down.
Messages in Gauge for Problematic Conditions
If an abnormal condition occurs, the gauge will display one of the following messages. It can be com-
bined with a pilot lamp.
Message Description
All active or previously activated faults that require attention.
CHECK ENGINE No engine limitation engaged.
Critical faults requiring diagnostic as soon as possible.
LIMP HOME An engine limitation is engaged and/or the engine behavior is modified.
LO BATT VOLT Low battery voltage detected by ECM.
HIGH BATT VOLT High battery voltage detected by ECM.
LOW OIL Low oil pressure detected by the ECM.

D.E.S.S. KEY NOT D.E.S.S. KEY is not recognized by ECM.
RECOGNIZED
HI TEMP High temperature detected by the ECM.
ECM CRC ERROR Error message from ECM.

TPS (throttle position sensor) fault, generally followed by a Limp Home
TPS FAULT message.
BRAKE SWITCH Brake signal fault.
FAULT
103
Message Description
ECM NOT Message displayed when the gauge is unable to identify the ECM.
RECOGNIZED
TRANSMISSION Gearbox position sensor fault active.
SIGNAL FAULT "E" is also displayed in the gear display.
When one or both sensor of the TAS (throttle accelerator sensor) is/are
PPS FAULT faulty, erratic or out of range or that the ratio between the two is incorrect,
the message will be displayed and the check engine pilot lamp will be lit.
When the TAS Limp Home (throttle accelerator sensor) is engaged, the
MANUAL LIMP HOME message will be displayed.
Limp Home Mode

Refer to Limp Home Mode in the Engine Management System subsection.
Fault Codes
Fault Code Categories
1. A fault code consists of an alphanumeric designator followed by a hexadecimal number of 3 digits.
The alphanumeric designator defines the category of the fault code while the hexadecimal number re-
fers to a unique fault.
Fault Code Categories

Module/ Example of Fault
Alphanumeric Designator
System Code
From P0 to P3 Power train P0116
Communication between module and
From U0 to U3 U0073
sensors
Related Module and Faults

Module Fault Code Category
ECM P and U
Cluster P and U
DPS P and U
Fault Code States

Fault codes have 3 possible states:
– Active
– Occurred
– Inactive.
Active Fault Codes
An active fault code is an indication of a fault that is c u r r e n t l y t r i g g e r e d .
The active fault may or may not compromise normal operation of the system(s). Service action should be
taken to correct the problem that caused the fault code.
Once the fault condition(s) of the active fault is no longer present, its state will change to "occurred".
104
Occurred Fault Codes

An occurred fault code indicates a fault that was active, but n o l o n g e r is.
The occurred fault does not presently affect system or component operation but is retained as a history
of the faults that were detected.
The fault may have been generated due to a system or component that was momentarily operating out-
side normal parameters. Repeated occurred faults of this type should be considered when troubleshoot-
ing a problem, and may require that maintenance action be taken.
An occurred fault may also be generated when disconnecting and reconnecting a component, replacing
a burnt fuse, when the software update of an electronic module has been carried out, or may be due to a
momentary high or low voltage.
Inactive Fault Codes
An inactive fault code represents a fault code that is neither active, nor occurred.
It is simply part of a list of all possible faults that can be monitored by the ECM and multifunction gauge,
which may become active or occurred if the monitoring system detects an applicable fault. 05
These codes can be viewed in BRP diagnostic software BUDS2.
Reading and Clearing Fault Codes
For more information pertaining to the faults code status and report, refer to BUDS2.
How to Read Fault Codes Using the Multifunction Gauge
Refer to the applicable Gauge subsection.
N O T E : A fault code must be in an "Active" state to be displayed in the multifunction gauge. BRP diag-
nostic software BUDS2 must be used to read all fault codes states.
How to Find Fault Code Descriptions
Connect BUDS2 to the vehicle.
Navigate to the F a u l t s page.
Browse lists of active/occurred and inactive fault codes.
Fault Code Diagnostic
Diagnostic Tips
To see the last two minutes of operating conditions, click on the S u m m a r y tab in BUDS2 and select
Statistics.
N O T E : The page displays data whatever there is fault code(s) or not.
105
General Guidelines to Solve Fault Codes

Condition Action
Use BUDS2 to:
Read fault codes.
Display "Active" faults to see components currently not operating
normally.
Display "Occurred" faults to troubleshoot intermittent problems.
Monitor system(s), sensor(s), switches and actual conditions.
Troubleshooting vehicle
Activate component(s) for troubleshooting.
Set components (resets etc).
Know the last minute of operating conditions by using the "History"
page.
Know the operating conditions, if available, when a fault code
occurred by using the "More details" button in the fault page.
Check sensor connections or mixed up connections.
B e f o r e vehicle maintenance:
Read the electronic modules with BUDS2
Save and print the BUDS2 file (keep faults option only).
New fault(s) appear after a
vehicle maintenance or repair A f t e r vehicle maintenance:
Read the electronic modules with BUDS2
Compare the fault code(s) before and after the maintenance using
the printed copy and the current reading.
Investigate only the newly fault codes.
Clear all occurred faults
Sensor "Active" fault Read the fault description in BUDS2
Check related fuse(s) and relay.
Check related power and ground wires.
Low system voltage on one
Check for common power supply to several sensors/modules (refer
module.
to power distribution and grounds).
Power problem on sensor(s)
N O T E : Some sensors are supplied by the battery while others are
supplied by a module.
Low system voltage on several
Check battery condition and connections.
modules
(several communication faults
Check voltage regulator/rectifier.
will also appear)
A battery charger has likely been used to substitute the vehicle
High system voltage on several battery.
modules Clear all occurred faults and check again.
Check voltage regulator/rectifier.
Check the module that is reported as missing.
When all modules report that a
module is missing
Check related power and ground wires.
When several modules are in Search for a common problem such as a faulty sensor.
fault
106
General Guidelines to Solve Fault Codes

Condition Action
When several modules and sensors report that a module is missing.
The missing module may report CAN bus off.
Check related CAN wires (continuity, short to ground, short between
CAN buss OFF CAN low and high).
Check module pins and wiring terminals.
Then, the other modules should stop reporting that module is
missing.
May have been generated due to a system or component that was
momentarily operating outside normal parameters.
May be generated when disconnecting and reconnecting a
component, replacing a burnt fuse, or may be due to a momentary
high or low voltage. 05
Occurred fault(s) Before being "Occurred", a fault has always been "Active" for a
certain time, indicating that an unexpected condition or problem has
been present during the driving cycle.
A frequent momentarily fault or an intermittent fault may never be
seen as "Active" in BUDS2 while there is still a pending problem.
This type of malfunctions can be discovered by looking at the
"Occurred" faults and then by evaluating the fault count.
As long as a fault is present, it is displayed as "Active".
L o w v a l u e : Suggests handling problems (connections, terminal
contact/
Fault count
shape etc.).
(0 - 255)
H i g h v a l u e : Suggests a frequent and unsolved problem.
The problem should be investigated.
Fault conditions Look for abnormal, excessive values.

When the basic troubleshooting has been done and the fault code(s)
persists, often the problem is related to the wiring harness,
connections or electromechanical components.
Hard to find problems Short to ground, to battery or between wires.
Wire splices, chafing, terminal problems (pulled out, bent, out of
shape, corroded etc.).
Bad contacts in switch or relay.
ECUs share information and their systems may interact with each other. Certain faults may cause more
than one ECU to set a fault code or indication (pilot lamp or message) as the failure of some components
may affect the operation of several systems.
107
Specific Faults
TPS Fault
A TPS fault may be considered to be a major fault as the TPS provides the most important feedback (2
signals) to the ECM on throttle position.
A TPS fault affects engine control as the throttle plate is moved by the ETA (electric throttle actuator)
which, is controlled by the ECM (see Intelligent Throttle Control (ITC) subsection).
A TPS fault is generally followed by LIMP HOME mode and the engine is brought back to idle, or may be
completely shutdown.
Low Battery Voltage Fault
If the battery voltage is low when the engine is running at idle RPM, the ECM will command an increase
in RPM to a set value, thereby increasing the charging system output in order to prevent the battery from
being discharged, and to allow normal system operation.
TAS Fault
If one TAS (throttle accelerator sensor) signal is missing, LIMP HOME MODE will be activated and the
check engine light will come ON. Pressing and holding the OVERRIDE button will allow normal control of
the accelerator pedal.
If both sensors in the TAS are at fault, a TAS FAULT message will appear in the gauge, the check engine
light will come ON and the engine will run at idle. The accelerator pedal will not have any affect on engine
RPM. However, the vehicle may be driven in LIMP HOME MODE by pressing the OVERRIDE button.
When limp home mode is engaged using the override button, a MANUAL LIMP HOME message will ap-
pear in the gauge. The OVERRIDE button can then be used as the accelerator, vehicle speed is con-
trolled by pressing and/or releasing the button.
Brake Activation Fault Message in Gauge
If a brake signal is received continuously for 15 seconds above 5 km/h (3 MPH), a BRAKE message will
be displayed in the gauge.
108
06
FUEL SYSTEM
109
Fuel System
Intelligent Throttle Control (iTC)
06 Fuel System
Intelligent Throttle The position of the throttle is measured with two

potentiometers.
Control (iTC) The ECM evaluates the throttle position with these
two measures and controls the motor to reach the
General desired position.
System Description
The iTC is an electronic throttle control system These potentiometers are powered by the ECM
often referred to as a "throttle by wire" system. with a voltage of 3.3 volts.
This system recives information from the following The signals given by these potentiometers vary
components: from 0.33V to 2.97V for (SIGNAL 1) and 2.97V to
0.33V for (SIGNAL 2).
– Throttle Accelerator Sensor (TAS) - located in
the throttle housing The relation between these two signals is (SIG-
– Electronic Throttle Actuator (ETA) - located on NAL 1) + (SIGNAL 2) = 3.3V.
the throttle body
When ECM is woken up, throttle body will close
– Engine Control Module (ECM)
completely to reinitialize. For both signals to be
properly set at idle position.
If a problem occurs with any of these controls or
signals then a diagnostic fault code will be
generated.
Learning Key (If Equipped)
The learning key limits the torque and speed of
the vehicle, therefore enabling first time users and
less experienced operators to learn how to oper-
ate while gaining the necessary confidence and
control.
To adjust the speed limiter, Refer to Radio Fre-
TYPICAL
quency digitally encoded security system (rf d.e.s.
1. Throttle lever s.) subsection.
Procedures
Throttle Accelerator Sensor (TAS)
General
1. The throttle accelerator sensor (TAS) is a dou-
ble hall effect sensor, which translates the po-
sition of the lever into two analog voltage and
sends a signal to the ECM which is proportion-
al to the throttle lever angle.
2. These Hall effect sensors are powered by the
ECM with a voltage of 5.0 volts.
3. The signals given by these sensors vary from
1. Throttle body 0.53V to 3V for (SIGNAL 1) and 0.25V to 1.5V
2. ETA connector for (SIGNAL 2).
The ETA is an electric motor which controls the 4. The relation between these two signals is (Sig-
throttle opening. nal 1) = (Signal 2) X 2.
5. If a problem occurs with any of these signals
then a diagnostic fault code will be generated.
110
Fuel System
Replacing the TAS

1. Refer to appropriate subsection and remove:
– LH inner fender panel
– Multifunction gauge.
2. Disconnect RSS and TAS connectors.
1. Throttle lever
6. First ensure the throttle lever functions ad-

equately. Apply throttle lever fully then release
it. It must reach the wide open position and re-
turn to the idle position freely when released.
Otherwise, refer to Steering System for PARTS REMOVED FOR CLARITY
inspection. 1. RSS connector 06
Testing the TAS Voltage
1. Disconnect TAS connector and measure volt-
age on the main harness side.
3. Cut locking ties securing TAS harness.
TAS Connector Test

Pin Measurement
B and A 5V
D and E 5V
2. If not 5V, ECM might be defective, oxidation

might be present in circuits or terminals might
not have good contact.
1. TAS connector
3. Reconnect TAS connector and backprobe to 2. Locking tie
measure voltage.
4. If 2 for 1 relation is not met for signal 1 and 2 4. Remove TAS housing retaining screws.
ratio, then TAS sensor is defective. Refer to
Replacing the TAS in this subsection for re-
placement procedure.
111
Fuel System
Drive Mode Switch (If Equipped)

Testing the Drive Mode Switch Operation
Installing the TAS Housing

procedure. However, pay attention to the 1. Drive mode switch
following.
2. Tighten TAS housing retaining screws to speci- 1. Remove gauge support and gauge.
fication in the following order.
Step 1. Remove gauge support

Step 2. Remove gauge
Tightening Torque 2. Disconnect RSS connector and measure on

the switch connector side.
TAS housing retaining 3.5 ± 0.5 Nm
3. Turn handlebar completely from side to side

making sure it does not exert unwanted ten-
sion on handlebar wires.
PARTS REMOVED FOR CLARITY

1. RSS connector
N O T E : The RSS connector will have red tape

around it.
112
Fuel System
3. Set multimeter to Ω.
4. Test the drive mode switch for continuity as per
following table.
Drive Mode Switch Connector Test

Measure
Position Pin
ment
Left 4 and 5 0Ω
Released 4 and 5 Infinite (OL)
Right 5 and 6 0Ω
4WD/6WD SWITCH
Released 5 and 6 Infinite (OL)
1. 4WD/6WD Switch
2. 6WD position
If the drive mode switch does not test as specified,
3. 4WD position
replace the TAS assembly.
1. Disconnect right steering switch (RSS) con-
2WD/4WD/6WD Switches
nector and measure on the switch connector
Testing 2WD/4WD/6WD Switch side.
2. Set multimeter to Ω
06
3. Test switch for continuity as per the following
tables.
2WD/4WD Switch Test
Without Visco-4Lock
Switch
Switch Position Specification
Connector Pin
1 to 2 Open circuit
2WD
2 to 3 Close to 0 Ω
4WD
2WD/4WD SWITCH 2 to 3 Open circuit
1. 2WD/4WD Switch
2. 4WD position 2WD/4WD Switch Test
3. 2WD position With Visco-4Lock
Switch
Connector Pin
1 to 2 Open circuit
2WD
1 to 3 Open circuit
4WD
1 to 3 Open circuit
4WD Lock
2WD/4WD SWITCH WITH 4WD-L OCK
1. 2WD position
2. 4WD position
3. 4WDLock position
4. 4WDLock telltale
113
Fuel System
4WD/6WD Switch Test

To replace throttle body assembly. Refer to Elec-
tronic Fuel Injection (EFI).
Switch
Connector Pin
1 to 2 Open circuit
4WD
6WD
2 to 3 Open circuit
If the results are not within specifications, re-

place the ETC (Electronic Throttle Control)
assembly.
If the result is within specification, test continu-
ity of wiring, refer to the appropriate wiring
diagram.
Electronic Throttle Actuator (ETA)
The ETA is part of the throttle body.
The ETA is an electric motor that receives signals
from the ECM to control the throttle plate opening.
N O T E : As a first troubleshooting step, always

check for applicable fault codes using the BRP di-
agnostic software (BUDS2).
Testing the ETA Voltage
1. Disconnect ETA connector on throttle body
and measure on the engine harness.
ETA Connector Test
Engine Measure
Pin
ment
570, 650 and
2 and 6
1000
3.3V
450, 850 and
2 and 3
1000R
2. If not 3.3V, ECM is might be defective, oxida-

tion might be present in circuits or terminals
might not have good contact.
3. Reconnect ETA connector and backprobe to
measure voltage.
4. If (Signal 1) + (Signal 2) does not equal 3.3V,
then the ETA is defective, replace throttle
body. Refer to Throttle body in Electronic Fuel
Injection (EFI) subsection.
Replacing the ETA
The ETA comes assembled with the complete
throttle body unit.
114
Fuel System
Fuel Tank and Fuel Pump

SERVICE TOOLS
FUEL HOSE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529 036 396) . . . . . . . . . . . . . . . . . . . . . . . 118

FUEL PUMP NUT TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529 036 427) . . . . . . . . . . . . . . . . . . . . . . . 127
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529 036 395) . . . . . . . . . . . . . . . . . . . . . . . 118
SMALL HOSE PINCHER . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 295 000 076) . . . . . . . . . . . . . . . . . . . . . . . 131
VACUUM/PRESSURE PUMP . . . . . . . . . . . . . . . . . . . . . . (P/N 529 021 800) . . . . . . . . . . . . . . . . . . . 119, 131
06
115
Fuel System
NEW
NEW
To engine
29 ± 1 N•m
NEW (21 ± 1 lbf•ft)
NEW
6.5 ± 0.5 N•m

(58 ± 4 lbf•in)
NEW
NEW
6.5 ± 0.5 N•m

(58 ± 4 lbf•in) 6.5 ± 0.5 N•m
NEW (58 ± 4 lbf•in)
NEW
NEW NEW
6.5 ± 0.5 N•m
(58 ± 4 lbf•in)
116
Fuel System
General
WARNING
Fuel is flammable and explosive under cer-
tain conditions. Ensure work area is well ven-
tilated. Do not smoke or allow open flames or
sparks in the vicinity.
WARNING TYPICAL - FUEL TANK VENT SYSTEM

1. Vent hose
Always disconnect battery prior disconnect- 2. Vent system hose inlet
ing a fuel system pressure hose. 3. Vent system connected to fuel pump
4. Fuel tank
5. Engine air intake system
WARNING Air can enter the fuel tank at all times through the
Always proceed with care and use appropri- vent system INLET check valve. This prevents
ate safety equipment when working on pres- negative pressure within the fuel tank which could
surized fuel system. Wear safety glasses. cause fuel starvation.
WARNING
Do not allow fuel to spill on hot engine parts 06
and/or on electrical connectors.
When the repair is completed, ensure that all ho-

ses are connected and secured. Perform the Fuel
Pressure Test and the Fuel Tank Leak Test as ex-
plained in this subsection.
Fuel lines remain under pressure at all times. Pro-
ceed with care when removing/installing high pres-
sure test equipment.
TYPICAL - AMBIENT AIR PRESSURE IN
Use the BRP diagnostic software (BUDS2) or dis- 1. Vent inlet check valve
connect the fuel pump electrical connector to dis- The vent inlet check valve also prevents fuel from
able fuel pump and crank engine to release fuel flowing out through the inlet of the vent system.
pressure prior to disconnecting any fuel hose.
If the pressure in the fuel tank builds up and ex-
Cover the fuel hose connections with an absorb- ceeds 2.5 - 7.6 kPa (.36 - 1.1 lbf/in²), the pressure
ent shop rag and carefully disconnect them to min- relief valve opens and lets the excess pressure
imize spilling. evacuate through the vent system OUTLET hose.
System Description
Fuel Tank Vent System
The fuel tank is equipped with a vent system that
provides over pressure relief and negative pres-
sure relief of the fuel tank.
TYPICAL - OVER PRESSURE RELIEF

1. Outlet pressure relief valve
117
Fuel System
Fuel Tank Vent Breather Filter and the fuel pump, and allows for checking the fuel
The vent system is equipped with an in-line system for leaks (high pressure side).
breather filter that prevents entry of particles such
as dust or small insects. It is located next to the N O T E : Refer to the Fuel System Diagnostic
fuel pump, on the inlet hose, before the air inlet Flow Chart in this subsection to help diagnose a
check valve. fuel system related problem.
To access the fuel tank vent breather filter, re- 1. Ensure the fuel level in the tank is sufficient.
move the rear body module. 2. Ensure the battery voltage is over 12 volts.
3. Remove seat.
4. Remove RH side body panel, refer to Body
subsection.
5. Remove the fuel pump relay in the front fuse
box.
6. Release fuel pressure by running engine until it
runs out of gas.
7. Carefully disconnect the fuel hose fitting from
the injector fuel rail by pressing on the release
tab of the quick disconnect fitting.
8. Remove the 2 most forward locking ties secur-
ing the fuel hose to the upper cable support.
N O T E : This is required to provide more hose

TYPICAL
1. Fuel tank vent breather filter length for proper connection to test equipment.
Fuel Pump Module

The fuel pump module is inserted in the fuel tank.
It provides fuel delivery for the EFI system and en-
compasses the following components:
– Electric fuel pump
– Fuel pump prefilter (replaceable)
– Fuel pump filter (integrated)
– Fuel pressure regulator
– Fuel level sender.
Fuel Filters
The system comprises two levels of filtration:
– A replaceable pre-filter element attached to the
1. Forward injector rail fitting
bottom of the fuel pump. 2. Locking ties
– A non-replaceable fine filter element that is in-
tegral to the fuel pump module. 9. Install the fuel pressure gauge and fuel hose
adapter between the disconnected injector
Fuel Pump Pressure Regulator hose and fuel rail (in-line installation).
The fuel pressure regulator is integral to the fuel
pump module. The pressure regulator maintains Pressure gauge (P/N
proper fuel pressure for the EFI system. 529 036 395)
Inspection
Fuel System Pressure Test
The pressure test will show the available pressure
in the system. It validates the pressure regulator Fuel hose adapter
(P/N 529 036 396)
118
Fuel System
PRESSURE GAUGE SETUP 1. Fuel tank vent inlet hose

1. Pressure gauge to fuel hose adapter 2. Gauge connector
2. Fuel hose adapter to fuel rail
3. Fuel hose adapter to fuel pump pressure hose
Time Without
10. Reinstall the fuel pump relay. Pressure Pressure Drop
11. Turn ignition key ON or press briefly the
START/STOP button and observe fuel 14 kPa (2 lbf/in²) 3 minutes
pressure. 06
If pressure drops, locate fuel leak(s) and repair
350 ± 10 kPa or replace leaking component(s).
Fuel Pressure (51 ± 1 lbf/in²)
To locate a leak, check for a fuel smell or leak-
ing fuel.
N O T E : Valid at 12v ± 0.1v.
To ease locating leak(s), spray soapy water on
12. Start engine and observe fuel pressure. all hose connections and components; bubbles
13. Stop engine. will indicate the leak location(s).
14. Remove test equipment and reconnect fuel
hose to injector fuel rail by proceeding in the Test Conclusion
same manner as for its installation. The fuel pressure should be within specification in
static or dynamic tests.
Fuel Tank Leak Test
Rapid Pressure Drop
WARNING
If there is a rapid pressure drop after the engine is
Always carry out a fuel tank leak test when- stopped, check for leakage at:
ever the fuel tank shows signs of wear or
damage which may cause a leak, or when the – A fuel hose
fuel pump has been removed or replaced, or – A fuel rail.
if you suspect a leak. If the fuel tank is dam- N O T E : The fuel pump check valve integral to the
aged, the fuel tank should be replaced even if fuel pump module may also be at fault.
no leak is present. Do not attempt to repair
the fuel tank. If no leak is detected, replace fuel pump.
1. Refill fuel tank and ensure fuel tank cap is in Slow Pressure Drop
good condition and properly installed. If there is a slow pressure drop after the engine is
2. Remove the gauge support for access to the stopped, check for a fuel injector leak. Refer to
fuel vent inlet hose. Electronic Fuel Injection (EFI) subsection.
3. Pressurize the fuel tank through the vent hose.
N O T E : The fuel pressure regulator or fuel pump
Vacuum/pressure check valve integral to the fuel pump module may
pump (P/N 529 021 also be at fault.
800)
If no leak is detected, replace fuel pump.
119
Fuel System
Troubleshooting
Fuel System Diagnostic Flow Chart
Fuel pump does not run Activate electric system to enable fuel pump Fuel pump runs
for 2 sec. then stops
Check fuse, relay and connections. Install fuel pressure gauge

Check fuel pump operation. on fuel pressure line
Repair or replace if necessary.
Activate electric system to enable fuel pump Replace fuel

pump module
Fuel pump runs
Repair or Fuel pressure less Fuel pressure within Fuel pressure more
replace than specifications specifications than specifications
Fails
Check fuel line/
rail for leaks
Fails OK Crank or
Perform fuel pump test start
OK
Fast Fuel pressure less Fuel pressure more Fuel pressure within
pressure drop than specifications than specifications specifications
No
Yes
Check
OK fuel line/
Verify fuel
pump check rail for leaks Repair or
valve Fails
replace FUEL SYSTEM OK
Fails OK
Fails
OK
Check fuel Perform fuel Replace fuel
injector pump test pump module Retest
OK
120
Fuel System
Procedures 5. Refer to Exhaust System and remove the

Fuel Hose and Oetiker Clamps following:
Disconnecting a Fuel Pressure Hose – Muffler assembly

– Muffler/exhaust pipe heat shield.
1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2). 6. Remove rear frame, refer to Frame subsection.
2. In BUDS2, go to: 7. Disconnect the following from the fuel pump
module:
– F u n c t i o n page
– I O C o n t r o l button – Fuel pump electric connector
– Execute Fuel Pressure Relief – Fuel system vent hose
– Fuel pump pressure hose.
3. Carefully disconnect the fuel hose fitting from
the injector fuel rail by pressing on the release
tab of the quick disconnect fitting.
Replacing the Fuel Hose
When replacing fuel hoses, be sure to use hoses
and clamps as available from BRP. This will en-
sure continued proper and safe operation.
WARNING 06
Use of fuel lines other than those recom-
mended by BRP may compromise fuel sys-
tem integrity.
1. Fuel pump connector
WARNING 2. Vent hose
3. High pressure fuel hose
Whenever removing a hose in the fuel sys-
tem, always use new Oetiker clamps at as- 8. Disconnect the RED (+) battery cable from the
sembly. Then validate fuel system tightness starter solenoid.
by performing a fuel pressure test. 9. Remove the 2 screws that secure the front of
the battery support.
Replacing the Oetiker Clamp
Required Tool
Oetiker plier
(P/N 295000070)
Fuel Tank
Draining the Fuel Tank
Remove fuel tank cap and siphon gas into an ap-
proved fuel container.
1. Battery support
Removing the Fuel Tank 2. Support retaining screws
1. Drain fuel tank. Refer to Draining the Fuel Tank

in this subsection. N O T E : It is not necessary to remove the wiring
2. Disconnect the fuel pressure hose from the harness or other components from the battery
fuel injector fuel rail. support.
3. Disconnect and remove the battery.
4. Remove the rear body module, refer to Body 10. Flip the battery support over towards the RH
subsection. side of the vehicle for access to the rear frame
extension.
121
Fuel System
TYPICAL
1. Battery support
2. Rear frame extension 1. Final drive unit
2. Vent tube to remove
11. Remove the upper mounting bolt from both
15. Remove fuel tank retaining screws (4).
rear shock absorbers.
N O T E : Note position of washers and bushings
on each screw.
TYPICAL
1. Upper shock mounting bolts
12. Block the front wheels with wheel chocks.

13. Lift back end of vehicle and properly support
under the lower rear portion of the frame, near 16. Loosen the front 2 nuts and remove the 4 bolts
the final drive. retaining the frame extension.
CAUTION
Before working on vehicle, ensure the vehicle
is securely supported.
14. Remove vent tube from final drive.
17. Remove nuts and screws securing trailer hitch/

final drive protector and rear frame support to
rear final drive.
122
Fuel System
TYPICAL
1. Trailer hitch TYPICAL
2. Bolts to remove 1. Rear shock absorbers
2. Fuel tank
18. Remove 2 nuts and screws securing rear
frame support to rear frame section. Removing the Fuel Tank
1. Drain fuel tank, refer to Draining the Fuel Tank.
2. Remove the fuel pump relay in the front fuse 06
box.
3. Release fuel pressure by running engine until it
runs out of gas.
4. Disconnect and remove the battery.
5. Remove the flat bed or the cargo box, refer to
Body subsection.
6. Refer to Exhaust System and remove the
following:
– Muffler assembly
– Muffler/exhaust pipe heat shield.
7. Remove rear frame. Refer to FRAME
subsection.
8. Disconnect the following from the fuel pump
module:
– Fuel pump electric connector
– Fuel system vent hose
19. Lift up on frame extension and pull fuel tank

out of vehicle.
N O T E : When lifting up on the frame extension,
the shock absorbers will fall backwards.
123
Fuel System
1. Battery support
2. Support retaining screws

2. Vent hose N O T E : It is not necessary to remove the wiring
harness or other components from the battery
9. Disconnect the positive (+) battery cable from support.
the starter solenoid.
11. Flip the battery support over towards the RH
side of the vehicle for access to the rear frame
extension.
TYPICAL
1. Starter solenoid
2. Positive (+) battery cable to disconnect TYPICAL
1. Battery support
10. Remove the 2 screws that secure the front of 2. Rear frame extension
the battery support.
12. Remove the upper mounting bolt from both
rear shock absorbers.
1. Upper shock mounting bolts
13. Remove vent tube from middle drive.
124
Fuel System
1. Middle drive unit 1. Upper frame support (welded)

2. Vent tube to remove
17. Lift up on frame extension and pull fuel tank
14. Remove fuel tank retaining screws (4). out of vehicle.
N O T E : Note position of washers and bushings N O T E : When lifting up on the frame extension,
on each screw. the shock absorbers will fall backwards.
06
TYPICAL
15. Loosen the front 2 nuts and remove the 4 bolts 1. Rear shock absorbers
retaining the frame extension. 2. Fuel tank
Inspecting the Fuel Tank

1. Inspect fuel tank for any damages or cracks
which may result in fuel leaks.
2. Inspect fuel tank and fuel tank protector on
frame for damages.
3. Inspect protector for damages.
4. If cracks, gouges or other damages which may
lead to a fuel leak, or damages to attachment
points that could prevent the tank from being
secure are found, replace fuel tank.
Installing the Fuel Tank
1. Installation is the reverse of the removal proce-
1. Frame extension dure. However, pay attention to the following.
2. Loosen these 2 nuts 2. Install a bushing on each fuel tank mounting
3. Remove these 4 bolts
screw. The bushing inserts within the fuel tank
16. Remove upper frame support. screw hole cavity.
125
Fuel System
3. Be sure to install the washers between the fuel

tank and the fastener as noted at removal.
4. Install a l l fuel tank fasteners loosely.
NOTICE
The fuel tank fasteners must not be tightened
to specified torque until complete assembly
in vehicle.
5. Install all frame component fasteners loosely,

then apply torque as specified in the Frame
subsection.
6. Apply specified torque to fuel tank retaining
screws.
Tightening Torque TYPICAL
2. Fuel tank
Fuel tank retaining 6.5 ± 0.5 Nm 3. Underside of RH rear fender
Testing the Fuel Pump Input Voltage
7. Be sure to properly connect and route: 1. Disconnect the fuel pump connector.
– Fuel tank vent tube 2. Activate the electrical system.
– Fuel pump pressure hose 3. Read voltage as follows.
– Electrical connectors.
N O T E : The fuel pump voltage will be read only
8. Refuel tank and ensure there are no leaks by when the fuel pump is activated.
performing a Fuel Tank Leak Test and a Fuel
Pump Pressure Test. Fuel Pump Input Voltage Test
Fuel Pump
Voltage
Test Probes Reading
Fuel Pump Quick Test
1. Turn ignition key to ON. Fuel pump Fuel pump
2. Listen for fuel pump operation. Battery
connector connector voltage
N O T E : Fuel pump should come ON for a few Pin 3 Pin 4
seconds, then stop.
If battery voltage is read, carry out a fuel pump
3. If fuel pump does not come ON, carry out the resistance test.
following: If battery voltage is not read, test fuel pump
– Check fuel pump relay fuse and fuel pump power input as follows.
relay.
– Check in BRP diagnostic software (BUDS2) Fuel Pump Power Wire Test
for applicable fault codes.
Voltage
– Carry out a fuel pump input voltage test. Test Probes Reading
Accessing the Fuel Pump Connector
Fuel pump Battery Battery
The fuel pump connector can be accessed from connector
under the RH rear fender, just above the forward ground voltage
Pin 3
end of the fuel tank.
If battery voltage is now read, check fuel pump
ground circuit between fuel pump connector
FP-4 and battery ground.
If battery voltage is still not read, check the
following:
126
Fuel System
– Fuse Fuel Pump Resistance Test

– Fuel pump relay (at Fuel Pump Connector)
– Fuel pump relay input voltage (control and
power circuits) Pins 3 and 4 Approximately 2 Ω
– Fuel pump relay control circuit continuity to
ECM-J1 5. If test failed at pump connector, replace fuel
– Fuel pump power circuit pump.
– Wiring and connectors. 6. If test succeeded at pump connector, check
Testing the Fuel Pump Resistance wiring and connectors from:
1. Ensure fuel pump connector is properly – Fuse box to fuel pump
connected. – Fuel pump to battery ground.
2. Remove fuel pump relay. 7. Repair or replace as necessary.
Releasing the Fuel System Pressure
Refer to Disconnecting a Fuel Pressure Hose in
this subsection.
Removing the Fuel Pump
1. Release the pressure of the fuel system.
2. Disconnect the following from the fuel pump: 06
– Fuel pump electric connector
– Fuel system vent hose
1. Fuel pump relay
3. Measure fuel pump resistance as follows.
Fuel Pump Resistance Test

(at Fuse Box)
Resistance Ω
Test Probes @ 20 °C (68 °F)
Fuse box Battery Approximately 2

contact A11 ground Ω
TYPICAL
2. Vent hose
3. Remove fuel pump retaining nut.
Fuel pump nut tool

(P/N 529 036 427)
FUSE BOX COORDINATES
4. If resistance test failed, disconnect fuel pump

connector and measure resistance at fuel
pump connector.
127
Fuel System
WARNING
Fuel vapors are flammable and explosive
under certain conditions. Use only non-
sparking tools.
CAUTION
Replace fuel pump gasket whenever fuel
pump retaining nut is loosened.
TYPICAL
1. Gasket ring here
2. Fuel pump flange
WARNING
Ensure gasket ring makes good contact all
around fuel pump and fuel pump mounting
neck on fuel tank.
3. Ensure proper fuel pump orientation as in fol-

lowing illustration.
TYPICAL - FUEL PUMP REMOVAL
1. Fuel pump retaining nut
4. Carefully pull out and rotate fuel pump as

required.
NOTICE
Pay attention not to damage fuel sender and
fuel pump prefilter.
5. Discard gasket ring.

6. Wipe off any fuel spillage.
Installing the Fuel Pump
The installation is the reverse of the removal pro- 1. Fuel tank pump index
cedure. However, pay attention to the following. 2. Fuel pump index
Rotate fuel pump during insertion as per removal 4. Insert fuel pump retaining nut over the fuel
procedure. pressure hose and electrical wiring connector.
5. While firmly holding pump against tank, en-
CAUTION gage fuel pump retaining nut on fuel tank
Pay attention not to damage fuel sender and flange.
fuel pump pre-filter.
N O T E : If necessary, move the pump in order to
ensure the flange is sitting completely flat on the
1. Install a N E W gasket ring. tank.
2. Place gasket so that it is properly located be-
tween fuel pump and fuel pump mounting neck 6. Tighten fuel pump retaining nut to
on fuel tank. specification.
128
Fuel System
N O T E : Ensure pump is properly aligned with in-

dex marks after nut is tightened to specification.
Tightening Torque
Fuel pump retaining 29 ± 1 Nm

nut (21 ± 1 lbf-ft)
7. Install fuel pressure hose on fuel pump using a

N E W Oetiker clamp.
8. Install fuel vent tube on fuel pump.
9. Install electrical connector on fuel pump.
10. Install fuel pump relay.
11. Refuel tank and ensure there are no leaks by
performing a Fuel Tank Leak Test and a Fuel
5. Pull strainer off fuel pump.
Pump Pressure Test.
12. Check fuel level sender operation.
Fuel Pump Pre-filter (Strainer)
Replacing the Fuel Pump Pre-filter
1. Remove Fuel Pump. 06
2. Unlock 3 tabs on strainer plastic ring.
N O T E : A non-serviceable filter is located within

the fuel pump module. If it is clogged, replace fuel
pump.
6. Insert the new strainer on fuel pump making
sure to press it in tightly against the fuel pump
Step 1. Lift these tabs to unlock ring surface.
Step 2. Pull ring off pump inlet 7. Press in a N E W push nut to secure strainer.
3. Remove rubber pad. 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.
4. Remove push nut securing strainer to fuel 1. Fuel level sender

pump. Be careful not to break the plastic pin.
129
Fuel System
Testing the Fuel Level Sender Resistance

(Fuel Pump Module Installed)
1. Disconnect multifunction gauge, refer to the
appropriate Gauge subsection.
2. Measure the resistance of the fuel level sender
as follows.
Fuel Level Sender Resistance Test
Resistance Ω
Gauge @ 20 °C (68
Fuel Level
Connector °F) MULTIFUNCTION 4.5" DIGITAL DISPLAY GAUGE CONNEC-
TOR (PIN-OUT)
Full 5Ω±1 If readings are out of specification, refer to
Pins 4 and 21 Testing the Fuel Level Sender Resistance (at
Empty 100 Ω ± 5
Fuel Pump Connector).
If readings are as specified, refer to Testing
the Fuel Level Sender Input Voltage.
Testing the Fuel Level Sender Resistance
(at Fuel Pump Connector)
Fuel Level Sender Resistance Test

Resistance Ω
Fuel Pump @ 20 °C (68
Fuel Level
Connector °F)
Full 5Ω±1
Pins 1 and 2
Empty 100 Ω ± 5
If resistance test at fuel pump connector is failed,

replace fuel pump module.
Testing the Fuel Level Sender Input Voltage
1. Set ignition switch to ON.
Fuel Level Sender Resistance Test 2. Disconnect fuel pump connector.
3. Measure for input voltage as follows.
4.5" Digital Resistance Ω
Display @ 20 °C (68 Fuel Level Sender Input Voltage Test
Fuel Level
Gauge °F)
Connector Fuel Pump Battery Voltage
Connector
Full 5Ω±1
Pins 3 and 8 Negative
Empty 100 Ω ± 5 Pin 2 5V
terminal
130
Fuel System
Test Result Service Action

Test wiring continuity
between fuel level
5V is not read sender and
multifunction gauge
Wiring continuity is Replace multifunction
good gauge
Wiring continuity is not Repair or replace

obtained wiring
Replacing the Fuel Level Sender TYPICAL

Replace fuel pump, refer to Fuel Pump. 1. Fuel tank vent hose inlet
2. Gauge connector
Fuel Tank Vent Valves
5. Remove fuel tank cap.
Testing the Fuel Tank Vent Valve 6. Set vacuum/pressure pump to P R E S S U R E
Testing the Inlet Check Valve and activate pump. The gauge on the pump
should not change in reading.
1. Remove rear body module, refer to Body
subsection.
7. Set vacuum/pressure pump to V A C U U M and 06
activate pump. The g a u g e s h o u l d i n c r e a s e i n
2. Remove multifunction gauge for access to the
reading.
vent system inlet hose, refer to the appropriate
Gauge subsection. If the test failed, carry out the following:
3. Install a small hose pincher between the vent – Ensure breather filter is properly installed,
pressure relief valve and the fuel pump vent refer to Periodic Maintenance Procedures.
inlet. – Ensure inlet check valve is properly in-
Small hose pincher stalled, refer to Installing the Fuel Tank
(P/N 295 000 076) Vent Valve.
– Test inlet check valve separately. If good,
replace the breather filter, refer to Periodic
Maintenance Procedures.
Testing the Pressure Relief Valve
1. Install the small hose pincher between the inlet
check valve and the fuel pump vent inlet fitting.
TYPICAL
1. Pressure relief valve
2. Fuel pump vent inlet
3. Install small hose pincher here
4. Connect the vacuum/pressure pump to the fuel

tank vent hose inlet. TYPICAL
1. Inlet check valve
Vacuum/pressure 2. Fuel pump vent inlet fitting
3. Install small hose pincher here
pump (P/N 529 021
800)
131
Fuel System
2. Set vacuum/pressure pump to P R E S S U R E

and activate pump. The g a u g e s h o u l d i n -
crease in reading.
3. Set vacuum/pressure pump to V A C U U M and
activate pump. The gauge on the pump s h o u l d
not change in reading.
If the test failed, carry out the following:
– Ensure pressure relief valve is properly in-
stalled, refer to Installing the Pressure Re-
lief Valve.
– Replace pressure relief valve if it fails the
test.
TYPICAL
1. Pressure relief valve flow direction arrow
TYPICAL
1. Pressure relief valve flow direction arrow
Installing the Fuel Tank Vent Valve

Installing the Inlet Check Valve
Ensure white portion of inlet check valve is to-
wards the vent breather filter.
TYPICAL
1. Vent breather filter
2. White portion of inlet check valve
Installing the Pressure Relief Valve

Ensure pressure relief valve flow arrow is pointing
away from fuel pump vent fitting.
132
07
ELECTRICAL SYSTEM
133
Electrical System
Power Distribution and Grounds
07 Electrical System
Power Distribution and fUSE identification

Grounds F10 Flashers 10 A
General F11 ABS Valves 25 A

Overview F12 Cooling Fan 25 A
The battery is the primary source of power for the
electrical system, it is recharged by the magneto. Fuse Links And Fuse Box 2
Some components are permanently connected to
the battery (unswitched) while some require a re-
lay or switch to be closed (switched).
At high RPM if the magneto power is greater than
the loads, the rectifier/regulator will regulate power
as necessary.
The system uses an external voltage regulator/
rectifier.
Fuses
Fuse Box 1
LOCATION OF FUSE LINKS AND FB2
1. Connector support (right side of vehicle)
2. Fuse box 2
3. Fuse links 1 and 2
4. Starter solenoid
5. Battery
6. Battery support
FUSE BOX
fUSE identification
F1 Key/Clock 10 A
F2 Lights 30 A
FUSE BOX 2
F3 Acc1 20 A
F4 Acc2 20 A Fuse Link Identification
F5 INJ/ING/Fuel 10 A 1 Main 16 awg
Fuse
Speedo links
F6 10 A 2 Fan/accessories 16 awg
(Gauge)
Fuse in fuse Box 2 Identification
F7 Tail Lamp 10 A
DPS
F8 ECM 10 A Fuse 3 (dynamic power 40 A
F9 2WD/4WD 10 A steering)
134
Electrical System
Fuse Holder Relay Relay state

identifi Relay state (off)
P (on)
Fuse ABS pump 40 A cation
F3
When When ignition key is
Fuse Box #3 ignition key turned OFF
R is turned ON OR
ABS pump 40 A Light
Y AND When engine speed
s
3 Run/Stop is less than 1000
switch is set RPM for at least 50
to RUN minutes
Trail
er
R When a
Flas When there is no
Y trailer is
her trailer plugged
4 plugged
Re
lay
When When ignition key is
ignition key turned OFF
Ac
R is turned ON OR
Fuse Box #4 ces
Y AND When engine speed
so
5 Run/Stop is less than 1000
Battery/Voltage regulator 40 A ries
switch is set
to RUN
RPM for at least 50
minutes
07
R
Brak
Y See Brakes
e
6
Grounds
All grounds are grouped at the same location on
RH side of frame.
Relays
The relays are located in the fuse box #1.
Relay Relay state

identifi Relay state (off)
(on)
cation
R Cool
Y ing See Cooling System
1 fan
When
ignition key TYPICAL - RH SIDE
Approximately 30 1. Battery ground
R is turned ON 2. Engine ground
Y Main AND seconds after ignition 3. DPS ground
2 Run/Stop key is turned OFF 4. Wiring harness ground
switch is set
to RUN
135
Electrical System
Procedures tightly around the terminals and wire

Testing a Fuse Link insulators.
7. Reconnect the battery.
1. Measure the fuse link output voltage (at the
fuse box)..
2. If no voltage is measured, carry out the
following:
–Remove the right side panel and extension
panel.
– Grab each end of the fuse link and gently
pull in opposite directions.
3. If the fuse link is open, the insulator should
stretch and break where the link has failed.
N O T E : Failure of a fuse link is usually due to a

severe overload (or short circuit) between the fuse
link and the load it protects (the fuse box).
Replacing a Fuse Link
NOTICE
Before replacing a fuse link, be sure to find
and repair the cause of the failure.
The gauge of the fuse link can be identified by the

color of its insulator, and by an identification label.
Be sure to replace a fuse link by an identical fuse
link.
– BLUE = 18 awg
– BLACK = 16 awg
– GRAY = 14 awg
PRE-ASSEMBLED REPLACEMENT FUSE LINK

1. Insulated fuse link wire
2. Butt end terminal
3. Terminal factory crimped on fuse link
4. Crimp here when installing in circuit
5. Solder ring
1. Disconnect the battery.

2. Cut the circuit wiring as close as possible to
the fuse link terminals.
3. Remove 8 mm (5/16 in) of insulator from the
ends of the circuit wiring.
4. Insert the circuit wire end in the link terminal
making sure the wire end bottoms out in the
center of the terminal.
5. Crimp the terminal on the bare wire.
6. Using a heat gun, carefully heat the link termi-
nal until the solder ring has melted into the wir-
ing, and the terminal insulator has shrunk
136
Electrical System
Wiring Harness And Connectors
Wiring Harness And

Connectors
SERVICE TOOLS
D.E.S.S. POST REMOVER . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529035943) . . . . . . . . . . . . . . . . . . . 170–171

ECM ADAPTER TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529 036 166) . . . . . . . . . . . . . . . . . . . . . . . 160
ECM TERMINAL REMOVER 2.25 . . . . . . . . . . . . . . . . . . . (P/N 529 036 175) . . . . . . . . . . . . . . . . . . . . . . . 147
FLUKE 115 MULTIMETER . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529 035 868) . . . . . . . . . . . . . . . . . . . . . . . 182
General different number of pin cavities, are used on the

The illustrations in this subsection are typical. Sev- vehicle.
eral variants of the connector types, such as
Main Harness
Main Harness (Except T Category)
SW_CL CL RSS DC3 DC1 DB BN2 TL_R REG FP
PL 07
HO2S1
DC5
TL_L
PF1
HL_RL
BP1
SS
BN1
HL_RH
PF2
DESS
ECMB
DPS FT HL_RH HL_RL SWW MG2 MG1 TAS HIC
137
Electrical System
Main Harness (T Category)
138
Electrical System
Main Harness Splice Location

Main Harness (Rear Part)
JT WH/BK
JT WH/BG JT RD
DB
PF2
TL_L
07
139
Electrical System
Main Harness (Front Part 1/2)
TYPICAL
140
Electrical System
Main Harness (Front Part 2/2)
07
141
Electrical System
Connector Abbreviation Description

Abbreviation Description
Abbreviation Description PLL Left position light
Anti-lock braking system (If PLR Right position light
ABS equipped)
Pressure Sensor (If ABS
BN Ground terminal PSI equipped)
BP Positive terminal
RL_F Rear Left Flasher
CL Cluster
REG Voltage regulator/rectifier
DB Diagnostic connector
RR_F Rear Right Flasher
DC Accessory outlet
RSS Right Steering Switch
DPS Dynamic power steering
SS Starter solenoid
Engine Control Module
ECMB (Connector B) Winch relay (If winch
SW equipped)
FL Fuse link
SW_CL Cluster Switch
FL F Front Left Flasher
Winch remote switch (If
FP Fuel pump SWW winch equipped)
FR F Front Right Flasher TAS Throttle Accelerator sensor
FRR1 Rear brake light switch TELLTALE Telltale
Brake lever switch (If ABS TL_L Rear LH light
FRR2 equipped)
TL_R Rear RH light
FT Cooling fan
TRL Trailer harness
HIC Harness interconnect Wheel Speed Sensor (If ABS
WSS equipped)
Oxygen sensor 1 (if
H02S1 equipped)
Procedures
HL LL LH LO beam headlight
Deutsch Connectors
HL LH LH HI beam headlight Deutsch Connector Application
HL RL RH LO beam headlight A variety of Deutsch connectors are used on vari-
ous systems:
HL RH RH HI beam headlight – Diagnostic connector
– Vehicle speed sensor (VSS) connector.
KEY Ignition switch
The following procedures may be used on each as
KX Horn they are similar in construction.
MC1 Vehicle Flasher Module
MC2 Trailer Flasher Module
MG LH multifunction switch
PF Fuse box
142
Electrical System
Disassembling and Reassembling Deutsch

Connector
TYPICAL —DEUTSCH CONNECTOR

1. Male connector
2. Female connector
3. Secondary lock
4. Sealing cap TYPICAL — MAL E CONNECTOR
1. Male lock
NOTICE
Do not apply dielectric grease on terminal in- N O T E : Before pin extraction, push wire forward
side connector. to relieve pressure on retaining tab.
Removing Terminal 2. Insert a 4.8 mm (.189 in) wide screwdriver

To remove terminals from connector, proceed as blade inside the front of the terminal cavity. 07
follows: 3. Pry the retaining tab away from the terminal
while gently pulling the wire and terminal out of
1. Using long nose pliers, pull out the secondary the back of the connector.
plastic lock from between the terminals.
TYPICAL — FEMALE CONNECTOR

1. Retaining tabs
Inserting Terminal
TYPICAL — FEMALE CONNECTOR 1. For insertion of a terminal, ensure the secon-
1. Female lock
dary plastic lock is removed.
2. Insert terminal through the back of the connec-
tor in the appropriate position, and push it in as
far as it will go. You should feel or hear the ter-
minal lock engage.
143
Electrical System
3. Pull back on the terminal wire to be sure the re- Packard Connector (Multifunction Gauge)
taining tabs are holding the terminal. 1. Firmly push down tab and hold to unlock con-
4. After all required terminals have been inserted, nector while pulling it out.
the lock must be installed.
TYPICAL — CONNECTOR PIN-OUT

1. Terminal position identification numbers
Packard Connectors
Packard Connector Application
Packard connectors are used to connect:
– Electrical harnesses
– Gauges.
3-Pin Packard Connector
C B A CONNECTOR PINOUT
2. Push on both tabs to remove retainer.
F04H45A
VIEW O F A 3-PIN PACKARD CONNECTOR

1. Identification letters
N O T E : This type of connector also comes in oth-

er pin configurations.
Use a terminal remover to remove a terminal from

a 3-pin Packard connector.
WARNING
Ensure all terminals are properly crimped on
wires and connectors are properly fastened.
144
Electrical System
TYPICAL
1. Retainer
2. Tab (one on each side)
TYPICAL
3. Open housing by lifting 4 tabs. 1. Lift and hold plastic lock
2. Lift to unlock and push out
Molex Connector
1. There are 2 connectors on the ECM.
2. The engine wiring harness connector is con-
nected to ECM connector "A". The vehicle wir-
ing harness connector is connected to ECM 07
connector "B".
3. Each ECM connector has 48 pins however,
connectors "A" and "B" are not interchange-
able due to their specific keyways.
N O T E : If you need to remove the connector, be

TYPICAL sure to not disconnect fuel quick-connector at
1. Tabs (2 on each side)
ECM. If you need to remove the ECM or fuel quick
4. Lift the top plastic lock of the female terminal to connector, insure the ECM electrical connectors
be removed and hold in position. Lift the fe- are securely in place and avoid fuel intrusion into
male terminal to unlock from the housing and connector/seal.
push out of housing.
Removing Molex Connector

1. Push and hold the locking tab.
145
Electrical System
2. Install connector to ECM.

2. Rotate connector lock until it stops.
3. Rotate connector lock until it snaps locked.
1. Locked here
3. Pull out connector.
Probing Molex Connector
The most recommended and safest method to
probe ECM connector terminals is to use the ECM
adapter tool. This tool will prevent deforming or
enlarging terminals which would lead to bad ECM
terminal contact creating intermittent or permanent
problems.
Required Tools
ECM adapter tool

(P/N 529 036 166)
Disconnect the ECM connector and reconnect on

Installing Molex Connector the tool connector. Probe required terminals di-
rectly in the tool holes.
1. Fully open connector lock.
146
Electrical System
1. ECM connector (harness side)

2. ECM adapter
NOTICE 3. Insert tool to unlock terminal.

Never probe directly on ECM harness con-
nector. This could change the shape or en- ECM terminal remover 2.25
large the terminals and create intermittent or (P/N 529 036 175)
permanent contact problems.
Inspecting Molex Connector ECM terminal remover 3.36

(P/N 529 036 174)
Before replacing an ECM, always check electrical
connections.
1. Ensure connector locking mechanism is func-
tioning properly.
To remove a signal terminal from the ECM har-
ness connector, use the 2.25 terminal
07
2. Ensure all wire terminals (pins) are properly remover.
locked in the connector.
To remove a power terminal, use the 3.36 ter-
3. Ensure they are very tight, make good contact
minal remover.
with the pins in the ECM.
4. Ensure the pins in the harness connector and
the ECM connector are clean, shiny and corro-
sion-free.
5. Check wiring harness for signs of scoring.
N O T E : A “defective ECM module” could possibly

be repaired simply by disconnecting and recon-
necting it.
NOTICE
Do not apply any lubricant product to the pins
of the ECM connector.
Removing the Molex Connector Terminal 1. Unlock here

(Harness Connector)
1. Remove rear protector from connector. 4. Gently pull on the wire to extract the terminal
2. Pull out the connector lock. out the back of the connector.
147
Electrical System
1. Step 2: Insert GM terminal extractor tool
3. Gently pull on the wire to extract the pin out the

NOTICE back of the connector.
Before installing wire terminals in the con-
nector, ensure all terminals are properly
crimped on wires. After installation of wire
terminals in the connectors, ensure they are
properly locked by gently pulling on them as if
to extract them.
Furukawa Connector
Furukawa Connector Application
Voltage regulator/rectifier.
Removing the Terminal
1. Remove the secondary lock (plastic insert).
1. Step 3: Pull wire to extract pin
NOTICE
Before installing terminals in the connectors,
ensure all terminals are properly crimped on
the wires. After installation of the wire termi-
nals in the connectors, ensure they are prop-
erly locked by gently pushing on them as if to
extract them.
Battery And Starter Cable Terminals

Crimping Cable
Step 1. Remove the secondary lock
1. Carefully strip the wire approximately to 13 mm
(1/2 in) in length, using a wire stripping tool or
2. Carefully insert a terminal extractor between sharp blade/knife.
the lock and the pin to release the pin.
148
Electrical System
PROPERLY CRIMPED WIRE
5. To verify, if the wire is properly crimped, apply

A. 10 mm (3/8 in)
some pulling force on wire and the terminal at
the same time from both directions.
N O T E : Make sure not to cut wire strands while
stripping the wire. NOTICE
Never weld the wire to the terminal. Welding
2. Install the appropriate terminal on the wire ac- can change the property of the wire and it can
cording to the requirement. Refer to appropri- become brittle and break.
ate parts catalog.
6. Install the protective heat shrink rubber tube on
the terminal. Heat the heat shrink rubber tube
using the heat gun so that it grasps the wire
and the terminal.
NOTICE 07
Make sure that the protective heat shrink rub-
ber tube has been properly installed and no
INSTALLATION OF TERMINAL part of wire is exposed.
3. Follow the instructions provided with the crimp-
ing tool to select the proper position of the tool. Splices Repair Procedure
1. Make sure to perform the usual tests described
N O T E : Different wires require different crimping in electrical system sections before investigat-
pliers settings. ing the harness splices.
2. If an electrical issue can not be found with the
4. After positioning the crimping pliers, crimp the usual tests, locate the main harness splice that
terminal already installed on wire. is involved in the faulty circuit and repair it as
per the Splices repair procedure.
3. To repair a splice, we recommend the use of a
tin solder meeting the followings requirements
or an equivalent.
Tin Solder Requirements

SN 60
PB 40
DIA 0.062
FLUX RA 2%
Case 1: Wire Detached from Splice

WARNING
CRIMPING OF WIRE
Repairs described in this section should
never be performed on harness sections that
can be exposed to water.
149
Electrical System
1. Locate splice. Refer to splices location

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

1. Shrink tube
4. Remove the shrink tube.

1. Using a blade, cut the shrink tube.
NOTICE
Be careful with the blade to avoid cutting
wires insulation.
1. Twisted wire
7. Perform a tin solder on twisted wire.

8. Apply electrical tape to cover splice.
N O T E : Make sure tape overlaps on wire insula-

2. Slightly heat the shrink tube using a heat tion, approximately 13 mm (1/2 in) each side.
gun.
9. Reinstall wires into protector tube.
Case 2: Wire Broken from Splice
NOTICE
Repairs described in this section should
never be performed on harness sections that
can be exposed to water.
1. Locate splice. Refer to splices location

diagrams.
2. Remove wires from protector tube.
3. Remove the shrink tube with long nose 3. Locate the shrink tube protecting the defective
pliers. splice.
5. Locate detached wire from splice.
150
Electrical System
6. Strip wire insulation at the end of broken wire.

7. Strip wire insulation below the splice.
1. Shrink tube
4. Remove the shrink tube.

1. Using a blade, cut the shrink tube.
1. Broken wire stripped
2. Splice wire stripped
8. Twist wire around stripped wire.
NOTICE
Be careful with the blade to avoid cutting
wires insulation.
07
2. Slightly heat the shrink tube using a heat
gun.
1. Twisted wire
9. Perform a tin solder on twisted wire.

10. Apply electrical tape to cover splice.
N O T E : Make sure tape overlaps on wire insula-

tion, approximately 13 mm (1/2 in) each side.
11. Reinstall wires into protector tube.
N O T E : Always perform a solder on a bigger wire

(lower gage).
3. Remove the shrink tube with long nose
pliers.
5. Locate broken wire from splice.
1. Broken wire
2. Splice
151
Electrical System
Charging System
Charging System Component Voltage VDC
General Minimum 12.5

Voltage Regulator
System Description Maximum 15
The purpose of the charging system is to keep the
battery at a full state of charge.
N O T E : For an overview of the vehicle electrical
system, refer to engine management system
section.
Magneto
The magneto is the primary source of electrical
energy. It transforms a magnetic field into electric
current (AC).
The alternating current is regulated and trans-
formed into direct current (DC) by the voltage reg-
ulator, and normally powers all of the vehicle's
systems and accessories.
The magneto has a 3 phase delta wound stator. TYPICAL
Battery
The battery supplies DC power to every electrical
and electronic system in the vehicle as well as all
accessories. At low engine RPM operation and
high current load conditions, it supplements the
magneto's output as required, and helps to main-
tain a steady system voltage.
Inspection
Charging System Output
First ensure that battery is in good condition prior
to performing the following tests.
Testing the Output Voltage
TYPICAL 1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).
Voltage Regulator
In BUDS2, go to:
The regulator receives AC current from the mag-
neto and transforms it into direct current (DC). – M e a s u r e m e n t s page
– E C M button
The voltage regulator output voltage is distributed – B a t t e r y v o l t a g e (V)
as follows: 2. Start engine.
– Fuse links 3. Increase engine RPM as specified in the fol-
– Battery. lowing table.
The voltage regulator limits voltage to prevent any Output Voltage Test Using BUDS2
damage to electrical components.
ENGINE SPEED VOLTAGE (DC)
4000 RPM 14.5 ± .5 Vdc
152
Electrical System
Charging System
If voltage is above specification, replace volt- Test Conditions

age regulator/rectifier.
Initial battery voltage Above 12.5 Vdc
If voltage is below specification, check stator
output and wiring harness prior to concluding Engine OFF
that voltage regulator/rectifier is defective. Re-
fer to MAGNETO System. 3 times the amp-hour
Load (AH) rating
Troubleshooting
Time 15 seconds
It is good practice to check for fault codes using
the BRP diagnostic software (BUDS2) as a first ‡ Required for accurate testing
troubleshooting step. Refer to Diagnostic and fault
codes subsection. Specification
Troubleshooting
Battery Above 9.6 Vdc
1. Battery Regularly Discharged Or Weak
Loose or corroded battery cable connections. If battery voltage drops below specification during
test, replace battery and perform a Charging Sys-
– Tighten or repair battery cable connections. tem Load Test.
Worn or defective battery. Load Testing the Charging System
– Charge and test battery.
Defective magneto stator.
– Test stator, refer to magneto and starter sys- RD1-1
BN4 BAT2
12V,18AH
BAT1
07
tem subsection. RD RD1-3 BN1
Defective regulator/rectifier. SS-1 BP3
– Test system voltage. BP1
Damaged magneto rotor or Woodruff key.

– Replace magneto rotor or Woodruff key, refer 1. Remove seat.
to magneto and starter system subsection. 2. Connect a battery load tester.
3. Start vehicle and read voltage on tester.
Procedures
Ensure battery is fully charged. Specification
Refer to wiring harness and connectors subsec- Voltage 12.5 - 15 Vdc
tion for harness layout and connector locations on
vehicle. If voltage is a b o v e specification, replace regu-
Refer to appropriate wiring diagram for additional lator and continue Load Testing the Charging
information. System.
4. Connect an ammeter around RD1-1 wire.
The magneto is covered in magneto and starter
subsection.
WARNING
Ensure vehicle is in PARK when performing
charging system tests.
Load Testing the Battery

1. Remove seat.
2. Connect a battery load tester.
3. Ensure proper test conditions.
153
Electrical System
Charging System
Voltage Regulator (RD)
12V,18AH
RD2-1
RD1-1
BN4 BAT2 BAT1
R D2-2
RD RD1-3 BN1
RD2-3
SS-1 BP3
BP1
DC CURRENT TEST WITH INDUCTIVE AMMETER

1. Output connector of voltage regulator
2. Ammeter clamped over RED wire
5. Ensure proper test conditions. Testing Voltage Regulator Continuity

Due to internal circuitry, there is no static test
Test Conditions available.
Battery voltage at idle* Above 12.6 Vdc Testing Voltage Regulator Power
The voltage regulator/rectifier is accessible on the
Engine Increase to 4000 RPM RH rear side of the vehicle.
As required to
Load decrease battery
voltage to 12 Vdc
Time 15 seconds
*Required for accurate testing
6. Read amperage on ammeter.
Model Specification
Base/DPS 41 ± 5 Amps
All other models 50 ± 5 Amps

1. Check voltage at RD1-1.
N O T E : With a fully charged battery and no elec- +
trical loads, specification is less than 10A. RD
RD1 -
+
If amperage or voltage is not within specification,

verify magneto and wires. Refer to Magneto and
Starter subsection. Replace:
– Voltage regulator if magneto test is within
specifications.
– Magneto if magneto test is not within -
RD2
specifications.
Test Conditions
RD1-1 Hot at all times
154
Electrical System
Charging System
BackProbe Probe specification +

RD
RD1 -
+
RD1-1 BAT2 (-) Battery voltage

3. Start vehicle.
4. Ensure proper test conditions.
-
Test Conditions RD2
Battery voltage at idle‡ Above 12.6 Vdc
Engine Increase to 4000 RPM Test Conditions
As required to RD1-3 Permanent ground
Load decrease battery
voltage to 12 Vdc BackProbe Probe specification
Time 15 seconds Battery
RD1-3 BAT1 (+)
voltage
‡ Required for accurate testing
5. Measure voltage drop.
3. Start vehicle.
+ 4. Ensure proper test conditions.
RD
RD1 - Test Conditions
07
+
Battery voltage at idle* Above 12.6 Vdc

Engine Increase to 4000 RPM
As required to
- Load decrease battery
RD2
voltage to 12 Vdc
Time 15 seconds
BackProbe Probe specification
*Required for accurate testing
RD1-1 BAT1 (+) Under 0.2 Vdc
If voltage drop is above specification, locate and
repair damaged connector/wire. +
RD
RD1 -
Testing Voltage Regulator Ground
+
1. Check ground at RD1-3.
-
RD2
BackProbe Probe specification
RD1-3 BAT2 (-) Under 0.4 Vdc
155
Electrical System
Charging System
If voltage drop is above specification, locate and

repair damaged connector or wire.
Battery
Battery Information
These vehicles are equipped with a VRLA battery
(Valve Regulated Lead Acid). It is a maintenance-
free type battery.
Refer to battery manufacturer's instructions for
proper filling, activation and routine charging
procedures.
Removing the Battery
1. Remove seat.
2. Disconnect BLACK (-) cable first, then the
RED (+) cable.
NOTICE
Always respect this order for removal; dis-
connect BLACK (-) cable first.
3. Remove battery retaining plate.
TYPICAL
1. Battery retaining plate
2. Retaining plate screws (3)
4. Remove battery.
Installing the Battery
NOTICE
Always connect RED (+) cable first then
BLACK (-) cable.

Tightening Torque
Battery retaining plate 4.5 ± 0.5 Nm

156
Electrical System
Ignition System
Ignition System
SERVICE TOOLS

General Refer to Wiring Harness and Connectors for ve-

The following tools are required to test most of the hicle wiring harness layout and component
electrical parts. locations.
Refer to Engine Management System (EMS) for
Required Tools powertrain wiring harness layout and component
locations.
Fluke 115 multimeter Diagnostic Guidelines
(P/N 529 035 868) The following is provided to help in diagnosing the
probable cause of a problem. It is a guideline and
ECM adapter tool
should not be assumed to list all possible causes. 07
Troubleshooting
(P/N 529 036 166) 1. ENGINE WILL NOT START (ENGINE TURNS
OVER)
System Description
The battery supplies the primary side of ignition Fouled or defective spark plug
coils through the main relay while the ECM com- – Replace.
pletes the circuit for each cylinder by switching it
to ground at the right moment. The ECM can de- Defective CPS
tect an open and short circuit in the primary wind- – Check operation of CPS and replace if neces-
ing but it does not check the secondary winding. sary. Refer to Electronic Fuel Injection (EFI)
The Engine Management System (EMS) controls subsection.
the ignition system. For more information, refer to Defective trigger wheel
Engine Management.
– Inspect trigger wheel. Refer to Magneto Sys-
Ignition Timing tem subsection.
Ignition timing is not adjustable.
Defective ignition circuit
Troubleshooting – Check ignition fuse of fuse box 1, ignition coil
It is good practice to check for fault codes using and wiring condition.
the BRP diagnostic software (BUDS2) as a first
troubleshooting step. Refer to Diagnostic and Defective fuel pump
Fault Codes subsection. – Check fuel pump, refer to Fuel System
Always refer to the appropriate Wiring Diagram subsection.
when troubleshooting an electrical circuit. Defective fuel injectors or circuit
Refer to Power Distribution and Grounds for fuse – Check fuel injectors, refer to Engine Manage-
and relay information. ment System.
157
Electrical System
Ignition System
2. ENGINE HARD TO START – Ignition switch

– Emergency engine stop switch.
Spark plug faulty, fouled or worn out
Ignition Switch Access
– Check spark plug condition. Replace if
Refer to body subsection and remove the LH side
necessary.
panel.
Low fuel pressure
– Test fuel pressure, refer to Fuel System
subsection.
3. ENGINE MISFIRES, RUNS IRREGULARLY
Fouled, defective, worn spark plugs

– Check and verify the heat range, the gap and
replace if necessary.
Damaged trigger wheel/loose CPS
– Inspect trigger wheel. Refer to Magneto Sys-
tem subsection.
TYPICAL
Defective ignition circuit 1. Ignition key
2. Ignition switch connector
– Check ignition coil, the ignition fuse, and wiring 3. ECM
condition. Emergency Engine Stop Switch
Poor engine grounds Testing the Emergency Engine Stop Switch at
– Check/clean/repair. ECM (with Ignition Switch)
1. Disconnect the ECM-B connector from ECM
4. ENGINE CONTINUALLY BACKFIRES and install it on the ECM adapter tool.
2. Remove ignition key switch fuse, refer to
Fouled, defective spark plugs Power Distribution and Grounds subsection.
3. Turn ignition key to ON position.
– Clean/replace spark plugs. 4. Test for continuity as per following table.
Damaged trigger wheel/defective or loose CPS
Emergency Engine Stop Switch Test at ECM
– Inspect trigger wheel and CPS, refer to Magne-
to System and Electronic Fuel Injection (EFI) Switch
ECM Adapter Measurement
subsections. Position
RUN B-F2 B-E4 Close to 0 Ω
Procedures
Ignition Switch STOP B-F2 B-E4 Open circuit
Ignition Switch Quick Test If switch fails the test, refer to Testing the
1. Turn ignition switch to ON position. Emergency Engine Stop Switch at Multifunc-
2. If multifunction gauge turns on (assuming it tion Switch Connectors.
works), the ignition switch is good.
3. If multifunction gauge does not turn on, check Testing the Emergency Engine Stop Switch at
the following in this order: ECM (with RF D.E.S.S. Key)
1. Disconnect the ECM-B connector from ECM
– Battery and install it on the ECM adapter tool.
– Fuse link 1 2. Disconnect the RF D.E.S.S. connector.
– Key ECM fuse 3. Remove ECM and RF D.E.S.S. power supply
– Ignition coil fuse fuse, refer to Power Distribution and grounds
– Start switch fuse subsection.
– ECM is properly powered (refer to Elec- 4. Test for continuity as per following table.
tronic Fuel Injection (EFI) subsection)
158
Electrical System
Ignition System
Emergency Engine Stop Switch Test at ECM

The emergency engine stop switch is wired into
the LH multifunction switch connectors (MG1 and
Switch Connec ECM MG2).
Measurement
Position tor Pin Adapter 1. Remove gauge support, refer to Gauge
RFID-B* B-E4 Close to 0 Ω subsection.
RUN 2. Disconnect MG1 and MG2 connectors.
FB-A3** B-E4 3. Test switch continuity as per following table.
Open circuit
RFID-B* B-E4 Emergency Engine Stop Switch Pin-Out
STOP
FB-A3** B-E4 Close to 0 Ω
Switch
Probe Measurement
* RF D.E.S.S. connector, pin B Position
** Fuse box contact A3 MG1-3 and MG2-

Open circuit
3
If switch fails the test, refer to Testing the RUN
MG1-1 and MG1-
Emergency Engine Stop Switch at Multifunc- 2
tion Switch Connectors. Close to 0 Ω
MG1-3 and MG2-
Testing the Emergency Engine Stop Switch at 3
Multifunction Switch Connectors (with Ignition STOP
Switch) MG1-1 and MG1-
Open circuit
Refer to Wiring Harness and Connectors subsec- 2
tion for connector locations.
The emergency engine stop switch is wired into
If switch tests good, test continuity of wiring, re- 07
fer to the appropriate Wiring Diagram.
the LH multifunction switch connector (MG1).
If wiring continuity tests good, test RF D.E.S.S.
1. Remove gauge support, refer to Gauge post. Refer to RF D.E.S.S. subsection.
subsection.
2. Disconnect MG1 connector. Ignition Coil
3. Test switch continuity as per following table.
Emergency Engine Stop Switch Pin-Out
Switch
Probe Measurement
position
MG1-1 and MG1-

Open circuit
2
RUN
MG1-2 and MG1-
3
Close to 0 Ω
MG1-1 and MG1-
3
STOP
MG1-1 and MG1-
Open circuit
2
If switch tests good, test continuity of wiring. Ignition Coil Access

Refer to appropriate Wiring Diagram. Refer to Body subsection and remove RH inner
fender panel(s) for access to the ignition coil.
Testing the Emergency Engine Stop Switch at
Multifunction Switch Connectors (with RF D.E.
S.S. Key)
Refer to Wiring Harness and Connectors subsec-
tion for connector locations.
159
Electrical System
Ignition System
1. Ignition coil connector
2. Set emergency engine stop switch to RUN.

TYPICAL
3. Install RF D.E.S.S. key on post or turn the igni-
1. Ignition coil location tion key to ON.
4. Read voltage as per following table.
Ignition Coil Connector Access
Ignition Coil Input Voltage Test
Remove the LH inner fender panel (s) for access
to the ignition coil. Ignition coil
Battery Measurement
connector pin
Negative
2 Battery voltage
post
If battery voltage is NOT read, check continuity

of ignition coil supply circuit. Refer to the ap-
propriate wiring diagram.
Testing the Ignition Coil Ground Circuit
Continuity
1. Disconnect the ECM-A connector from the
ECM.
2. Connect the ECM-A connector to the ECM
adapter tool.
ECM adapter tool (P/

N 529 036 166)
VIEW L H SIDE OF VEHICLE
1. Ignition coil connector
3. Check wiring continuity as per following table.
Installing the Ignition Coil
Tighten bolt to specification. Ignition Coil Ground Circuit Continuity Test
Ign. Coil
Tightening Torque ECM
Cyl Connect. Measurement
Adapter
Ignition coil retaining 9 ± 1 Nm Pin
bolt (80 ± 9 lbf-in) 1
3 A-M1
(Front)
Testing the Ignition Coil Input Voltage Close to 0 Ω
1. Disconnect the 3-pin connector from the igni- 2
(Rear) 1 A-M2
tion coil.
160
Electrical System
Ignition System
Testing the Ignition Coil Resistance Troubleshooting Fouled Spark Plug

An ignition coil with good resistance measurement Fouling of the spark plug is indicated by irregular
can still be faulty. Voltage leakage can occur at running of the engine, decreased engine speed
high voltage levels which is not detectable with an due to misfiring, reduced performance, and in-
ohmmeter. Replacing the ignition coil may be nec- creased fuel consumption. This is due to a loss of
essary as a test. compression.
Primary Windings (ECM 2 Connectors) Other possible causes are: prolonged idling or
1. Disconnect HIC connector. low-speed riding, a clogged air filter, incorrect fuel,
defective ignition system, incorrect spark plug
gap, lubricating oil entering the combustion cham-
ber, or too cold spark plug.
The plug face of a fouled spark plug has either a
wet black deposit or a black carbon fouling. Such
coatings form a conductive connection between
the center electrode and ground.
Spark Plug Analysis
TYPICAL
1. HIC connector
2. ECM-A connector
2. Disconnect the ECM-A connector and connect

07
it to the ECM adapter tool.
3. Using a multimeter set to Ω, check resistance
TYPICAL
in primary windings as follows. 1. Overheated (light grey, white)
2. Normal (light brown, brown)
Ignition Coil Resistance Test 3. Fouled (black, wet or dry, dark deposits, grey, melted coating)
Engine The plug face reveals the condition of the engine,

ECM Measurement operating condition, method of driving and fuel
Connector
adapter @ 20 °C (68 °F) mixture. For this reason it is advisable to inspect
(HIC)
the spark plug at regular intervals, examining the
M1 plug face (i. e. the part of the plug projecting into
(Cylinder 1) the combustion chamber).
Pin E .3 - .6 Ω
M2
(Cylinder 2)
If any resistance is not good, measure resist-

ance directly on coil. If second test is ok, check
wiring.
Secondary Windings
Due to the integrated diode, it is not possible to
take any resistance measurement of the secon-
dary winding.
Spark Plug
For spark plug replacement procedure, refer to
Periodic Maintenance Procedures subsection.
161
Electrical System
Starting System
Starting System If the “Engine cranking conditions” are met and

the starter will not crank the engine, check the
General following:
The following tools are required to test most of the 1. Battery and connections (refer to charging
electrical parts. system).
2. Starter solenoid.
Required Tool 3. Start button switch.
4. Starter (refer to magneto and starter
subsection).
Fluke 115 multimeter 5. Wiring and connections.
(P/N 529 035 868) Engine Turns
Starting system is OK.
ECM adapter tool 1. Verify ignition system. Refer to ignition system

subsection.
(P/N 529 036 166) 2. Verify EFI systems. Refer to Electronic fuel in-
jection (EFI) subsection.
3. Verify mechanical condition of engine. Refer to
Starting System Operation engine, cvt and gearbox section.
When the START button is pressed, 12 Vdc is ap-
plied through the key switch (KEY ) and the start
Procedures
button (MG2) to the starter solenoid coil and ECM. Ensure battery is fully charged.
The ECM completes the starter solenoid control Refer to applicable wiring harness and connectors
circuit by providing a ground. The starter solenoid for harness layout and connector locations on
then closes its contacts and battery power is ap- vehicle.
plied to the starter for cranking the engine.
Refer to applicable wiring diagram for additional
Engine Cranking Conditions information.
The following conditions must be met to allow en-
gine cranking. WARNING
– Ignition switch turned ON Ensure vehicle is in PARK when performing
– Engine stop switch to RUN starting system tests.
– Transmission in Park, Neutral or a brake ped-
al/lever is applied Starting System Tests
– Start button is pressed and held.
Starter Solenoid
Troubleshooting
+
Check for fault codes. Refer to: diagnostic and

-
fault codes subsection.

Engine Will Not Turn
If the starter cranks over the engine with the
brakes applied, check the following:
1. Shifter rod adjustment, (refer to appropriate
shifter subsection).
2. Gearbox position indicator switches or the
gearbox position sensor (GBPS), (refer to ap-
propriate gearbox and coupling unit
subsection). 1. Disconnect SS+ and SS-
3. Switches or sensor wires and connectors, (re-
fer to appropriate wiring diagram).
162
Electrical System
Starting System
Starter Solenoid Control Circuit
+
-
F8 5 A
1. SS+
ECM
2. Activate the starter solenoid.

Test Condition
Engine stop switch RUN
Ignition switch ON
Start button Pressed
07
SS+ IS ON THE RIGHT
1. Apply 12Vdc to SS+

2. Ground SS-
3. If starter turns, verify starter solenoid control
circuit.
4. If starter does not turn, verify starter solenoid
continuity. SS+ IS ON THE RIG HT
Probe Probe specification
SS+ SS- Battery voltage
SS+ BAT - Battery voltage
BAT + SS- Battery voltage
1. If voltage is as per specification replace starter

solenoid.
2. If voltage is not as per specification, verify
Starter solenoid control Power Circuit or starter
solenoid control ground circuit as applicable.
Starter Solenoid Control Power Circuit
NOTE: This procedure also tests the start
button.
163
Electrical System
Starting System
ECMB
If start switch tests as specified, repair wire to
starter solenoid SS+ terminal.
A2 B
WAKE UP YE/RD-20
L4
Starter Power Circuit Voltage Drop
SOLENOID CONTROL OG/BN-20 OG/BN-20
SS-(−)
N O T E : Engine must be in starting condition for
D2
this test. Do not perform on a «No Start» vehicle.
D1 SS-(+)
START SIGNAL BK/YE-20 BK/YE-20
Test Condition
MG2
START RD/VT
YE/RD
1
6
BK/YE-20
YE/RD-20
Fuse F10 /
Fuse F3 (Europe and Removed‡
1. Disconnect MG2 connector. International Models)
Ignition switch ON
Engine Cranking
‡ Will prevent engine from starting
+
-
TYPICAL - MG2 STEERING HARNESS CONNECTOR PIN-OUT
Test Condition
Ignition switch ON
MG2-1 BAT - Battery voltage.

2. If voltage is not as per specification:
1. Check fuse(s). Starter B+
2. Test engine stop switch. Refer to Ignition BAT1 Below 0.4 Vdc
terminal
system subsection.
3. Test ignition switch Refer to Ignition system If voltage drop is above specification, repair or re-
subsection. place sources of high resistance in circuit.
3. Test start button.
Test Condition

MG2-1 MG2-6 Close to 0Ω
If start button does not test as specified, re-

place the multifunction switch assembly.
164
Electrical System
Starting System
Starter Solenoid Control Ground Circuit circuit both test good, test ECM ground circuits.
INTER CONNECTOR
HIC1 Refer to Electronic fuel injection (EFI) subsection.
B JT VT/BG
WAKE UP / START VT/BG-22
N O T E : Supply a ground with a jumper wire if you

suspect that the ECM is not supplying a ground to
J
STARTER CONTROL OG/BN-20 OG/BN-20 SS-( −)
the solenoid.
Starter Solenoid Continuity
D2
LEFT STEERING SWITCHES
START SWITCH
MG2
6
RD/VT YE/RD-20 YE/RD-20 SS-(+)
1
YE/RD VT/BG-22
BAT2 BAT1
Europe and International Models
ECMB
BP3
WAKE UP
M BP1
L4
SOLENOID CONTROL OG/BN-20 OG/BN-20
SS-(−)
D2
START SIGNAL
D1
BK/YE-20 BK/YE-20
SS-(+)
1. Disconnect the BLACK (-) negative battery
cable.
1. Disconnect SS-. 2. Disconnect SS+ and SS-.
2. Install the ECM adapter onto the ECM 07
connector.
1. SS+
1. ECM connector
2. ECM adapter tool

ECM-HIC1 /
ECM-L4
SS- (Europe and Close to 0Ω
International
Models)
If resistance is not as specified, repair or replace

wiring/connections. specification @
Probe Probe 20 °C (68 °F)
If solenoid power control circuit and ground control
SS+ SS- Close to 6Ω
165
Electrical System
Starting System
If resistance is not as per specification, replace Solenoid Diode Test

the solenoid.
3. Disconnect BP1.
SS2- SS1-
1. Disconnect SS+ and SS- from starter solenoid.

Terminal to
BP1 starter O.L.
motor
4. Jump starter solenoid.
1. SS+
2. Set the multimeter to the diode symbol as

shown.
SS+ IS ON THE RIGHT

Terminal to
BP1 starter Close to 0Ω
motor
If resistance is not as per specification, replace

the solenoid. 3. Probe wires while paying attention to the diode
polarity.
If starter power and ground circuits are good,
refer to magneto and starter subsection for
starter diagnosis and replacement.
166
Electrical System
Starting System
FORWARD POLARITY, MUST BE AROUND 0 .5 V

1. SS-
07
REVERSE POLARITY, MUST BE OPEN CIRCUIT
1. SS+
If test failed, replace diode. Refer to wiring har-

ness and connectors for diode location.
N O T E : The diode is integrated in the harness
near the starter solenoid.
167
Electrical System
Radio Frequency Digitally Encoded Security System (RF D.E.S.S.)
Radio Frequency Security System (RF D.E.

Digitally Encoded S.S.)
SERVICE TOOLS

General RF D.E.S.S. Key

System Description
This system limits engine or vehicle speed.
At startup the RF D. E. S. S. module attempts to
read the key and sends a signal to the ECM. The
ECM analyses the signal and determines if the
key is:
– Performance (ATV and SSV)
– Normal (ATV and SSV)
– Work (SSV)
Speed/Torque Limited To
The RF D. E. S. S. key contains a magnet and a
Key Limit How RFID chip.
No D.E.S.S. – The magnet closes the hall effect switch inside
Performance Not applicable
imposed limit the engine cut-off switch.
– The RFID chip contains a unique digital code.
Vehicle speed By varying
It is the equivalent of the tooth-pattern cut on a
Normal limited to 70 throttle opening
conventional ignition key.
km/h (43 MPH) (iTC)
RF D. E. S. S. keys are programmed in the ECM
Vehicle speed By varying memory using BUDS2. The keys can also be
Work limited to 40 throttle opening erased individually.
km/h (25 MPH) (iTC)
N O T E : If desired, a RF D. E. S. S. key can be
DESS key not ECM will not used on another vehicle equipped with the RF D.
Engine will not
recognized / ground starter E.S.S. system. It only needs to be programmed for
start
Bad Key1 solenoid that vehicle.
1BUDS2 will display an error when trying to read
key. Messages will scroll on gauge.
N O T E : Additional information on learning key

modes and how an operator can modify engine
torque and vehicle speed is available in the Oper-
ator's Guide.
168
Electrical System
RF D.E.S.S. Module / Cut-Off Switch / D.E.S. The RF D.E.S.S. module emits an RF signal when
S. Post the vehicle is powered up that activates the chip in
the key, the module can then read the key.
The RF D.E.S.S. module does not determine the
type of key, it only reads the chip for the ECM.
The hall effect switch (cut off switch) must be

closed to start the engine.
Troubleshooting
When starting the engine with a RF D.E.S.S. key on the engine cut-off switch, the key is identified by the
ECM and RF D.E.S.S. signals will be issued according to the key recognition.
RF D.E.S.S. Signal 07
Displayed Description Comment
Beeper
Message
Welcome message,
2 shorts beeps Can-Am Working RF D.E.S.S. key.
good key
– Make sure no accessory or accessory wires are near

Short beeps key or engine cut-off switch.
CHECK
repeating Unable to read key – RPM limited to 2500. Vehicle cannot be driven.
KEY
slowly – Check D.E.S.S. status in BUDS2.
– No voltage at RFID connector pin D.
Shorts beeps – Use the proper key for this vehicle or have the key
BAD Invalid key or key not
repeating programmed.
KEY programmed
rapidly – RPM limited to 2500, Vehicle can not be driven.
Procedures 4. In BUDS2, go to:

RF D.E.S.S. Key – K e y s page
Programming RF D.E.S.S. Keys – Ensure that anti theft system is activated. If
not, activate it before trying to add a key.
1. Connect the vehicle to BRP diagnostic soft- – In C u r r e n t I n s e r t e d K e y , select R e a d to
ware (BUDS2). read and detect the key to be programmed.
IMPORTANT: Ensure all connections have – Select the K e y T y p e
been made b e f o r e s t a r t i n g BUDS2 to allow prop- – Then click on the A d d button.
er operation. The RF D.E.S.S. key is now saved in the com-
2. Briefly press the START/STOP button to power puter and should be displayed in the table.
the ECM. 5. To program other key(s), install a new key on
3. Install the RF D.E.S.S. key to be programmed the engine cut-off switch and repeat the
on the engine cut-off switch. procedure.
169
Electrical System
Erasing RF D.E.S.S. Keys Individually Bad Key

1. Install the D.E.S.S. key to be erased on the en- 1. The gauge scrolls the message: "Bad key".
gine cut-off switch. 2. Possible causes:
ware (BUDS2). – Key not programmed to vehicle
3. Briefly press the START/STOP button to power 3. Condition can be duplicated by installing a key
the ECM. that is not programmed to the vehicle.
4. In BUDS2, go to: Gauge and Vehicle Won't Stay Awake
– K e y s page 1. The gauge powers off shortly after the start/
– In C u r r e n t I n s e r t e d K e y stop button is pressed.
– Select E r a s e k e y 2. Possible causes:
After approximately 10 seconds, a message – No key on D.E.S.S. post.
will appear. – Engine stop switch is in OFF position (if
equipped).
The key is now erased.
– Magnet in key not closing hall effect switch
N O T E : This will only erase the key inserted in in D.E.S.S. post.
the engine cut-off switch. – No voltage at RFID-D connector
– No ground at RFID-B connector
Erasing All RF D.E.S.S. Keys – No ground at RFID-A connector
1. Connect the vehicle to the BRP diagnostic soft- 3. Condition can be duplicated by unplugging the
ware (BUDS2). RFID connector.
2. Briefly press the START/STOP button to power
Testing the Engine Cut-off Switch (D.E.S.S
the ECM. Post)
3. In BUDS2, go to :
1. Use the following table and the appropriate wir-
– K e y s page ing diagram to test the engine cut-off switch.
– In G e n e r i c S e t t i n g s
– Select E r a s e A l l K e y s RFID Connector Pin Specifications
4. When done, program at least one new key to
the vehicle. Refer to Programming RF D. E. S. A Ground thru ECM
S. Keys. B Ground to Stop Switch
RF D.E.S.S. / Engine Cut-Off Operation 0 Vdc (data signal to
C ECM)
Normal Operation
1. Put the RF D.E.S.S. key on the engine cut-off D 12 Vdc
switch (D.E.S.S. post).
2. BUDS2 reads and recognizes the RF D.E.S.S. 2. Remove all necessary panels to reach the
key type. RFID connector.
3. Vehicle starts when the START/STOP button 3. Disconnect the RFID connector.
is pressed. 4. Briefly press the START/STOP button to power
4. If not, check the messages into the digital the ECM.
display. 5. Perform your tests.
5. Refer to Testing the Engine Cut-off Switch if
required. Removing the Engine Cut-Off Switch (D.E.S.
S. Post)
Key Not Recognized 1. Remove all necessary panel to reach the RFID
The gauge scrolls the message: "Key not connector.
recognized". 2. Unscrew the large plastic nut retaining the en-
Possible causes: gine cut-off switch in place.
– Wrong key D.E.S.S. Post Remover
– Damaged RFID chip (P/N 529035943)
– No signal at RFID-C to ECM
170
Electrical System
3. Remove the engine cut-off switch.

Installing the Engine Cut-Off Switch (D.E.S.S.
Post)
1. Install and align the engine cut-off switch in this
hole.
2. Secure the engine cut-off switch using the
large plastic nut.
D.E.S.S. Post Remover

(P/N 529035943)
3. Connect the RFID connector.

4. Reinstall all removed parts.
5. Test operation of the engine cut-off switch.
07
171
Electrical System
Lights
Diagnostic Guidelines
Lights
Troubleshooting
General 1. Low And High Beam Headlights Will Not Come
On Simultaneously
NOTICE
It is recommended to always disconnect the Jumper JP1 is open circuit or missing.
battery when replacing any electric or elec-
tronic parts. Always disconnect battery ex- – Check jumper (fuse) JP1 in front fuse box, re-
actly in the specified order, BLACK (-) cable fer to power distribution subsection.
first.
2. Brake Lights Will Not Come On When Brakes
Troubleshooting Are Applied
Diagnostic Tips Defective fuse.
It is a good practice to check for fault codes using
the BRP diagnostic software (BUDS2) as a first – Check fuse, refer to the appropriate Brake
troubleshooting step. Refer to Communication Light Circuit Protection in this subsection.
Tools subsection. Defective brake relay.
When troubleshooting an electrical system fault, – Test brake relay (R8), refer to power distribu-
check battery condition, cables and connections tion subsection.
first.
Defective brake light switch(es).
Inspecting an Electrical Connection
– Refer to brake light switches in the brake
When replacing an electric or electronic compo-
subsection.
nent, always check electrical connections. Make
sure they are tight, make good contact, and are Defective wiring/connectors.
corrosion-free. Dirty, loose or corroded contacts
are poor conductors and are often the source of a – Test wiring continuity, refer to applicable wiring
system or component malfunction. diagram.
Pay particular attention to ensure that pins are not 3. Turn Signal Lights Will Not Come On When
bent or pushed out of their connectors. Selected
Ensure all wire terminals are properly crimped on Defective fuse.
wires, and connector housings are properly
fastened. – Check fuse, refer to the appropriate Turn Sig-
nal/Hazard Circuit Protection in this
Check for signs of moisture, corrosion or dullness. subsection.
Clean pins properly with Deoxit lubricant (P/N 293
550 034) and coat them with Dielectric grease (P/ Defective Flasher Module.
N 293 550 004) or other appropriate lubricant
when reassembling them, except if otherwise – Replace flasher module, refer to Turn Signals/
specified such as for the ECM connector. HAZARD in this subsection.
Pay attention to ground wires. Defective wiring/connectors.
For wiring harness connector locations, refer to – Test wiring continuity, refer to applicable wiring
Wiring Harness and Connectors subsection. diagram.
Testing a Circuit Defective Turn Signal Switch.

Check the related-circuit fuse condition with a fuse – Test switch, refer to appropriate Turn Signals/
tester or test lamp (a visual inspection could lead HAZARD in this subsection and to applicable
to a wrong conclusion). wiring diagram.
N O T E : If the electrical system is left activated for 4. Hazard Lights Will Not Come On When
a certain period of time, the accessory relay will Selected
shut down. See Activating the Electrical System in
this subsection for details. Defective fuse.
172
Electrical System
Lights
– Check fuse, refer to Turn Signal/Hazard Circuit – Replace multifunction gauge, refer to gauge
Protection in this subsection. subsection.
Hazard lights 12 Vdc input circuit open.
7. Hazard Lights Indicator Not Working With
– Check wiring and connectors, refer to the ap- Ignition Switch Off
propriate turn signal/hazard in this subsection.
Refer to wiring diagram. Diode D10 open circuit.
Hazard lights selector switch defective. – Test diode, refer to applicable wiring diagram.
– Test switch, refer to the appropriate turn sig- 8. Position Lights Will Not Come On
nal/hazard in this subsection. Refer to wiring
diagram. Defective fuse.
Defective wiring/connector between hazard lights – Check fuse, refer to the appropriate Position
selector switch and flasher module. Lights in this subsection.
– Refer to applicable wiring diagram. Power or ground circuit wiring.
Flasher module ground circuit open. – Check wiring continuity, refer to wiring
– Test wiring and connectors, refer to applicable diagram.
wiring diagram. Defective light bulbs
Defective flasher module. – Test/replace light bulbs.
– Replace flasher module, refer to the appropri-
ate turn signal/hazard in this subsection.
Procedures 07
Activating the Electrical System using an
Ignition Switch
5. Hazard Lights Come On Without Being
Selected NOTICE
Activating the electrical system repeatedly or
Hazard lights switch or wiring short circuit.
using electrical equipment will discharge the
– Check for water in LH multifunction switch. battery and you may not be able to start the
engine.
– Test hazard light switch and wiring, refer to ap-
plicable wiring diagram.
Turn the ignition key to the ON position
Flasher module parallel Resistor is open.
Activating the Electrical System using a RF D.
– Test resistor (between hazard switch output E.S.S. Key
and ground), refer to applicable wiring NOTICE
diagram.
Activating the electrical system repeatedly or
6. Turn Signal/Hazard Lights Indicator In
using electrical equipment will discharge the
Multifunction Gauge Will Not Come On With battery and you may not be able to start the
Turn Signal Or Hazard Lights Selected On, engine.
Ignition Switch On
Press and release the START button for less than
Signal wire from flasher module to multifunction half a second and the electrical system will turn
gauge open circuit. ON:
– Test circuit continuity from flasher module – For 30 seconds, w i t h o u t powering any equip-
(MC2–4) to multifunction gauge (C1–8). ment, if the D.E.S.S. key is N O T installed on
the D.E.S.S. post O R if the Emergency Engine
Defective flasher module. Stop switch is set to the STOP position;
– Replace flasher module, refer to the appropri- – For 10 minutes, powering equipment, if the RF
ate flasher module in this subsection. D.E.S.S. key is installed on the D.E.S.S. post
A N D Emergency Engine Stop is set to the
Defective multifunction gauge. RUN position. The electrical system will be
173
Electrical System
Lights
shutdown after 30 seconds if either the D.E.S. 5. Validate headlight operation.

S. key is removed O R the Emergency Engine
Stop is set to the STOP position. Headlamp Beam Aiming (All Models)
N O T E : If the vehicle is connected to BUDS2 and N O T E : Load vehicle as per normal use.
the RF D. E. S. S. key is installed on its post, the 1. Position vehicle on a level surface 5 m (16 ft) in
electrical system will not shut down. front of a test surface ( wall or screen) as in first
Headlights illustration.
2. Measure the distance from the center of each
Testing the Headlights (ECM 2 Connectors) headlight to the ground (high beam and low
1. Disconnect LOW beam and HIGH beam head- beam).
light bulb connectors. Refer to Replacing the 3. Trace a line on the test surface parallel to the
Headlight Bulb in this subsection. ground at each measured height (one for high
2. Activate the electrical system, refer to Activat- beam and one for low beam).
ing the Electrical System in this subsection. Low beam aiming is correct when the crest of
3. Measure the voltage on headlight connector as the low beam is b e l o w the applicable horizon-
follows. tal center line traced on the test surface as per
Light specification.
switch Wire color Voltage High beam aiming is correct when the center of
position the high beam (focus point) is b e l o w the appli-
cable horizontal center line traced on the test
LO beam GN
Battery surface as per specification.
(Low beam BK
HI beam voltage
connector) Specification
Replacing the Headlight Bulb Low beam crest (top of
low beam) 25 to 125 mm (1 to 5
NOTICE in) b e l o w applicable
Never touch glass portion of a halogen bulb High beam center line
with bare fingers, it shortens its operating life. (focus point)
If glass is touched, clean it with isopropyl al-
cohol which will not leave a film on the bulb.
1. Unplug connector from bulb.

2. Rotate bulb.
TYPICAL
1. Light beam center
A. 5 m (16 ft)
B. Beam aiming specification
TYPICAL
3. Pull bulb out.

4. Properly reinstall removed parts in the reverse
order of their removal.
174
Electrical System
Lights
Taillights/Brake Lights
Brake Light Switch
For brake light switch location and testing, refer to
Brakes subsection.
Taillight/Brake Light Bulb Replacement
1. Unplug connector from bulb.
2. Rotate light bulb counterclockwise to remove it
from taillight.
TYPICAL
1. Headlight center lines
2. Light beam center
Adjusting Beam Aiming

Turn adjustment knobs to adjust beam height and
side orientation to specification.
07
ROTATE BUL B COUNTERCLOCKWISE
3. Remove bulb socket from taillight.

Installation is the reverse of the removal
procedure.
Trailer Plug
Trailer Plug Wire Identification
OUTLANDER LOW BEAM Trailer Flasher Module
1. Adjustment knobs
Function Pin Color
Output to trailer
adaptor to RH turn MC2_2-
GN
signal 2
Output to trailer
adaptor to LH turn MC2_2-
YE
signal 3
12 volt input from

fuse F10 MC2_2-
YE/RD
(unswitched) 1
MC2_2-
Indicator to tell tale OG
4
OUTLANDER HI GH BEAM AND RENEGADE L OW BEAM/HIGH Hazard 12 volt input
BEAM M2_1-6 BG/RD
1. Adjustment knobs from hazard switch
12 volt input from MC2_1-
fuse F7 (switched) VT/WH
5
175
Electrical System
Lights
Trailer Flasher Module

Function Pin Color
LH turn 12 volt input MC2_1-
BG/GY
from flasher switch 2
RH turn 12 volt input MC2_1-
BG/BN
from flasher switch 1
MC2_1-
Ground BK
4
176
Electrical System
Compact Digital Gauge

SERVICE TOOLS

General
NOTICE
It is recommended to always disconnect the
tronic parts. Always disconnect battery ex-
actly in the specified order, BLACK (-) cable
first.
Compact Digital Multifunction Gauge

1. Transmission position
Multifunction Gauge Description 07
Display Function
P Park
R Reverse
N Neutral
H High range
L Low range
1. Selector button
2. Transmission position display
3. Main screen 3) Main Screen
4. Fuel level display
5. 4WD indicator lamp The main screen is used to display numerous
6. Low fuel level indicator lamp functions of the multifunction gauge.
7. Check engine indicator lamp
8. High beam indicator lamp Refer to Multifunction display Modes for the avail-
9. MPH, Km/h indicator lamp
10. Signal lights/hazard lights indicator lamp able display modes.
11. ABS indicator lamp
4) Fuel Level Display
1) Selector Button Bar gauge continuously indicates the level of fuel
The selector button is used to navigate or change in the fuel tank while riding.
settings in the multifunction gauge.
2) Transmission Position Display
This display will show transmission position.
1. Fuel level display
177
Electrical System
5) 4WD Indicator Lamp
When this indicator is ON, it indicates the 4 W D

system is activated.
6) Low Fuel Level Indicator Lamp
RPM Mode
When this indicator is ON, it indicates that there is
approximately 5 l (1.3 gal (liq., US)) of fuel left in In this mode, the display shows the engine RPM.
fuel tank.
7) Check Engine Indicator Lamp
When this indicator is ON, it indicates an engine

fault code, look for a message in the main screen
display.
When this indicator blinks, it indicates that L I M P
H O M E mode is activated. Combined Mode
8) High Beam Indicator Lamp In this mode, the display shows the speed of the
vehicle and the engine RPM.
When this indicator is ON, it indicates that h i g h

b e a m is selected on the headlights switch and
that the ignition key is in the "ON with lights"
position.
9) KM/H or MPH Indicator Lamp
1. Vehicle speed
The applicable lamp turns on to indicate the active 2. Engine RPM
speedometer unit of display.
Odometer (OD)
10) Turn Signal/Hazard lights Indicator Lamp Odometer records the total distance travelled ei-
(If equipped) ther in miles or kilometers.
When this indicator is ON, it indicates:

– A turn signal is activated, or
– The hazard lights are activated.
11) ABS Indicator Lamp (If equipped)
The applicable lamp turns on to indicate ABS sys- Clock

tem malfunction.
Shows current time.
Multifunction Display Modes
Speed Mode
In this mode, the display shows the speed of the
vehicle either in km/h or in MPH.
178
Electrical System
Message Display Mode

If an abnormal engine condition occurs, a mes-
Refer to procedures to set current time. sage may scroll across the main screen in con-
junction with a pilot lamp.
Trip Meter (TP)
The trip meter records the travelled distance since Refer to Diagnostic and fault codes subsection.
it has been reset. Distance travelled is displayed Driving Modes (If Equipped)
either in kilometers or miles.
Some models are equipped with a driving mode
selector.
07
Press and HOLD the selector button for 2 seconds

to reset the trip meter. 1. Driving mode selector
Trip Hour Meter (TH) A message of the selected mode will be displayed
The trip hour meter records vehicle running time at activation and deactivation as follow:
when the electrical system is activated. It can be
used to establish traveling time between 2 places. Drive mode message at Activation
Sport SPORT MODE
Normal NORMAL MODE
Work (If
equipped) WORK MODE
Eco (If equipped) ECO MODE
Navigating the LCD Gauge

Press and HOLD the selector button for 2 seconds WARNING
to reset the hour meter. Never adjust or set functions on the multi-
Engine Hour Meter (EH) function gauge while riding the vehicle.
The engine hour meter records engine running
time. Default Display Mode
After vehicle startup, the default display mode is
either:
– Vehicle speed
– Engine revolutions per minute (RPM)
179
Electrical System
– Both parameters simultaneously (combined While in a resettable mode, push and HOLD se-
mode). lector button for 2 seconds to reset it.
To change from one display to the other, proceed Troubleshooting
as follows.
Diagnostic Tips
1. Turn ignition key to ON to power-up the
system. N O T E : It is a good practice to check for fault co-
2. Wait until the “greeting message” has been des using Use the BRP diagnostic software
displayed. (BUDS2) as a first troubleshooting step. Refer to
3. Press and release selector button once to dis- communication tools subsection.
play OD (odometer).
4. Press the selector button again, this time for 2 I M P O R T A N T : When troubleshooting an electri-
seconds. cal system fault, check battery condition, cables
and connections first.
This will change the Mode to either Speed,
RPM or Combined. Testing a Circuit
Check the related-circuit fuse condition with a fuse
tester or test lamp (a visual inspection could lead
to a wrong conclusion).
N O T E : If the ignition switch is left ON for a cer-
tain period of time, the accessory relay will shut
down.
When replacing an electric or electronic compo-
5. To select another mode, repeat steps 3 and 4 nent, always check electrical connections. Make
until the desired mode is displayed. sure they are tight, make good contact, and are
Temporary Display Mode
are poor conductors and are often the source of a
In the temporary display mode, the following func- system or component malfunction.
tions are available:
– Odometer Pay particular attention to ensure that pins are not
– Clock bent or pushed out of their connectors.
– Trip meter (resettable) Ensure all wire terminals are properly crimped on
– Trip Hour meter (resettable) wires, and connector housings are properly
– Engine hour meter. fastened.
Press and release selector button to change the Check for signs of moisture, corrosion or dullness.
default display mode to the temporary mode. Clean pins properly with Deoxit lubricant (P/N 293
550 034) and coat them with Dielectric grease (P/
N 293 550 004) or other appropriate lubricant
when reassembling them, except if otherwise
specified such as for the ECM connector.
Pay attention to ground wires.
For wiring harness connector locations, refer to
wiring harness and connectors subsection.
Diagnostic Guidelines
1. Selector button Troubleshooting
The gauge will display the selected mode for 10 1. Multifunction Gauge Will Not Come On
seconds then will return to the normal display
mode. Multifunction gauge not powered up.
– Check fuse(s), refer to Circuit Protection in this
subsection.
180
Electrical System
– Test multifunction gauge 12 Vdc input and Gauge type Display Button (Hold)
ground circuits as per Wiring identification in
this subsection. Refer to applicable wiring Analog /
diagram. digital
Odometer SET (S)
Defective Multifunction Gauge. multifunction
gauge
– Replace multifunction gauge.
Compact
2. Multifunction Gauge Communication Error digital Selector
multifunction Default
button
Multifunction gauge CAN circuit open. gauge
– Ensure multifunction gauge is properly con- 2. While holding the button, alternate between
nected and powered up. LOW beam and HIGH beam 3 times.
– Check for applicable fault code using BUDS2,
refer to Diagnostic and fault codes subsection. N O T E : Step 2 must be started on high beam
and completed within 2 s e c o n d s .
– Carry out Testing the CAN Resistor in this
subsection. 3. Release SET button.
– Carry out a continuity test of the multifunction Wiring Identification
gauge CAN wires, refer to applicable wiring
diagram. function PIN
Switched 12 volt input from fuse F6
3. No Fuel Quantity Indication (1000R, T series and European models) 07
17
Defective fuel level sender or wiring. Switched 12 volt input from fuse F4 (All
– Refer to fuel tank and fuel pump subsection. others)
Defective Multifunction Gauge. Unswitched 12 volt input from fuse F1

(1000R, T series and European models)
– Replace multifunction gauge, refer to proce- 16
dures in this subsection. Unswitched 12 volt input from fuse F8
(All others)
Procedures
Multifunction Gauge Ground 20
Resetting the "Maintenance Required" CAN LO 18

Message Using BUDS2 CAN HI 19
1. Connect the vehicle to the lBRP diagnostic
software (BUDS2).. Fuel level gauge signal 4
2. Go to: Fuel level gauge ground 21
– S u m m a r y page
– V e h i c l e button 4WD ON 7
3. Click on the R e s e t S e r v i c e button. HI beam signal (+) 5
Resetting the "Maintenance Required" Overdrive ON 6
Message Using the Gauge Button
1. Select display and hold button as per following Flasher Signal 8
table:
181
Electrical System
Circuit Protection – F u n c t i o n s tab.

– Execute Cluster WOW test
Condition Circuit Protection
Monitoring Measurement Values
Fuse 1 of fuse block 1
Supplied at all times 1. Connect the vehicle to the BRP diagnostic soft-
(from fusible link 1)
ware (BUDS2).
Fuse 6 of fuse block 1 2. In BUDS2, go to:
Supplied with main
(from main relay RY2 – M e a s u r e m e n t s page
relay activated
in fuse block 1) – C l u s t e r button
– P r e s e t or C u s t o m tab.
Setting Using BUDS2 3. In P r e s e t tab, select desired preset values (for
Connect the vehicle to the BRP diagnostic soft- example: Cluster Basic).
ware (BUDS2). 4. In C u s t o m tab, a large list of measurements is
Language Selection displayed. It is possible to choose several val-
ues by clicking "Please Select".
Go to:
– S e t t i n g s page Testing the CAN Resistor
– C l u s t e r button. Disconnect DPS connector. Refer to the appropri-
– Configuration - Change Cluster Language ate Dynamic Power Steering (DPS) subsection.
tab
1. Remove seat to access diagnostic link connec-
Selecting Units tor (DB).
Go to: 2. Remove diagnostic link connector from its
holder.
– S e t t i n g s page
– C l u s t e r button.
– C o n f i g u r a t i o n - C h a n g e C l u s t e r U n i t s tab
Setting the Clock
Go to:
– Configuration - Change Real Time Clock
tab
Selecting Tire Size
Go to:
– E C M button.
– C o n f i g u r a t i o n - C h a n g e T i r e S i z e tab 1. Diagnostic link connector (DB)
Testing Using BUDS2 3. Measure the resistance of the CAN resistors

as follows.
Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).. REQUIRED TOOLS
WOW Test Fluke 115 multimeter
This function is used to check if the indicator lights, (P/N 529 035 868)
display and analog indicators (if applicable) are
functional.
N O T E : This function does not test the signals or

external circuits.
Go to:
– F u n c t i o n s page
182
Electrical System
CAN RESISTOR TEST Release tabs.
diagnostic link Tilt gauge rearward.

Resistance
connector
Pins 1 and 2 Approximately 60 Ω
N O T E : This tests both the ECM and the Cluster

CAN resistors and wires.
TEST RESULT
reading possible cause
Approximate ECM and CLUSTER CAN wires
ly 60 Ω and resistors good
CAN wire to CLUSTER open
Approximate CAN wire to ECM open Disconnect the gauge connector.
ly 120 Ω CLUSTER CAN resistor open
ECM CAN resistor open Remove gauge from the inner support by pulling it
up.
Infinite Removing the Multifunction Gauge
(open CAN wire to DB connector open
circuit (Renegade)
circuit)
1. Remove console panel, refer to
subsection.
body 07
Removing the Multifunction Gauge 2. Remove the gauge support as shown.
(Outlander)
1. Remove gauge outer support.
– Push in on both sides of its leading edge to
disengage it.
– Lift up and pull forward to remove.
N O T E : There are a total of 6 tabs that retain the

gauge support.
3. From the back of the gauge support, release

the gauge retaining tabs and remove the
gauge from its support.
OUTER GAUGE SUPPORT REM OVAL

1. Push in and lift up here (both sides)
2. From the back of gauge support, rotate the

gauge clockwise to release it from its support.
Analog / Digital Multifunction Gauge
183
Electrical System
GAUGE RELEASE TABS (4 )
Installing the Multifunction Gauge

For the installation, reverse the removal
procedure.
184
Electrical System
4.5" Digital Display gauge
4.5" Digital Display Refer to wiring diagram information subsection for

diagnostic tips on troubleshooting electrical
gauge problems.
General NOTICE
Most of the electrical tests require the following It is recommended to always disconnect the
tools. battery when replacing any electrical compo-
nent. Always disconnect battery as specified,
Required Tools BLACK (-) cable first. Do not place tools on
battery.
Fluke 115 multimeter
(P/N 529 035 868)
Test light
Indicator Lamps Description

Important information about vehicle condition is displayed on the multifunction gauge. When starting the
engine, always look at the gauge for any indicator lamps or special messages.
N O T E : The low oil indicator lamp will stay ON as long as the engine is not started.
Important information messages can also be displayed temporarily in the lower display to assist indicator
lamps. 07
LOWER DISPL AY
Indicator Lamps (Malfunctions)

Indicator
Message Cause What To Do
Lamp
BAD KEY Defective key Replace key.
WRONG KEY Wrong key Use the right key for the vehicle.
NA
Problem of reading
CHECK KEY Verify end replace key if necessary.
key
– Stop and wait for engine
Engine is to cool off.
HIGH ENGINE overheating – Check for leaks.
TEMPERATURE or faulty sensor – Check coolant level and
adjust (see Mainte-
nance procedures).
Low battery Low battery voltage – Check charging system.

– Check battery connections.
185
Electrical System

Indicator
Message Cause What To Do
Lamp
– Check for brake fluid leaks.

BRAKE FAILURE - Low brake fluid level – Check brake fluid level and
LOW BRAKE FLUID or faulty sensor adjust (see mainte-
nance procedures).
Dynamic power Refer to Dynamic Power Steering (DPS)for
CHECK DPS steering component diagnostic procedure.
Transmission – Remove key, wait 20 seconds, and

TRANSMISSION Control Module reinsert key.
SIGNAL FAULT component – Diagnose using the BRP diagnostic
software (BUDS2)
Important engine
management Diagnose using the BRP diagnostic
LIMP HOME MODE software (BUDS2)
component
malfunction
– Check for oil leaks.
LOW OIL - STOP Low oil pressure – Check oil level and adjust
ENGINE
(see maintenance procedures.
--- Faulty sensor – Check sensor.

– Check sensor connection to cluster.
(Flashing)
NA = Not applicable
Troubleshooting troubleshooting procedures may not cover prob-
Diagnostic Tips lems resulting from one of these causes.
I M P O R T A N T : When solving an electrical prob- NOTICE
lem, the first thing to do is to check the battery
Ensure all terminals are properly crimped on
condition as well as its cables and connections.
wires and connector housings are properly
Install a battery charger on battery terminals for fastened. When replacing any electric or
any tests that involves a prolonged "key ON" peri- electronic part(s), always check electrical
od. If battery voltage gets too low, not only test re- connections. Make sure that they are clean,
sults can be altered, but the vehicle electrical corrosion-free, tight and make good contact.
system may not operate normally. The voltage and current might be too weak to
go through dirty or corroded connector pins
Pay attention to ground wires. They could become or terminals.
loose or corroded which causes them to act as an
additional load in a circuit, dropping voltage and Multifunction Gauge Troubleshooting
reducing current to components. Some compo-
nents may be grounded through their outer casing Troubleshooting
and mounting hardware. This should also be 1. Gauge Functions Inoperative Or Working
considered. Intermittently
Electrical Connectors Power supply or ground problem

Pay particular attention to ensure that pins are not – Check power supply and ground circuits.
out of their connectors, loose, or damaged. The
186
Electrical System
Procedures multifunction gauge power test

Multifunction Gauge
CL battery Ignition
Results
connector Position
Multifunction Close to
connector Any battery
pin 1 Negative voltage
Multifunction (-) post Close to
connector ON battery
Testing the Multifunction Gauge pin 11 voltage
Testing the Multifunction Gauge Using BRP
Diagnostic Software (BUDS2). If there is no power at pin 1, check fuse F1 and
1. Connect the vehicle to the BRP diagnostic soft- the related circuit.
ware (BUDS2). If there is no power at pin 11, in check fuse F6,
2. In BUDS2, select the following: relay RY3, and the related circuit.
– F u n c t i o n s page If the power test is within specification, contin-
– C l u s t e r button ue with Testing the Multifunction Gauge
– Execute WOW Test Ground Circuit.
N O T E : The W O W T e s t only tests the gauge Testing the Multifunction Gauge Ground
L E D s and L C D . It does not test the actual circuit Circuit
functions related to each indication. 1. Test as per the following table. 07
Testing the Multifunction Gauge Power Input Multifunction Gauge Ground Test
If the multifunction gauge is inoperative, first check
for fault codes with BRP Diagnostic Software, re- CL Connector Battery Result
cord all faults then erase them. Reactivate the
electrical system and recheck for faults. If any fault Negative (-)
Pin 2 post Close to 1 Ω
code appears, perform service actions required.
Refer to communication tools subsection.
2. If the ground at pin 2 is not within specification,
1. Remove multifunction gauge. check the related circuit.
2. Perform testing at multifunction gauge connec- 3. If the ground tested to specification, continue
tor as per following illustration and tables. with Testing the multifunction gauge CAN
Circuit.
Testing the Multifunction Gauge CAN Circuit
1. Remove the seat for access to the DLC (Diag-
nostic Link Connector). Refer to body
subsection.
2. Test as per the following table.
Multifunction Gauge CAN Wire Test

CL
DLC Results
MUL TI FUNCTION GAUG E CONNECTOR (PIN-OUT) Connector
Pin 13 (CAN
HI) Pin 1 Close to 0.4 Ω
Pin 14 (CAN
LO) Pin 2 Close to 0.4 Ω
187
Electrical System
If the CAN wire verification test fails, check the

related circuit.
If the multifunction gauge functions, however
there is a suspected communication problem
with another component, perform this test be-
tween the multifunction gauge and that
component.
If the multifunction gauge power, ground and
CAN verification tests are all to specifications
and the multifunction gauge is inoperative, re-
place the multifunction gauge.
Removing the Multifunction Gauge 1. Push in
1. Remove gauge support.

– Push in on both sides of its leading edge to 1. The installation is the reverse of the removal
disengage it. procedure. However, pay attention to the
– Lift up and pull forward to remove. following.
2. Start vehicle engine and test gauge functions.
N O T E : There are a total of 6 tabs that retain the 3. When updates are completed, perform the
gauge support.
following:
– Transfer the vehicle mileage as described
in Vehicle Mileage Transfer.
– Change settings as per customer preferen-
ces (language and units) as described in
setting language and units of measurement
Vehicle Mileage Transfer
1. In BUDS2, go to:
– S E T T I N G S page
– C L U S T E R button
– S E T T I N G S tab.
2. Select I n c r e a s e O d o m e t e r M i l e a g e .
OUTER GAUGE SUPPORT REMOVAL 3. Click on the upper right arrow in the green
circle.
Disconnect the gauge connector. 4. Read carefully the on-screen instructions be-
fore clicking in the value box.
5. Enter the new mileage if it is different from the
indicated one.
6. Press SET button.
7. Press the WRITE TOTAL button.
8. Select OK to confirm the mileage.
9. Close the window.
Setting Language and Units of Measurement
1. In BUDS2, go to:
– S E T T I N G S tab
– Configure Language and Units.
From the back of the gauge support, release the
gauge retaining tabs and remove the gauge from
its support.
188
Electrical System
7.6" Digital Display Gauge
7.6" Digital Display Indicator Lamps (Malfunctions)
Gauge Indica
tor Digital
Cause What To Do
General Lamp( Warning
Most of the electrical tests require the following S)
tool. - Recharge battery.
LO BATT
Required Tool Low or
VOLT - Check battery
high
or connections.
battery
Fluke 115 multimeter HI BATT
voltage - Check the charging
ON VOLT
(P/N 529 035 868) system.
ABS - Refer to the Brakes

Refer to wiring diagram information subsection for malfunc subsection and check
diagnostic tips on troubleshooting electrical ABS tion. No the system.
problems. FAULT ABS
ON opera
NOTICE tion
battery when replacing any electrical compo- - Refer to the VSS
VSS subsection and check
nent. Always disconnect battery as specified, VSS
malfunc the system.
BLACK (-) cable first. FAULT
ON
tion
07
Indicator Lamps Description
EBD - Refer to the Brakes
Important information about vehicle condition is EBD
subsection and check
malfunc
displayed on the multifunction gauge. When start- FAULT
tion the system
ing the engine, always look at the gauge for any
indicator lamps or special messages. Low - Check for brake fluid
brake leaks.
Indicator Lamps (Malfunctions) BRAKE fluid
- Check and adjust the
FAILURE level or
Indica ON brake fluid level.
faulty
tor Digital
Cause What To Do sensor
Lamp( Warning
S) - Move the park position
Park lever in the locked
- Use the right key for position.
FLASH position
the vehicle.
ING lever
Wrong - Program a new key if + NONE not
or the previous key is BEEP locked
None BAD KEY
defec defective. ING AT at key
tive key KEY off
- Check wiring and
connectors. Refer to OFF
the Wiring Diagram. Engine - Stop the engine. The
manage cluster must be
Stop and wait for
- ON ment completely shut down.
HIGH Engine engine to cool off. CHECK
compo
ENGINE is ENGINE
- Check for leaks. nent
TEMPER over
malfunc
ATURE heating - Check and adjust the
ON tion
coolant level.
189
Electrical System

troubleshooting procedures may not cover prob-
lems resulting from one of these causes.
Indica
tor Digital NOTICE
Cause What To Do Ensure all terminals are properly crimped on
Lamp( Warning
S) wires and connector housings are properly
fastened. When replacing any electric or
Impor - Connect the vehicle to electronic part(s), always check electrical
tant the BRP diagnostic connections. Make sure that they are clean,
engine software (BUDS2). corrosion-free, tight and make good contact.
manage Check faults codes and The voltage and current might be too weak to
LIMP
ment perform recommended go through dirty or corroded connector pins
HOME
FLASH compo actions. or terminals.
MODE
ING nent or
VSS Multifunction Gauge Troubleshooting
malfunc
tion Troubleshooting
1. Gauge Functions Inoperative Or Working
Low oil - Check for oil leaks. Intermittently
NONE pres - Check and adjust the
ON sure Power supply or ground problem
engine .
– Check power supply and ground circuits.
Variable messages - The message changes in
accordance with the defective component. Procedures
ON Multifunction Gauge
Troubleshooting Testing the Multifunction Gauge

Diagnostic Tips Before beginning any troubleshooting, test or re-
pair, always check for fault codes.
I M P O R T A N T : When solving an electrical prob-
lem, the first thing to do is to check the battery 1. Check for fault codes using BUDS2.
condition as well as its cables and connections. 2. Record all fault codes, then erase them.
3. Perform a complete shutdown of the electrical
Make sure the battery is fully charged or install a system and reactivate it.
power pack for any tests that involves a prolonged 4. Check fault codes. If a previous fault codes re-
"key ON" period. If battery voltage gets too low, appears, perform the required service actions.
not only test results can be altered, but the vehicle
electrical system may not operate normally. Testing the Multifunction Gauge Using BRP
Diagnostic Software (BUDS2)
Pay attention to ground wires. They could become 1. Connect the vehicle to the BRP diagnostic soft-
loose or corroded which causes them to act as an ware (BUDS2).
additional load in a circuit, dropping voltage and 2. In BUDS2, go to:
reducing current to components. Some compo-
nents may be grounded through their outer casing – F u n c t i o n s page
and mounted hardware. This should also be – C l u s t e r button
considered. – Routines - Execute Cluster WOW test.
Electrical Connectors 3. All indications will come and stay ON so that
you can verify each indication.
Pay particular attention to ensure that pins are not
out of their connectors, loose, or damaged. The N O T E : The W O W T e s t only tests the gauge
L E D s and L C D . It does not test the actual circuit
functions related to each indication.
Testing the Multifunction Gauge Power Input
1. Remove multifunction gauge.
190
Electrical System
2. Perform the test at multifunction gauge con- Testing the Multifunction Gauge CAN Circuit
nector as per following illustration and tables. 1. Remove the seats for access to the DLC (Diag-
nostic Link Connector). Refer to body
subsection.
Multifunction Gauge CAN Wire Test

CL
DLC Results
Connector
Pin 13 (CAN
HI) Pin 1 Close to 0.4 Ω
MUL TI FUNCTION GAUG E CONNECTOR (PIN-OUT)
Pin 14 (CAN
LO) Pin 2 Close to 0.4 Ω
Multifunction Gauge Power Test
If the CAN wire verification test fails, check the
CL_A Battery Ignition related circuit.
Results
Connector Position
If the multifunction gauge functions, however
Multifunction Close to there is a suspected communication problem
connector Any battery with another component, perform this test be-
pin 1 Negative voltage tween the multifunction gauge and that
(-) post component.
Multifunction
connector ON
Close to
battery If the multifunction gauge power, ground and
07
pin 11 voltage CAN verification tests are all to specifications
and the multifunction gauge is inoperative, re-
If there is no power at pin 1, check fuse F1L place the multifunction gauge.
and the related circuit.
Removing the Multifunction Gauge
If there is no power at pin 11, in check fuse Remove gauge support.
F7L, MAIN relay RY3L, and the related circuit. – Push in on both sides of its leading edge to dis-
If the power test is within specification, contin- engage it.
ue with Testing the Multifunction Gauge – Lift up and pull forward to remove.
Ground Circuit.
N O T E : There are a total of 6 tabs that retain the
Testing the Multifunction Gauge Ground gauge support.
Circuit
Multifunction Gauge Ground test
CL Connector Battery Result

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

check the related circuit.
3. If the ground tested to specification, continue
with Testing the multifunction gauge CAN wire
Circuit. OUTER GAUGE SUPPORT REMOVAL
Disconnect the gauge connector.
191
Electrical System
– Transfer the vehicle mileage as described

in Vehicle Mileage Transfer.
– Change settings as per customer preferen-
ces (language and units) as described in
Setting Language and Units of
Measurement
Vehicle Mileage Transfer
1. In BUDS2, go to:
– S E T T I N G S tab.
2. Select I n c r e a s e O d o m e t e r M i l e a g e .
1. Remove retaining screws securing gauge trim. 3. Click on the upper right arrow in the green
circle.
4. Read carefully the on-screen instructions be-
fore clicking in the value box.
5. Enter the new mileage if it is different from the
indicated one.
6. Press SET button.
7. Press the WRITE TOTAL button.
8. Select OK to confirm the mileage.
9. Close the window.
Setting Language and Units of Measurement
1. In BUDS2, go to:
2. Remove gauge by pinching the retaining tabs. – S E T T I N G S page
– S E T T I N G S tab
– Configure language and units.
Cluster Switch
Removing the Cluster Switch
1. Remove the console. Refer to Body
subsection.
2. Remove fuse box from console support without
disconnecting connectors.
3. Disconnect cluster switch connector.
following.
Tightening Torque
Multifunction 0.85 ± 0.15 Nm
gauge retaining (8 ± 1 lbf-in)
screws
2. If the multifunction gauge was replaced, con-

nect the vehicle to the BRP diagnostic software
(BUDS2) and apply any available updates.
3. When updates are completed, perform the
following:
192
Electrical System
4. If there is no current at pin 2 for either tests, re-

place cluster switch.
Installing the Cluster Switch
Make sure that the cluster switch is secured and
that wires are not pinched once reinstalled.
Testing the Cluster Switch with the Main

Harness
1. Disconnect the cluster connector CL.
2. Push the MODE button and test as per the fol-
lowing table.
Mode Position Ground Test

CL Connector Mode position
Pin 12 Pin 5 07
3. Push the SET button and test as per the follow-
ing table.
Set Position Ground Test

CL Connector Set Position
Pin 12 Pin 15
4. If there is no current at pin 12 for either tests,

check the related circuit.
Testing the Cluster Switch Alone
1. Disconnect the cluster switch.
2. Push the MODE button and test as per the fol-
lowing table.
Mode Position Ground Test

CL_SW Connector Mode Position
Pin 2 Pin 1
3. Push the SET button and test as per the follow-

ing table.
Set Position Ground Test

CL_SW Connector Set Position
Pin 2 Pin 3
193
Electrical System
Accessories
Accessories For wiring harness connector locations, refer to

wiring harness and connectors subsection.
General
Procedures
NOTICE Activating the Electrical System
NOTICE
tronic parts. Always disconnect battery ex- Activating the electrical system repeatedly or
actly in the specified order, BLACK (-) cable using electrical equipment will discharge the
first. battery and you may not be able to start the
engine.
Troubleshooting
Diagnostic Tips Turn the ignition key to the ON position
12 Volt Power Outlet
N O T E : It is a good practice to check for fault co-
des using BRP diagnostic software (BUDS2) as a Removing and Installing a 12 Volt Power
first troubleshooting step. Refer to communication Outlet
tools subsection. 1. Remove the gauge support, refer to GAUGE in
this subsection.
I M P O R T A N T : When troubleshooting an electri- 2. Unplug the connectors of the power outlet.
cal system fault, check battery condition, cables 3. Unscrew the retaining nut.
and connections first. 4. Reverse procedure for installation.
Testing a Circuit 12 Volt Power Outlet Wire Identification
Check the related-circuit fuse condition with a fuse
tester or test lamp (a visual inspection could lead Pi
Function Color
to a wrong conclusion). n
N O T E : If the electrical system is left activated for 12 volt input from fuse F3
a certain period of time, the accessory relay will (iTC equipped models)
2 RD/BN
shut down. See Activating the Electrical System in 12 volt input from fuse F12
this subsection for details. (All others)
Ground
When replacing an electric or electronic compo- (to ground terminal BK3) 1 BK
nent, always check electrical connections. Make
sure they are tight, make good contact, and are
12 Volt Power Outlet Circuit Protection
are poor conductors and are often the source of a Condition Circuit Protection
system or component malfunction.
Supplied with
Pay particular attention to ensure that pins are not accessories
bent or pushed out of their connectors. relay (RY3 for
Ensure all wire terminals are properly crimped on iTC equipped Fusible link 2 (FL2)
wires, and connector housings are properly models, RY5 for
fastened. all others)
activated
Check for signs of moisture, corrosion or dullness.
Clean pins properly with Deoxit lubricant (P/N 293 Heated Visor Connectors
550 034) and coat them with Dielectric grease (P/
N 293 550 004) or other appropriate lubricant Removing and Installing the Front Heated
Visor Connector
when reassembling them, except if otherwise
specified such as for the ECM connector. 1. Unscrew the cap from the connector.
Pay attention to ground wires.
194
Electrical System
Accessories
Removing and Installing the Rear Heated

Visor Connector
1. Remove the rear seat.
2. Underneath, disconnect the seat harness
connector.
3. Separate the seat cushion from the base.
2. Refer to gauge and remove the gauge support.

3. Refer to body and remove:
– Windshield
– Console
4. Disconnect the other end of the harness from
the accessory connector. 4. Remove the heated visor connector cap.
07
5. The installation is the reverse of the removal 5. Cut the black wire near the eyelet.
procedure, however, pay attention to the 6. Remove the heated visor connector from the
following. handhold, then pass it through the openings.
6. Install the negative wire eyelet between the 7. Disconnect the wires from the seat harness.
console and the connector body.

UNDERNEATH THE CONSO LE procedure, however, pay attention to the
1. Negative eyelet following.
2. Connector body
9. Pass the wires through the openings, then
crimp the new eyelet to the black wire.
195
Electrical System
Accessories
10. Install the eyelet between the seat base and

the connector body.
4. Move the air intake tube aside, and disconnect

the throttle lever wires from the accessories
connector.
TYPICAL - UNDERNEATH THE SEAT BASE
1. Negative eyelet
2. Connector body
Tightening Torque
Seat cushion retaining 5 ± 1 Nm

Handhold retaining 25 ± 3 Nm
screws (18 ± 2 lbf-ft)
Heated Visor Connectors Wire Identification 5. Note the wire routing and cable ties position.
The heated visor connectors are connected to the 6. Cut the cable ties.
DC3 accessory connector through an extension 7. Refer to Steering System and remove the
harness. throttle lever.
To verify the extension Harness, refer to Testing
procedure, however, pay attention to the
the Rear Extension Harness Output Voltage in
following.
Heated Passenger Grips.
Heated Throttle Lever Tightening Torque
Removing and Installing the Heated Throttle Air intake tube 1.6 ± 0.4 Nm
Lever retaining screw (14 ± 4 lbf-in)
1. Refer to Gauge and remove the gauge
support. Testing the Throttle Lever Heating Element
2. Refer to Body and remove: Resistance
– Windshield 1. Refer to Removing and Installing the Heated
– Console Throttle Lever for connector access.
2. Disconnect the heating element connector.
3. Remove the air intake tube retaining screw. 3. Measure the heating element resistance as
per following table.
Throttle Lever Heating Element Test

Resistance
Heater wire @ 20 °C (68 °F)
OR BK 21 to 26 Ω
196
Electrical System
Accessories
4. If the resistance is out of specification, replace 6. Remove the handlebar tip.

the throttle lever.
5. If resistance is good, carry out Testing the
Throttle Lever Heating Element Input Voltage.
Testing the Throttle Lever Heating Element
Input Voltage
1. I M P O R T A N T : Make sure the switch power
supply and ground are good before carrying
out this test.
2. Refer to Removing and Installing the Heated
Throttle Lever for connector access.
3. Activate the electrical system or start engine. 7. Loosen the grip clamping screw.
4. Backprobe the heating element connector and
measure voltage as per following table.
Heating Voltage
Selected
Element (Approximate)
Heat Level
Connector
1 3 to 3.5 Vdc
OR BK 2 6 to 7 Vdc
wire wire 3 9 to 10.5 Vdc
4 12 to 14 Vdc 07
8. Remove the grip.
5. If voltage is out of specifications, replace the
switch.
N O T E : If the grip does not come off, cut it
lengthwise.
Heated Handlebar Grips
Removing and Installing the Heated procedure, however, pay attention to the
Handlebar Grips following.
1. Refer to Body and remove:
Tightening Torque
– Windshield
– Console 4.5 ± 0.5 Nm
– Gauge support Clamping screw
(40 ± 4 lbf-in)
2. Disconnect the heated grip wires from the
switch harness. 0.4 ± 0.1 Nm
Handlebar tip screw
(4 ± 1 lbf-in)
Testing the Handlebar Grips Heating Element

1. If only one element is heating up, carry out this
test.
2. If no element is heating up, carry out Testing
the Heated Handlebar Grips Input Voltage.
Handlebar Grips for connector access.
5. Measure resistance as per following table.
RH CONNECTOR SHOWN
3. Note the wire routing and cable ties position.

4. Cut the cable ties.
5. On the LH side, split the multifunction switch.
197
Electrical System
Accessories
Grips Heating Element Test

Resistance
Heater Wire @ 20 °C (68 °F)
RD BK 8.5 to 10.5 Ω
6. If the resistance is out of specification, replace

the grip.
7. If resistance is good, verify the accessory har-
ness wiring continuity.
Testing the Heated Handlebar Grips Input 4. Note the wire routing.
Voltage 5. Disconnect the wires from the seat harness.
1. If no element is heating up, carry out this test. 6. Cut the heating element wires (on the hand-
2. If only one element is heating up, verify the ac- hold side).
cessory harness wiring continuity and carry out 7. Remove the handhold retaining screw.
Testing the Handlebar Grips Heating Element. 8. Remove the handhold from the seat base.
3. I M P O R T A N T : Make sure the switch power
supply and ground are good before carrying
out this test.
Handlebar Grips for connector access.
5. Activate the electrical system or start engine.
6. Backprobe the heating element connector and
measure voltage as per following table.
Heating Voltage
Selected
Element (Approximate)
Heat Level
Connector
1 3 to 3.5 Vdc
OR BK 2 6 to 7 Vdc procedure, however, pay attention to the
wire wire 3 9 to 10.5 Vdc following.
10. Once the wires are passed through the open-
4 12 to 14 Vdc ing, insert and lock the terminals in the connec-
tor housing as per following table.
7. If voltage is out of specifications, replace the
switch. Wire Connector housing PIN
Heated Passenger Grips GY 1
Removing and Installing the Heated GN 2
Passenger Grips
1. Remove the rear seat. RD 3
connector. Tightening Torque
Seat cushion retaining 5 ± 1 Nm
Handhold retaining 25 ± 3 Nm
198
Electrical System
Accessories
Testing the Rear Extension Harness Output

Voltage
Remove the rear seat.
Underneath, disconnect the seat harness
connector.
Rear Extension Voltage

Harness Connector (Approximate)
RD/BR wire BK wire 12 Vdc

7. Measure resistance as per following table.
Grips Heating Element Test

Resistance
Heater wire @ 20 °C (68 °F)
GN 13 to 17 Ω
GY
RD 6 to 8 Ω
8. If the resistance is out of specification, replace

Testing the Passenger Grips Switch Output
1. If no element is heating up, carry out this test.
the handhold. 07
2. If only one element is heating up, verify the ac- Winch (If Equipped)
cessory harness wiring continuity and carry out Winch Wire Identification
Testing the Passenger Grips Heating Element.
3. IMPORTANT: Make sure the switch power Winch Relay
supply is good before carrying out this test.
4. Backprobe the switch connector and measure Function Pin Color
voltage as per following table. 12 volt input from battery
(winch power) BP4 RD
Heat Heated Element Voltage
Level Connector (Approximate) S
Ground (Wire) BK
W4
HI RD wire 12 Vdc
GY wire Ground (Cable) BN4 BK
LO GN wire 12 Vdc
12 volt input from S
5. If voltage is out of specifications, replace the switch (IN) GN/BU
W1
switch.
6. If voltage is good, verify seat harness wiring 12 volt input from S
continuity. switch (OUT) LT BU
W2
Testing the Passenger Grips Heating Element
1. If only one element is heating up, carry out this
test.
2. If no element is heating up, verify the acces-
sory harness wiring continuity and carry out
Testing the Passenger Grips Switch Output.
3. Remove the rear seat.
connector.
199
Electrical System
Accessories
Winch Relay Access

Winch Relay
Remove the RH inner fender panel. Refer to Body
Function Pin Color subsection.
Motor power (switches Winch Motor Circuit Protection
S RD (with blue
polarity depending on Two circuit breakers (50 A) are used to protect the
W3 sleeve)
rotation direction) winch motor in case of overheating.
Motor power (switches Removing the Winch
S RD (with
polarity depending on 1. Disconnect the battery BLACK (-) cable first,
W5 yellow sleeve)
rotation direction) then the RED (+) cable.
N O T E : The small black wire at terminal SW4 NOTICE

connected to the diodes is used to prevent electric Always respect this order for disassembly;
arcs in the switch. It can also be connected to disconnect BLACK (-) cable first.
BN4.
2. Remove the hook.
WINCH RELAY
1. To GN / BU wire
2. To LT BU wire
3. To winch motor cable with BLUE sleeve
4. To BK ground cable 1. Hook
5. To winch motor cable with YELLOW sleeve 2. Hook pin
6. To RD positive cable 3. Cotter pin
7. BK ground wire (can also be connected with the ground cable)
1. Remove and discard the cotter pin.
2. Remove the hook pin.
Winch Switch 3. Remove the winch cable fairlead.
PI
FUNCTION COLOR
N
12 volt input from fuse A RD/BK
12 volt output to relay
winding (IN) C GN/BU
12 volt output to relay

winding (OUT) B LT BU
NOTICE
Before testing, make sure the winch is in
FREESPOOL mode (Freespool clutch TYPICAL
1. Winch fairlead
disengaged). 2. Fairlead retaining screws
200
Electrical System
Accessories
4. Remove the front skid plate.

5. Disconnect the turn signal lights and front
marker lights (If equipped).
TYPICAL
1. Front bumper support
2. Winch retaining screws
1. Front skid plate
2. Retaining screws 8. Remove winch.
6. Disconnect both winch power cables. Installing the Winch
N O T E : Note the position of the power cables for 1. The installation is the reverse of the removal
reinstallation. procedure. However, pay attention to the
following.
2. Connect winch power cables as noted at
removal. 07
N O T E : If the winch power cables are not con-
nected correctly, the winch motor will operate in
the reverse direction of selection.
Tightening Torque
Winch retaining 16 ± 2 Nm
7 ± .5 Nm
Winch power cables
(62 ± 4 lbf-in)
TYPICAL Winch fairlead elastic 16 ± 2 Nm
1. Winch power cables
nuts (142 ± 18 lbf-in)
7. Remove the four winch retaining screws from
the front bumper support. 3. Install a n e w cotter pin on the hook pin.
201
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
202
DRIVE SYSTEM
08
203
Drive System
Wheels and Tires
08 Drive System
Wheels and Tires

SERVICE PRODUCTS
LOCTITE 271 (RED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220, 246, 262–263

LOCTITE 648 (GREEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221, 233–234, 248, 255
LOCTITE 767 (ANTI-SEIZE LUBRICANT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
XPS SYNTHETIC GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213, 219–221, 227, 232–234,
240, 246–247, 252, 255
Procedures
Tires
WARNING
Do not rotate tires. The front and rear tires
have a different size. Respect direction of ro-
tation when applicable.
Tire Pressure
WARNING
Tire pressure greatly affects vehicle handling
and stability. Insufficient pressure may cause TYPICAL
tire to deflate and rotate on wheel. Excessive 1. Direction of rotation
pressure may burst the tire. Always follow
recommended pressure. Check for proper tire size
Check pressure when tires are c o l d before using

the vehicle. Tire pressure changes with tempera-
ture and altitude. Recheck pressure if one of these
conditions has changed.
Refer to Technical Specifications for tire pressure
table.
Tire Inspection
Check tire for presence of slits, bulges, wear or
other damage. Replace if necessary.
Tire Replacement
Use an automotive tire changer to replace tires.
WARNING
– Replace tires only with the same type and
size as original tires.
– For unidirectional tread pattern, ensure
that the tires are installed in the correct di-
rection of rotation.
204
Drive System
Wheels and Tires
Tire Mounting on Beadlock Wheels

NOTICE
Do not use an impact wrench for installing
beadlock screws. The risk of screw breaking
or screw stripping is high when using an im-
pact wrench.
3. Tighten beadlock screws as per following

specification and sequence.
N O T E : To ensure even pressure on the bead-

lock clamp ring, tighten screws a f e w t u r n s a t a
time.
Tightening Torque
TYPICAL
Beadlock screws
1. Inner tire bead seat 3 ± 1 Nm (27 ± 9 lbf-in)
2. Outer tire beadlock ring (FIRST TORQUE)
N O T E : Tires should be mounted, by an experi-

enced person, in accordance to good tire mount-
ing practices using acceptable tire mounting
equipment designed for the tire industry.
1. Mount the tire on wheel.

1. On the opposite side of beadlock, apply
the tire mounting lube on inner bead of tire
and wheel to ensure proper seating when
inflating. 08
2. Mount the inner bead over the wheel.
NOTICE
Mount tire from beadlock side only.
FIRST TIGHTENING SEQUENCE
3. Seat the tire outer bead in the shoulder of
4. At this time check if the tire is still centered on
the beadlock inner ring and center the tire.
wheel. Reposition it if necessary.
5. Tighten beadlock screws as per the s e c o n d
torque using the same sequence.
Tightening Torque
Beadlock screws
(SECOND 8 ± 1 Nm (71 ± 9 lbf-in)
TORQUE)
i. Tire outer bead

ii. Beadlock inner ring shoulder
2. Install all beadlock screws. To avoid cross

threading, start all screws by hand.
205
Drive System
Wheels and Tires
SECOND TIGHTENING SEQUENCE FINAL TIGHTENING SEQUENCE
8. Inflate tire to seat the inner bead on wheel. Al-

N O T E : The beadlock clamp ring should be in ways use safe practices, such as a tire safety
contact with the beadlock inner ring. The beadlock cage.
clamp ring can flex slightly to match the tire bead.
IT IS NORMAL. WARNING
Never exceed tire recommended maximum
6. Verify the gap between tire and beadlock
pressure for seating beads.
clamp ring, it should be practically equal all
around the ring.
Wheels
Removing the Wheel
1. Loosen nuts just enough to be able to unscrew
them once the vehicle will be off the ground.
2. Lift and support the vehicle. Refer to Introduc-
tion subsection.
3. Remove nuts, then remove wheel.
Inspecting the Wheel
Inspect wheel for wear or damage especially at
A. Gap equal all around beadlock clamp ring the mounting holes.
If the gap is not acceptable: Installing the Wheel
– Loosen all screws. 1. At installation it is recommended to apply anti-
– Check tire position on wheel and reposition seize lubricant on conical area o n l y .
it if necessary.
– Restart the tightening sequence as Loctite 767 (anti-seize lubricant)
detailed.
7. Tighten beadlock screws a f i n a l time as per
following specification and sequence.
Tightening Torque
Beadlock screws
11 ± 1 Nm (97 ± 9 lbf-in)
(FINAL TORQUE)
206
Drive System
Wheels and Tires
2. Check if tires are unidirectional.
TYPICAL
1. Direction of rotation
08
3. Tighten wheel lug nuts to the specified torque
using the illustrated sequence.
Tightening Torque
Wheel lug nuts 80 ± 5 Nm (59 ± 4 lbf-ft)
TIGHTENING SEQUENCE
NOTICE
Always use the recommended wheel lug nuts
for the type of wheel. Using a different lug nut
could cause damages to the rim or studs.
207
Drive System
Front Drive
Front Drive
SERVICE TOOLS
BACKLASH MEASUREMENT TOOL . . . . . . . . . . . . . . . . . (P/N 529 035 665) . . . . . . . . . . . . . . . 215, 229, 242
BACKLASH MEASUREMENT TOOL . . . . . . . . . . . . . . . . . . (P/N 529035665) . . . . . . . . . . . . . . . . . . . . . . . 257
BELLOWS CLAMP PLIERS . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529 036 120) . . . . . . . . . . 213, 227, 240, 253
CV JOINT EXTRACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529 036 005) . . . . . . . . . . 214, 227, 241, 253
DIFFERENTIAL NUT SOCKET 65MM . . . . . . . . . . . . . . . . (P/N 529 036 302) . . . . . . . . . . . . . . . . . . . 218, 245
DIFFERENTIAL NUT SOCKET 65MM . . . . . . . . . . . . . . . . . (P/N 529036302) . . . . . . . . . . . . . . . . . . . . . . . 260
SPANNER SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529 035 649) . . . . . . . . . . . . . . . . . . . 218, 231
SERVICE PRODUCTS
LOCTITE 271 (RED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220, 246, 262–263

LOCTITE 648 (GREEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221, 233–234, 248, 255
240, 246–247, 252, 255
450 models
208
Drive System
Front Drive
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
(M8)
NEW
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
(M10)
NEW
See
STEERING
SYSTEM
XPS
NEW 08
Synthetic
NEW
grease
205 ± 15 N•m
(151 ± 11 lbf•ft)
XPS
Synthetic
grease
Loctite
648
75 ± 5 N•m
(55 ± 4 lbf•ft)
209
Drive System
Front Drive
All except 450
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
(M8)
NEW
NEW
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
(M10) See
STEERING
SYSTEM
Loctite
648
NEW
XPS Synthetic XPS
grease Synthetic
grease
75 ± 5 N•m 205 ± 15 N•m

(55 ± 4 lbf•ft) (151 ± 11 lbf•ft)
Loctite
648
NEW
75 ± 5 N•m
(55 ± 4 lbf•ft)
210
Drive System
Front Drive
NEW XPS synthetic NEW

grease 37 ± 3 N•m
(27 ± 2 lbf•ft)
33 ± 3 N•m
(24 ± 2 lbf•ft)
22.5 ± 2.5 N•m

(17 ± 2 lbf•ft)
NEW
NEW
For backlash
NEW
For preload
adjustment
180 ± 15 N•m
(133 ± 11 lbf•ft)
08
Loctite 271 NEW NEW
XPS synthetic
7.5 ± 0.5 N•m grease
NEW
XPS synthetic
grease
FRONT DIFFERENTIAL
211
Drive System
Front Drive
General
The procedure explained below is the same for
the RH and LH sides unless otherwise instructed.
N O T E : ABS equipped vehicles do not have a

Visco-Lok® differential.
Visco-Lok System Description
The Visco-Lok® system constantly monitors front
wheel speed and, if it detects one wheel spinning
faster than its mate, it progressively sends more
power to the wheel with the better traction.
The Visco-Lok system is comprised of two princi- TYPICAL
pal components, a shear pump and the controlled 1. Cotter pin
2. Castellated nut
multi-plate clutch. 3. Belleville washer
A unique feature of the shear pump is that it is 5. Remove wheel hub.
self-contained and independent. It does not re-
quire an external source of hydraulic fluid. The Inspecting the Wheel Hub
self-contained viscous shear pump generates a 1. Check wheel hub for cracks or other damages.
pressure proportional to wheel speed differential - 2. Check inner splines for wear or other
meaning the difference in rotational speed be- damages.
tween the two wheels. This pressure engages the 3. If any damage is detected on wheel hub, re-
friction clutch via a piston to transmit the torque. place it with a new one.
In the event of a failure, the Visco-Lok carrier/ring Installing the Wheel Hub
gear and pinion gear will have to be replaced. 1. The installation is the reverse of the removal
N O T E : The Visco-Lok shear pump is not serv-
following.
iceable. If the pump is disassembled, the viscous
2. Install Belleville washer with its convex side
fluid contained inside will be lost and it cannot be
outwards.
replaced.
3. Tighten castellated nut to specification.
Procedures
Tightening Torque
Wheel Hub
205 ± 15 Nm
Removing the Wheel Hub Castellated nut (151 ± 11 lbf-ft)
1. Lift and support vehicle.
2. Select the 4WD or the 6WD position and place
the transmission lever on "P". N O T E : Tighten further castellated nut if required
3. Remove caliper from knuckle. Refer to Brakes to align grooves with drive shaft hole.
subsection.
4. Install a N E W cotter pin.
– Wheel cap
– Cotter pin
– Castellated nut
– Belleville washer.
212
Drive System
Front Drive
Check splines for excessive wear. Replace if

necessary.
N O T E : If the splines on plunging joint are worn,

a check of differential inner splines should be
done.
Installing the Front Drive Shaft
following.
2. Install a N E W stop ring.
Front Drive Shaft

Removing the Front Drive Shaft
2. Remove inner fender panel (s). Refer to Body
subsection.
3. Remove the Knuckle. Refer to Steering Sys-
tem subsection.
4. Remove shock absorber lower bolt.
5. Lift and attach the following parts to make
room.
TYPICAL
– Shock absorber 1. Stop ring
– Upper suspension arm.
3. Apply grease on the splines.
6. Strongly pull drive shaft out of differential.
XPS Synthetic grease 08
4. Ensure that wear ring is close to the
differential.
Drive Shaft Bellows
Removing the Drive Shaft Bellows
1. Remove Front Drive Shaft.
2. Remove drive shaft bellows clamps.

(P/N 529 036 120)
PULL DRIVE SHAFT

3. Dislodge the large end of the bellow.
4. Separate the joint from the shaft. Two proce-
7. Discard the stop ring at the end of the shaft. dures can be done.
Inspecting the Front Drive Shaft Without the Special Tool
Inspect the condition of boots. If there is any dam- 1. Clamp joint housing in a vise.
age or evidence of leaking lubricant, replace them. 2. Align shaft with joint.
Refer to Drive Shaft Bellow in this subsection. 3. Pull hard on shaft to remove from joint.
4. Remove bellows from drive shaft.
5. Remove and discard the circlip. A new one is
included in the bellows kit.
213
Drive System
Front Drive
With the Special Tool

1. Place drive shaft in vice with the joint
downward.
2. Install the tool on bearing.
CV joint extractor
(P/N 529 036 005)
FROM LH SIDE
1. Vent hose
450 models
4. Remove screw securing the propeller shaft to
the front differential.
TYPICAL — CV JOINT SHOWN

1. Joint extractor tool
3. With an hammer, hit on the tool to separate

joint from shaft.
4. When joint and shaft are separated, remove
bellows from drive shaft.
Installing the Drive Shaft Bellows
following.
2. Install the N E W circlip.
3. Pack bearing area with grease (included with N O T E : Heat screw to break the threadlocker
the new bellows kit). bond prior to removal.
N O T E : Do not use or add other grease. 5. Remove bolts securing front differential to
frame.
4. Install N E W drive shaft bellow clamps.
Front Differential
Removing the Front Differential
1. Drain front differential. Refer to Periodic Main-
tenance Procedures subsection.
2. Remove both front drive shafts. Refer to Front
Drive Shaft in this subsection.
3. Detach vent hose from front differential.
1. Bolts securing front differential to frame
6. Remove the following Oetiker clamps from

front propeller shaft.
214
Drive System
Front Drive
2. Place the backlash measurement tool at the

end of pinion gear.
3. From center of tool bolt, measure 25.4 mm (1
in) and draw a mark on the tab.
1. Oetiker clamps
All models except 450

7. Detach front propeller shaft from front differen-
tial by moving it rearward.
1. Tab of backlash measurement tool

2. Mark on tab
A. 25.4 mm (1 in)
4. Position the dial indicator tip against the tab at

a 90° angle and right on the previously drawn
mark.
5. G e n t l y , move the tool tab back and forth. Note
the backlash result.
08
FRONT PROPELLER SHAFT MOVED REARWARD
8. Remove front differential by pulling it from RH

side.
NOTICE
Be careful not to knock or to bend vent hose
fitting while removing front differential.
Front Differential Inspection (Assembled)

Manually turn the pinion gear; it should turn
smoothly. Repair if necessary.
6. Rotate pinion gear 1/2 turn and recheck back-
Check if oil seals are brittle, hard or damaged. Re- lash. Note the result.
place if necessary. 7. Rotate pinion gear 1 turn and recheck
backlash.
Backlash Inspection
1. When measuring backlash, the differential cov- Backlash Specification
er should be upside down to pull the ring gear
out of mesh. 0.1 mm (.004 in) to 0.25 mm (.01 in)
Backlash measure- 8. If backlash is out of specification, split final

ment tool drive housing, refer to Disassembling the Front
(P/N 529 035 665) Differential and adjust shim thickness as per
following guideline.
215
Drive System
Front Drive
Backlash Adjustment Guideline

Backlash
What to Do
Measurement
Below 0.1 mm (.004 in) Remove shim(s) and

recheck backlash
Above 0.25 mm (.01 Add shim(s) and
in) recheck backlash
Preload Specification
Maximum
1.50 Nm (13 lbf-in)
3. There should be close to zero resistance when

turning pinion shaft by hand.
4. If preload is out of specification, split front dif-
ferential housing, refer to Disassembling the
Front Differential and carefully inspect all bear-
ings conditions.
1. Backlash shim Disassembling the Front Differential
Preload Inspection Differential Housing
1. Screw the propeller shaft screw in pinion gear. 1. Remove front differential housing screws.
2. Using a needle torque wrench, measure the 2. Separate half housings.

preload. 3. If opening the housing for backlash or preload
adjustment, remove and set aside the cover O-
ring.
216
Drive System
Front Drive
TYPICAL
4. Remove oil seals.

3. Separate ring gear from Visco-Lok unit.
Visco-Lok Carrier/Ring Gear 08

1. Remove Visco-Lok carrier/ring gear out of half
housing.
1. Visco-Lok unit
2. Ring gear
Pinion Gear
1. Remove screw retaining front propeller shaft
adapter.
N O T E : Be careful to keep track of shims. Write 1. Retaining screw

down the thickness and position of every shim.
2. Remove and discard oil seal.
2. Remove screws securing ring gear to Visco-
Lok unit.
217
Drive System
Front Drive
1. Bearing
1. Oil seal 2. Pinion gear
3. Unscrew the pinion nut. 5. Remove and discard O-ring.

6. Remove bearing from pinion gear.
Spanner socket (P/N
529 035 649)
Differential nut sock-
et 65mm (P/N 529
036 302)
1. O-ring
2. Pinion gear
3. Bearing
7. Remove and discard the needle bearing.

Assembling the Front Differential
1. Adjustment is required when any of the follow-
ing part is changed.
1. Pinion nut – Pinion gear
– Ring gear
4. Remove bearing and pinion gear together.
– Visco-lok unit
– Housing.
Recommended Tools Qty
2. As a preliminary setup, install shim according
Pipe: 78 mm (3-1/16 in) diameter x 127 to the following table.
mm (5 in) in length 1
Recommended Shim Thickness
Threaded rod: M10 x 1.25, 178 mm (7 in)
length 1 0.5 mm (.02 in)
BACKLASH (as a preliminary adjustment)
M10 x 1.25 nut 3
Flat bar 1
218
Drive System
Front Drive
1. Backlash shim
3. Prior to finalizing assembly, proceed in this

order: 4. Check bearings. Replace with N E W bearings
4. if necessary.
– Temporarily assemble final drive using rec-
ommended torques.
– Do not apply thread locker product.
– Do not install a new pinion nut.
– Do not install the cover O-ring
– Check backlash.
– Check preload.
Visco-Lok Carrier/Ring Gear
procedure. However, pay attention to the 08
following.
2. Tighten Visco-Lok / ring gear screws to
specification.
Tightening Torque 5. Apply grease on N E W oil seals and install.
Visco-Lok / ring gear 37 ± 3 Nm XPS Synthetic grease

3. Check condition of O-ring before re installation.

Replace if damaged.
6. Tighten differential housing screws to

specification.
Tightening Torque
Differential housing 23.5 ± 3.5 Nm

219
Drive System
Front Drive
Pinion Gear 2. Remove front wheel. Refer to Wheels and

1. Install a N E W ball bearing. Tires subsection.
2. Install a N E W O-ring. 3. Remove inner fender panel (s). Refer to Body
3. Install a N E W needle bearing. subsection.
4. Apply a drop of threadlocker on threads of the 4. Remove front differential. Refer to Removing
pinion nut. the Front differential in this subsection.
450 models
Loctite 271 (red)
5. Remove screw securing front propeller shaft to
coupling unit.
5. Install and tighten the pinion nut to
specification.
Tightening Torque
180 ± 15 Nm
Pinion nut (133 ± 11 lbf-ft)
6. Apply grease on N E W oil seal and install.
7. Tighten front propeller shaft adapter retaining

screw to specification.
Tightening Torque
N O T E : Heat screw to break the threadlocker
Front propeller shaft 75 ± 5 Nm bond prior to removal.
adapter retaining (55 ± 4 lbf-ft)
screw 6. Remove front propeller shaft by pulling it
forward.
Installing the Front Differential
1. The installation is the reverse of the removal 7. Remove the following Oetiker clamps from
procedure. However, pay attention to the front propeller shaft.
following.
2. When inserting the small portion of propeller
shaft into propeller shaft bellow, make sure
both parts of propeller shaft are well indexed.
Tightening Torque
M 8 n u t securing front 24.5 ± 3.5 Nm

differential to frame (18 ± 3 lbf-ft)
M 1 0 n u t s securing 61 ± 9 Nm
front differential to (45 ± 7 lbf-ft)
frame
1. Oetiker clamps
3. Install N E W Oetiker clamps.
4. Refill front differential with recommended oil. 8. Detach front propeller shaft from front differen-
Refer to Periodic Maintenance Procedures tial by moving it rearward.
subsection.
Front Propeller Shaft
Removing the Front Propeller Shaft
220
Drive System
Front Drive
Loctite 648 (green)
4. Tighten propeller shaft adapter screw to

specification.
450 models
Tightening Torque
75 ± 5 Nm
Propeller shaft screw
(55 ± 4 lbf-ft)
FRONT PROPELLER SHAFT MOVED REARWARD Tightening Torque

9. Pry front differential upwards to make room. Propeller shaft screw -
M12 (engine side) 75 ± 5 Nm
Propeller shaft screw - (55 ± 4 lbf-ft)
M10 (differential side)
Propeller Shaft U-Joints

Removing the Propeller Shaft U-Joint
1. Remove internal snap ring from bearing caps.
08
1. Pry bar
10. Remove front propeller shaft by pulling it

forward.
11. Remove front propeller shaft adapters from en-
gine and from front differential.
Inspecting the Front Propeller Shaft
1. Inspect if propeller shaft is not bent or twisted.
2. Check propeller shaft splines for wear or 1. Snap ring
damage.
3. Check if propeller shaft bellows is pierced or 2. Support inner yoke in vice and drive other yoke
brittle. down with a soft hammer.
Installing the Front Propeller Shaft
1. The installation is the reverse of removal pro-
cedure. However, pay attention to the
following.
2. Apply grease on splines.
3. Apply a drop of threadlocker on threads of the

propeller shaft screws.
221
Drive System
Front Drive
TYPICAL
3. Support U-joint in vice and drive inner yoke 4. Install snap ring.
down to remove remaining bearing caps. 5. Complete installation for the other bearing
4. Remove U-joint cross. caps.
Installing the Propeller Shaft U-Joint
1. Install new U-joint in inner yoke.
TYPICAL
2. Install bearing caps. Use a vise to push bear-

ing caps.
TYPICAL
3. Using a suitable pusher, fully seat bearing cap

on one side.
222
Drive System
Front Drive - Models with ABS

SERVICE TOOLS
SERVICE PRODUCTS
LOCTITE 271 (RED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220, 246, 262–263

LOCTITE 648 (GREEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221, 233–234, 248, 255
240, 246–247, 252, 255
08
223
Drive System
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
(M8)
NEW
NEW
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
(M10) See
STEERING
SYSTEM
Loctite
648
NEW
XPS Synthetic XPS
grease Synthetic
grease
75 ± 5 N•m 205 ± 15 N•m

(55 ± 4 lbf•ft) (151 ± 11 lbf•ft)
Loctite
648
NEW
75 ± 5 N•m
(55 ± 4 lbf•ft)
224
Drive System
NEW XPS synthetic NEW

grease 37 ± 3 N•m
(27 ± 2 lbf•ft)
33 ± 3 N•m
(24 ± 2 lbf•ft)
22.5 ± 2.5 N•m

(17 ± 2 lbf•ft)
NEW
NEW
For backlash
adjustment
NEW 08
180 ± 15 N•m
(133 ± 11 lbf•ft)
Loctite 271 NEW NEW
XPS synthetic
grease
7.5 ± 0.5 N•m

NEW
XPS synthetic grease

FRONT DIFFERENTIAL
225
Drive System
General Tightening Torque

The procedure explained below is the same for
the RH and LH sides unless otherwise instructed. 205 ± 15 Nm
Castellated nut (151 ± 11 lbf-ft)
Procedures
Wheel Hub N O T E : Tighten further castellated nut if required
to align grooves with drive shaft hole.
Removing the Wheel Hub
1. Lift and support vehicle. 4. Install a N E W cotter pin.
2. Select the 4WD or the 6WD position and place
the transmission lever on "P".
3. Remove caliper from knuckle. Refer to Brakes
subsection.
– Wheel cap
– Cotter pin
– Castellated nut
Front Drive Shaft

subsection.
3. Remove the Knuckle. Refer to Steering Sys-
tem subsection.
TYPICAL 5. Lift and attach the following parts to make
1. Cotter pin room.
2. Castellated nut
3. Belleville washer – Shock absorber
5. Remove wheel hub. – Upper suspension arm.
6. Remove the wheel speed sensor support and
Inspecting the Wheel Hub set aside.
1. Check wheel hub for cracks or other damages.
2. Check inner splines for wear or other
damages.
3. If any damage is detected on wheel hub, re-
place it with a new one.
Installing the Wheel Hub
following.
outwards.
3. Tighten castellated nut to specification.
1. Wheel speed sensor support
2. Wheel speed sensor support retaining screws
7. Strongly pull drive shaft out of differential .
226
Drive System
Tightening Torque
Wheel speed sensor 13.5 ± 1.5 Nm
support screw (119 ± 13 lbf-in)
Drive Shaft Bellows


(P/N 529 036 120)
TYPICAL - PULL DRIVE SHAFT

8. Discard the stop ring at the end of the shaft. 4. Separate the joint from the shaft. Two proce-
dures can be done.
Inspecting the Front Drive Shaft
Inspect the condition of bellows. If there is any Without the Special Tool
damage or evidence of leaking lubricant, replace 1. Clamp joint housing in a vise.
them. Refer to Drive Shaft Bellows in this 2. Align shaft with joint.
subsection. 3. Pull hard on shaft to remove from joint.
4. Remove bellows from drive shaft.
Check splines for excessive wear. Replace if 5. Remove and discard the circlip. A new one is
necessary. included in the bellows kit.
N O T E : If the splines on plunging joint are worn, With the Special Tool
done.
downward.
08
Installing the Front Drive Shaft 2. Install the tool on bearing.
procedure. However, pay attention to the CV joint extractor
following. (P/N 529 036 005)
2. Install a N E W stop ring.

TYPICAL
1. Stop ring
3. Apply grease on the splines. joint from shaft.
XPS Synthetic grease bellows from drive shaft.
4. Tighten the wheel speed sensor to included in the bellows kit.
specification.
227
Drive System
Installing the Drive Shaft Bellows 5. Remove bolts securing front differential to
1. The installation is the reverse of the removal frame.
following.
3. Pack bearing area with grease (included with
the new bellows kit).
N O T E : Do not use or add other grease.

Front Differential
1. Bolts securing front differential to frame
Drive Shaft in this subsection. 6. Remove the following Oetiker clamps from
3. Detach vent hose from front differential. front propeller shaft.
1. Oetiker clamps
FROM LH SIDE All models except 450

1. Vent hose
450 models tial by moving it rearward.
4. Remove screw securing the propeller shaft to
the front differential.
FRONT PROPEL LER SHAFT MOVED REARWARD

N O T E : Heat screw to break the threadlocker side.
bond prior to removal.
228
Drive System
NOTICE

Check if oil seals are brittle, hard or damaged. Re-
place if necessary.
Backlash Inspection
1. When measuring backlash, the differential cov-
out of mesh. 6. Rotate pinion gear 1/2 turn and recheck back-
lash. Note the result.
Backlash measure-
7. Rotate pinion gear 1 turn and recheck
ment tool
backlash.
(P/N 529 035 665)
Backlash Specification
2. Place the backlash measurement tool at the 0.1 mm (.004 in) to 0.25 mm (.01 in)
end of pinion gear.
in) and draw a mark on the tab. 8. If backlash is out of specification, split final
drive housing, refer to Disassembling the Front
Differential and adjust shim thickness as per
08
Backlash
What to Do
Measurement

recheck backlash

2. Mark on tab
A. 25.4 mm (1 in)

mark.
5. G e n t l y , move the tool tab back and forth. Note
1. Backlash shim
Preload Inspection
1. Screw the propeller shaft screw in pinion gear.
229
Drive System
2. Using a needle torque wrench, measure the 2. Separate half housings.

preload. 3. Remove oil seals.
Preload Specification Carrier/Ring Gear

1. Remove carrier/ring gear out of half housing.
Maximum
1.50 Nm (13 lbf-in)

ings conditions.
Disassembling the Front Differential
Differential Housing
1. Remove front differential housing screws.
2. Remove screws securing ring gear to carrier.
230
Drive System
1. Oil seal
3. Unscrew the pinion nut.
3. Separate ring gear from carrier. Spanner socket (P/N

529 035 649)
08
1. Pinion nut
1. Carrier 4. Remove bearing and pinion gear together.

2. Ring gear
Recommended Tools Qty
Pinion Gear
1. Remove screw retaining front propeller shaft Pipe: 78 mm (3-1/16 in) diameter x 127
adapter. mm (5 in) in length 1
Threaded rod: M10 x 1.25, 178 mm (7 in)

length 1
M10 x 1.25 nut 3

Flat bar 1
1. Retaining screw
1. Bearing
2. Pinion gear
231
Drive System
5. Remove and discard O-ring. – Check backlash.

6. Remove bearing from pinion gear. – Check preload.
Carrier/Ring Gear
following.
2. Tighten carrier ring gear screws to
specification.
Tightening Torque
Carrier ring gear 37 ± 3 Nm

1. O-ring
2. Pinion gear
3. Bearing 3. Check condition of seal. Replace if damaged.
ing part is changed.
– Pinion gear
– Ring gear
– Carrier
– Housing.
to the following table.

0.5 mm (.02 in)
BACKLASH (as a preliminary adjustment) 4. Check bearings. Replace with N E W bearings
if necessary.
1. Backlash shim

order: 5. Apply grease on N E W oil seals and install.
4.
ommended torques.
– Do not install a new pinion nut.
232
Drive System

Tightening Torque
M 8 n u t securing front 24.5 ± 3.5 Nm

M 1 0 n u t s securing 61 ± 9 Nm
frame
6. Tighten differential housing screws to 3. Install N E W Oetiker clamps.
specification. 4. Refill front differential with recommended oil.
Refer to Periodic Maintenance Procedures
Tightening Torque subsection.
Differential housing 23.5 ± 3.5 Nm Front Propeller Shaft
Pinion Gear 1. Lift and support vehicle.
1. Install a N E W ball bearing. 2. Remove front wheel. Refer to Wheels and
2. Install a N E W O-ring. Tires subsection.
3. Install a N E W needle bearing. 3. Remove inner fender panel (s). Refer to Body
4. Apply a drop of threadlocker on the threads of subsection.
the pinion nut. 4. Remove front differential. Refer to Removing
the Front differential in this subsection.
Loctite 648 (green) 450 models 08
5. Remove screw securing front propeller shaft to
5. Install and tighten the pinion nut to coupling unit.
specification.
Tightening Torque
180 ± 15 Nm
6. Apply grease on N E W oil seal and install.

screw to specification.
Tightening Torque
Front propeller shaft 75 ± 5 Nm N O T E : Heat screw to break the threadlocker
adapter retaining (55 ± 4 lbf-ft) bond prior to removal.
screw
Installing the Front Differential forward.
1. The installation is the reverse of the removal All models except 450
procedure. However, pay attention to the 7. Remove the following Oetiker clamps from
following. front propeller shaft.
233
Drive System
2. Check propeller shaft splines for wear or

damage.
3. Check if propeller shaft bellows is pierced or
brittle.
following.

1. Oetiker clamps
8. Detach front propeller shaft from front differen- 3. Apply a drop of threadlocker on threads of the
tial by moving it rearward. propeller shaft screws.
Loctite 648 (green)

specification.
450 models
Tightening Torque
75 ± 5 Nm
(55 ± 4 lbf-ft)
FRONT PROPELL ER SHAFT MOVED REARWARD

Tightening Torque
9. Pry front differential upwards to make room. Propeller shaft screw -

M12 (engine side) 75 ± 5 Nm
Propeller shaft screw - (55 ± 4 lbf-ft)
M10 (differential side)

1. Pry bar

forward.
11. Remove front propeller shaft adapters from en-
gine and from front differential.
Inspecting the Front Propeller Shaft
234
Drive System
TYPICAL
1. Snap ring
2. Support inner yoke in vice and drive other yoke
on one side.
down with a soft hammer.
08
TYPICAL
3. Support U-joint in vice and drive inner yoke 4. Install snap ring.
down to remove remaining bearing caps. 5. Complete installation for the other bearing
4. Remove U-joint cross. caps.
Installing the Propeller Shaft U-Joint
1. Install new U-joint in inner yoke.
TYPICAL

ing caps.
235
Drive System
Front Drive with Visco-4Lok

SERVICE TOOLS
SERVICE PRODUCTS
LOCTITE 271 (RED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220, 246, 262–263

LOCTITE 648 (GREEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221, 233–234, 248, 255
240, 246–247, 252, 255
236
Drive System
NEW
24.5 ± 3.5 N•m
(18 ± 3 lbf•ft)
(M8)
NEW
NEW
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
(M10) See
STEERING
SYSTEM
Loctite
648
XPS Synthetic XPS

NEW 08
grease Synthetic
grease
75 ± 5 N•m 205 ± 15 N•m

(55 ± 4 lbf•ft) (151 ± 11 lbf•ft)
Loctite
648
NEW
75 ± 5 N•m
(55 ± 4 lbf•ft)
237
Drive System
5 ± 1 N•m
(44 ± 9 lbf•in)
NEW
24 ± 3 N•m
8 ± 1 N•m (18 ± 2 lbf•ft)
(71 ± 9 lbf•in) Synthetic
grease
NEW
Synthetic
grease
+
NEW
Loctite 271
NEW 37 ± 3 N•m
(27 ± 2 lbf•ft)
NEW
180 ± 15 N•m
(133 ± 11 lbf•ft)
2.5 ± 0.25 N•m

+
Synthetic
grease
238
Drive System
General The override mode will allow to reach an other

The procedure explained below is the same for speed limitation:
the RH and LH sides unless otherwise instructed. – 60 km/h (37 MPH) in HIGH or LOW gear
– 25 km/h (16 MPH) in reverse.
System Description
Visco-Lok Unit Procedures
The Visco-Lok® system constantly monitors front Wheel Hub
wheel speed and, if it detects one wheel spinning Removing the Wheel Hub
faster than its mate, it progressively sends more 1. Lift and support vehicle.
power to the wheel with the better traction. 2. Select the 4WD position and place the trans-
The Visco-Lok system is comprised of two princi- mission lever on "P".
pal components, a shear pump and the controlled 3. Remove caliper from knuckle. Refer to brakes
multi-plate clutch. subsection.
4. Remove the following parts.
A unique feature of the shear pump is that it is
self-contained and independent. It does not re-
quire an external source of hydraulic fluid. The
self-contained viscous shear pump generates a
pressure proportional to wheel speed differential -
meaning the difference in rotational speed be-
tween the two wheels. This pressure engages the
friction clutch via a piston to transmit the torque.
In the event of a failure, the Visco-Lok carrier/ring
gear and pinion gear will have to be replaced.
N O T E : The Visco-Lok shear pump is not serv-
iceable. If the pump is disassembled, the viscous 08
fluid contained inside will be lost and it cannot be TYPICAL
replaced. 1. Cotter pin
2. Castellated nut
Visco-4Lok System 3. Belleville washer
An electronic actuator pushes a fork to move a 5. Remove wheel hub.
collar.
Inspecting the Wheel Hub
The inner teeth of the collar are engaged into the
recesses of the Visco-4Lok unit internal gears to 1. Check wheel hub for cracks or other damages.
lock both front wheels together. 2. Check inner splines for wear or other
damages.
The actuator is controlled by the ECM. 3. If any damage is detected on wheel hub, re-
place it with a new one.
If all required conditions are fulfilled (speed and
throttle opening), a signal is sent to activate or de- Installing the Wheel Hub
activate the 4WDLock mode. 1. The installation is the reverse of the removal
When the 4WDLock is activated, the telltale on the procedure. However, pay attention to the
throttle lever control housing and the icon in the following.
digital display will turn on. 2. Install Belleville washer with its convex side
outwards.
In 4WDLock mode, a speed limiter restricts the ve- 3. Tighten castellated nut to specification.
hicle speed:
– 40 km/h (25 MPH) in forward
– 15 km/h (9 MPH) in reverse, same as the nor-
mal use.
.
239
Drive System
Inspecting the Front Drive Shaft

Tightening Torque
Inspect the condition of the bellows. If there is any
205 ± 15 Nm damage or evidence of leaking lubricant, replace
Castellated nut (151 ± 11 lbf-ft) them. Refer to Drive Shaft Bellow in this
subsection.
N O T E : Tighten further castellated nut if required Check splines for excessive wear. Replace if
to align grooves with drive shaft hole. necessary.
4. Install a NEW cotter pin. N O T E : If the splines on plunging joint are worn,
done.
Installing the Front Drive Shaft
following.
2. Install a NEW stop ring.
Front Drive Shaft

subsection.
3. Remove the Knuckle. Refer to Steering Sys- TYPICAL
tem subsection. 1. Stop ring
5. Lift and attach the following parts to make 3. Lubricate the drive shaft splines.
room.
– Shock absorber
– Upper suspension arm. 4. Ensure that wear ring is close to the
6. Strongly pull drive shaft out of differential. differential.
Drive Shaft Bellow
Removing the Drive Shaft Bellow
1. Remove the Front Drive Shaft.
2. Remove clamps from drive shaft bellows.

(P/N 529 036 120)

dures can be used.
Without the Special Tool
PULL DRIVE SHAFT 1. Clamp joint housing in a vise.
7. Discard the stop ring at the end of the shaft. 2. Align shaft with joint.
3. Pull hard on shaft to remove from joint.
240
Drive System
4. Remove the bellow from drive shaft. 2. Start engine.

5. Remove and discard the circlip. A new one is 3. Unplug the actuator connector.
included in the bellow kit. 4. Measure voltage as per the following table.
With the Special Tool Vehicle Harness Measurement
downward. Pin B Pin D Battery voltage
2. Install the tool on bearing.
If result is out of specification, repair the wiring
CV joint extractor (P/ harness wires or connectors.
N 529 036 005)
If the result is good, test the continuity of the ve-
hicle harness.
Testing the Continuity of the Differential
Actuator Harness
1. Measure resistance between the following.
Compo
Actuator Measurement
nent
Pin 4
multifunc
Pin A tion 0Ω

gauge
Pin J2
Pin C 0Ω
3. With an hammer, hit on the tool to separate ECM
joint from shaft.
4. When joint and shaft are separated, remove If result is out of specification, repair the wiring 08
the bellow from drive shaft. harness wires or connectors.
included in the bellow kit. If the result is good, replace the actuator.
Installing the Drive Shaft Bellow Replacing the Front Differential Actuator
1. The installation is the reverse of the removal 1. Place the vehicle level.
procedure. However, pay attention to the 2. Disconnect the actuator connector.
following. 3. Using a socket of 15mm, remove the actuator.
2. Install the NEW circlip.
the new bellow kit).

4. Install NEW drive shaft bellow clamps.
Front Differential Actuator
Testing the Front Differential Actuator
Using the BRP Diagnostic Software (BUDS2)
1. Connect the vehicle to the BRP Diagnostic
software (BUDS).
2. Active the differential actuator through BUDS2. 4. Install the new actuator.
3. If the actuator works, check the throttle handle.
NOTICE
Testing Differential Actuator Voltage Screw the first threads manually to avoid
1. Apply parking brake and select the PARK damaging them.
position.
241
Drive System
Tightening Torque
Actuator 5 ± 1 Nm (44 ± 9 lbf-in)
Front Differential
Drive Shaft in this subsection.
3. Detach vent hose from front differential.
FRONT PROPEL LER SHAFT MOVED REARWARD

side.
NOTICE

FROM LH SIDE
1. Vent hose Check if oil seals are brittle, hard or damaged. Re-
place if necessary.
4. Disconnect the actuator connector.
5. Remove the following Oetiker clamps from the Backlash Inspection
front propeller shaft. 1. When measuring backlash, the differential cov-
out of mesh.
Backlash measure-
ment tool (P/N 529
035 665)

end of pinion gear.
in) and draw a mark on the tab.
1. Oetiker clamps

tial by moving it rearward.
242
Drive System

Backlash
What to Do
Measurement

recheck backlash
TYPICAL
2. Mark on tab
A. 25.4 mm (1 in)

mark. Preload Inspection
5. Gently, move the tool tab back and forth. Note
08
2. Using a needle torque wrench, measure the

preload.
TYPICAL

backlash.
0.1 mm (.004 in) to 0.25 mm (.01 in)
8. If backlash is out of specification, split final TYPICAL

drive housing, refer to Disassembling the Front
Differential and adjust shim thickness as per Preload Specification
Maximum 1.50 Nm (13 lbf-in)
243
Drive System

ings conditions.
Disassembling the Front Differential
Differential Housing
1. Remove front differential housing screws.
Visco-4Lok Carrier/Ring Gear
Remove Visco-4Lok carrier/ring gear out of half
housing.
2. Separate half housings.

3. If opening the housing for backlash or preload N O T E : Be careful to keep track of shims. Write
adjustment, remove and set aside the cover O- down the thickness and position of every shim.
ring.
Separate ring gear from Visco-4Lok unit.
Pinion Gear
TYPICAL
1. Remove screw retaining front propeller shaft
4. Remove and discard oil seals. adapter.
1. Retaining screw
244
Drive System
1. Bearing
2. Pinion gear
1. Oil seal 5. Remove and discard O-ring.

6. Remove bearing from pinion gear.
3. Unscrew the pinion nut.
Differential nut sock-

et 65mm (P/N 529
036 302)
1. O-ring
2. Pinion gear
3. Bearing 08
1. Pinion nut
4. Remove bearing and pinion gear together. ing part is changed.
Recommended Tools Qty – Pinion gear

– Ring gear
Pipe: 78 mm (3-1/16 in) diameter x 127 – Visco-4lok unit
mm (5 in) in length 1 – Housing.
Threaded rod: M10 x 1.25, 178 mm (7 in) to the following table.
length 1
M10 x 1.25 nut 3
0.5 mm (.02 in)
Flat bar 1 BACKLASH (as a preliminary adjustment)
245
Drive System
1. Fill this cavity

order: 6. Tighten differential housing screws to
4. specification.
Tightening Torque
ommended torques.
– Do not apply thread locker product. Differential housing 23.5 ± 3.5 Nm
– Do not install a new pinion nut. screws (17 ± 3 lbf-ft)
– Do not install the cover O-ring
– Check backlash. Pinion Gear
– Check preload.
1. Install a NEW ball bearing.
Visco-4Lok Carrier/Ring Gear 2. Install a NEW O-ring.
1. The installation is the reverse of the removal 3. Install a NEW needle bearing.
procedure. However, pay attention to the 4. Apply a drop of threadlocker on threads of the
following. pinion nut.
2. Tighten Visco-4Lok / ring gear screws to
specification. Loctite 271 (red)
Tightening Torque 5. Install and tighten the pinion nut to

specification.
Visco-4Lok / ring gear 37 ± 3 Nm
screws (27 ± 2 lbf-ft) Tightening Torque
3. Check condition of O-ring before re installation. 180 ± 15 Nm

Replace if damaged.
6. Before installing the new oil seals, apply

grease inside their inner lips.
4. Check bearings in both half housings. Replace

with NEW bearings if necessary.
5. Before installing the new oil seals, apply 1. Fill this cavity
grease inside their inner lips.
XPS Synthetic grease screw to specification.
246
Drive System
Tightening Torque
Front propeller shaft 75 ± 5 Nm
adapter retaining (55 ± 4 lbf-ft)
screw
Installing the Front Differential

following.
FRONT PROPELL ER SHAFT MOVED REARWARD
Tightening Torque
7. Pry front differential upwards to make room.
M8 nut securing front 24.5 ± 3.5 Nm
M10 nuts securing 61 ± 9 Nm
frame
3. Install NEW Oetiker clamps.

4. Refill front differential with recommended oil.
Refer to Periodic Maintenance Procedures
subsection.
Front Propeller Shaft 08
2. Remove front wheel. Refer to Wheels and 1. Pry bar
Tires subsection.
3. Remove inner fender panel (s). Refer to Body 8. Remove front propeller shaft by pulling it
subsection. forward.
4. Remove front differential. Refer to Removing 9. Remove front propeller shaft adapters from en-
the Front Differential in this subsection. gine and from front differential.
5. Remove the following Oetiker clamps from Inspecting the Front Propeller Shaft
front propeller shaft. 1. Inspect if propeller shaft is not bent or twisted.
damage.
3. Check if propeller shaft bellows is pierced or
brittle.
following.

1. Oetiker clamps
6. Detach front propeller shaft from front differen- 3. Apply a drop of threadlocker on threads of pro-
tial by moving it rearward. peller shaft adapter screws.
247
Drive System
Loctite 648 (green)

specification.
Tightening Torque
Propeller shaft adapter
screw M12 (engine
side) 75 ± 5 Nm
Propeller shaft adapter (55 ± 4 lbf-ft)
screw M10 (differential
side)
248
Drive System
Rear Drive
Rear Drive
SERVICE TOOLS
SERVICE PRODUCTS
LOCTITE 271 (RED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220, 246, 262–263

LOCTITE 648 (GREEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221, 233–234, 248, 255
240, 246–247, 252, 255
08
249
Drive System
Rear Drive
90 ± 5 N•m
(66 ± 4 lbf•ft)
NEW
22.5 ± 2.5 N•m
(17 ± 2 lbf•ft)
Loctite
648
Loctite NEW
75 ± 5 N•m
648 (55 ± 4 lbf•ft)
NEW
NEW XPS Synthetic

XPS grease
Synthetic
grease NEW
XPS Synthetic
grease
Hi-temp bearing grease 205 ± 15 N•m

NLGI-2 or equivalent (151 ± 11 lbf•ft)
250
Drive System
Rear Drive
32 ± 3 N•m
(24 ± 2 lbf•ft)
For preload
adjustment
22.5 ± 2.5 N•m

For backlash (17 ± 2 lbf•ft)
adjustment
NEW
XPS synthetic NEW
grease
NEW
NEW
XPS synthetic
grease
180 ± 15 N•m 5 ± 1 N•m

(133 ± 11 lbf•ft) (44 ± 9 lbf•in)
LH threads
Loctite 271
NEW
For pinion
adjustment 08
251
Drive System
Rear Drive
Procedures
Wheel Hub
Removing the Wheel Hub
2. Remove the wheel.
– Caliper mounting bolts (if applicable), refer
to Brakes subsection
– Hub cap
– Cotter pin
– Wheel hub nut
Installing the Wheel Hub

following:
2. Apply grease on drive shaft splines.

outward.
1. Caliper
2. Remove bolts
4. Remove wheel hub.

Inspecting the Wheel Hub
1. Remove disk from RH wheel hub as
necessary.
2. Check wheel hub for cracks or other damages.
3. Check inner splines for wear or other
damages.
4. If any damage is detected on wheel hub, re-
place it with a new one. 1. Wheel hub
2. Washer — Convex side here
3. Nut
Tightening Torque
205 ± 15 Nm
Wheel hub nut (151 ± 11 lbf-ft)
N O T E : If required, tighten castle nut further to

align grooves with drive shaft hole.
4. Install a NEW cotter pin, bend as shown.
252
Drive System
Rear Drive
TYPICAL
1. Cotter pin correctly bent
1. NEW stop ring
2. Domed (convex) side here
Drive Shaft 3. After drive shaft insertion in rear final drive, val-
idate if properly locked.
Removing the Drive Shaft
Drive Shaft Bellows

(P/N 529 036 120)

dures can be done. 08
Without the Special Tool
1. Clamp joint housing in a vise.
TYPICAL 2. Align shaft with joint.
1. Drive shafts 3. Pull hard on shaft to remove from joint.
1. Lift and support vehicle. 4. Remove bellows from drive shaft.
2. Remove the wheel hub. See procedure in this 5. Remove and discard the circlip. A new one is
subsection. included in the bellows kit.
3. Remove trailing arm. Refer to Rear With the Special Tool
Suspension.
4. Strongly pull drive shaft out of final drive.
downward.
Inspecting the Drive Shaft 2. Install the tool on bearing.
1. Inspect the condition of bellows. If there is any
damage or evidence of leaking lubricant, re- CV joint extractor
place them. Refer to Drive Shaft Bellows. (P/N 529 036 005)
2. Check shaft splines. Replace drive shaft if
necessary.
3. Check dust shield on drive shaft end. Replace
if necessary.
Installing the Drive Shaft
following:
2. Install a NEW stop ring.
253
Drive System
Rear Drive
3. Detach brake master cylinder from frame (Out-

lander only). Refer to brakes subsection.


joint from shaft.
bellows from drive shaft.
1. Remove retaining screws
Installing the Drive Shaft Bellows
following.
the new bellows kit).
Propeller Shaft
1. Master cylinder moved apart
Removing the Propeller Shaft
5. From RH side of vehicle, remove propeller
shaft screw from gearbox output shaft.
N O T E : Heat screw to break the threadlocker

bond prior to removal.
TYPICAL
1. Propeller shaft
1. Remove wheels. Refer to wheels and tires

subsection.
2. Drain oil from rear final drive. Refer to periodic
maintenance procedures.
254
Drive System
Rear Drive
TYPICAL — RH SIDE OF VEHICLE

1. Remove screw 1. Pull out propeller shaft
6. From LH side of vehicle, remove propeller Inspecting the Propeller Shaft

shaft screw from rear final drive yoke.
damage.
3. Check if propeller shaft bellow is cracked,
pierced or brittle.
Installing the Propeller Shaft
1. Installation is essentially the reverse of remov-
al procedure. Pay attention to the following
details.
2. Apply grease to splines. 08
3. Apply a drop of threadlocker on threads of the

TYPICAL — L H SIDE OF VEHICLE propeller shaft screw (engine side only).
1. Remove screw
7. Remove rear final drive retaining bolts. Refer Loctite 648 (green)
to rear final drive in this subsection.
8. Remove bolts from rear retaining plate. Refer 4. On the engine side, install the Belleville with
to rear final drive in this subsection. the notches towards the screw head.
9. Move the rear final drive rearward to allow dis-
lodging the propeller shaft.
10. Dislodge the propeller shaft from the gearbox.
11. Remove the propeller shaft.
TYPICAL
5. Tighten screws to specifications.
255
Drive System
Rear Drive
Tightening Torque
75 ± 5 Nm
(55 ± 4 lbf-ft)
6. Refill rear final drive. Refer to Periodic Mainte-

TYPICAL

ing caps.
1. Snap ring
2. Support inner yoke in vice and drive other yoke

down with a soft hammer.
TYPICAL

on one side.
3. Support U-joint in vice and drive inner yoke

down to remove remaining bearing caps.
4. Remove U-joint cross. TYPICAL
Installing the Propeller Shaft U-Joint 4. Install snap ring.

1. Install new U-joint in inner yoke. 5. Complete installation for the other bearing
caps.
256
Drive System
Rear Drive
Rear Final Drive

Removing the Rear Final Drive
1. Drain oil. Refer to Periodic Maintenance Proce-
dures subsection.
3. Support rear bottom end of frame.
4. Remove drive shafts. See procedure in this
subsection.
5. Remove rear propeller shaft screw from the
rear final drive yoke. Refer to Propeller Shaft in
this subsection.
6. Remove rear final drive bolts.
1. Pull out
9. Remove the final drive.

Inspecting the Rear Final Drive (Assembled)
Manually turn rear final drive gear; it should turn
Check if oil seals are brittle, hard or damaged. Re-
place if necessary.
Measuring the Backlash
1. When measuring backlash, the differential cov-
out of mesh.
Backlash measure-
08
1. Remove bolts ment tool (P/N
7. Remove bolts from rear retaining plate. 529035665)

end of pinion gear.
in) and scribe a mark on the tab.
1. Remove bolts
8. Unplug the vent hose from final drive.

2. Mark on tab
A. 25.4 mm (1 in)
257
Drive System
Rear Drive

a 90° angle and right on the previously scribed
mark.
5. G e n t l y move the tool tab back and forth mak-
ing sure the ring gear does not turn. Note the
backlash result.
1. Backlash shim
Measuring the Preload


backlash.
0.1 mm (.004 in) to 0.35 mm (.014 in)
8. If backlash is out of specification, split final

drive housing, refer to Disassembling the Rear
Final Drive and adjust shim thickness as per
2. Using a needle torque wrench, measure the
Backlash Adjustment Guideline preload.
Backlash
What to Do
Measurement
Below 0.1 mm (.004 in) Add shim(s) and

recheck backlash
Above 0.35 mm (.014 Remove shim(s) and
Preload Specification
Maximum
0.50 Nm (4 lbf-in)
258
Drive System
Rear Drive
3. There should be close to zero resistance when 3. If opening the housing for backlash or preload
turning pinion shaft by hand. adjustment, remove and set aside the cover O-
4. If preload is out of specification, split final drive ring.
housing, refer to Disassembling the Rear Final
Drive and adjust shim thickness as per follow-
ing guideline.
5. Carefully inspect all bearings condition.
Preload Guideline
Preload
What to Do
Measurement
Below Add shim(s) and
0.06 Nm (.5 lbf-in) recheck preload
Above Remove shim(s) and
0.50 Nm (4 lbf-in) recheck preload
1. Backlash shim
08
2. Preload shim
3. Ring gear
1. Preload shim 4. Extract ring gear out of half housing.
Disassembling the Rear Final Drive N O T E : Be careful to keep track of shims. Write
Ring Gear down the thickness and position of every shim.
1. Remove the final drive housing screws. Pinion Gear
2. Split final drive housings. 2. Unscrew the pinion nut..
259
Drive System
Rear Drive
Differential nut sock- Recommended Shim Thickness

et 65mm (P/N
529036302) See procedure for pinion gear
Pinion Gear
shim thickness
Backlash 0.5 mm (.02 in)
Preload (as a preliminary adjustment)
N O T E : Heating the nut may be necessary.
Procedure for pinion gear shim thickness:
1. Measure the distance "B" on the new pinion
gear set. This is the distance between both
outer shells of the bearings.
2. Remove old pinion gear set.
3. Measure the distance "C" of the gear case.
This is the distance between the shim surface
of the case and outside surface of the case.
4. Install the new gear set without shims and
washer, it will be located at the "zero" position.
5. Measure the distance "A" between outside sur-
face of the gear case and the bearing shoulder
of the gear case.
6. The shim thickness including the washer will
N O T E : The pinion nut is left hand threaded. Un- be "C-A-B+0.78 mm (.031 in)".
screw by turning clockwise. 7. Select the good combination of shim to match
the thickness calculated on step 6.
3. Remove the bearing along with the pinion
gear. Be careful to keep track of shims..
1. M74x1.25 nut
2. Pinion gear assembly
3. Pinion gear shim
4. Needle bearing (discard)
NOTE: The replacement pinion comes

preassembled.
Assembling the Rear Final Drive
Adjustment is required when any of the following
part is changed.
– Pinion gear 1. Shims
– Ring gear 2. Washer
3. Pinion assembly
– Housing. 4. Pinion nut
As a preliminary setup, install shims according to Install shims calculated in Inspecting the Rear Fi-
the following table. nal Drive (Assembled) for preload and backlash.
260
Drive System
Rear Drive
Ring Gear
following:
2. Check condition of O-ring before re installation.
Replace if damaged.
1. Backlash side
2. Preload side
3. Install NEW bearings.
08
1. Backlash shim
4. Tighten final drive housing screws as per

specification.
Tightening Torque
1. Preload shim Final drive housing 32 ± 3 Nm

Prior to finalizing assembly, proceed in this order:
– Temporarily assemble final drive using recom- Pinion Gear
mended torques. 1. The installation is the reverse of the removal
– Do not apply thread locker product. procedure. However, pay attention to the
– Do not install a new pinion nut. following:
– Do not install the cover O-ring 2. Install a NEW needle bearing.
– Check backlash.
– Check preload.
261
Drive System
Rear Drive
3. Measure the distance "B" between outside sur-

face of the gear case and the bearing shoulder
of the gear case.
4. The shim thickness will be "A-B-0.53 mm (.021
in)".
5. Select the good combination of shim to match
the thickness calculated on step 4.
B
3. install a NEW O-ring.
4. Apply threadlocker to pinion nut threads.
Loctite 271 (red)
5. Install and tighten the pinion nut as per

Install shims calculated in Inspecting the Rear Fi-
specification.
nal Drive (Assembled) .
Tightening Torque
Pinion nut (LH 180 ± 15 Nm
THREADS) (133 ± 11 lbf-ft)
6. Lubricate and install a NEW oil seal.

Assembling the Rear Final Drive
Adjustment is required when any of the following
part is changed.
– Pinion gear
– Ring gear
– Housing.
As a preliminary setup, install shims according to
the following table.
1. Backlash side
Recommended Shim Thickness 2. Preload side
See procedure for pinion gear

Pinion Gear
shim thickness
Backlash 0.5 mm (.02 in)
Preload (as a preliminary adjustment)
Procedure for pinion gear shim thickness:

1. Remove the old pinion gear and install the new
one without the ball bearing. The new pinion
will be located at the "zero" location.
2. Measure the distance "A" between outside sur-
face of the gear case and the shim surface of
pinion. 1. Backlash shim
262
Drive System
Rear Drive
1. Preload shim
Prior to finalizing assembly, proceed in this order:

– Temporarily assemble final drive using recom- 4. Tighten final drive housing screws as per
mended torques. specification.
– Do not install a new pinion nut. Tightening Torque
– Check backlash.
– Check preload. Final drive housing 32 ± 3 Nm
Ring Gear
1. The installation is the reverse of the removal Pinion Gear
procedure. However, pay attention to the 1. The installation is the reverse of the removal
following: procedure. However, pay attention to the
2. Check condition of seal. Replace if damaged. following: 08
2. Install a NEW needle bearing.
3. Install the shim(s) then a NEW ball bearing.
4. install a NEW O-ring.
5. Apply a drop of threadlocker to pinion nut
threads.
Loctite 271 (red)
6. Install and tighten the pinion nut as per

specification.
Tightening Torque
Pinion nut (LH 180 ± 15 Nm
THREADS) (133 ± 11 lbf-ft)
3. Install NEW bearings. 7. Lubricate and install a NEW oil seal.

Installing the Rear Final Drive
following:
2. Install the lowest rear final drive retaining
screws first.
3. Install all screws and nuts prior to tighten.
4. Tighten nuts to specification.
263
Drive System
Rear Drive
Tightening Torque
Final drive retaining 90 ± 5 Nm (66 ± 4 lbf-

nuts ft)
5. Refill the final drive with recommended oil. Re-

fer to Periodic Maintenance Procedures
subsection.
264
CHASSIS
09
265
CHASSIS
Steering System
09 CHASSIS
Steering System
SERVICE TOOLS
SPRING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036184) . . . . . . . . . . . . . . . . . . . . . . . 313

STEERING ALIGNMENT TOOL . . . . . . . . . . . . . . . . . . . . . . (P/N 529036059) . . . . . . . . . . . . . . . . . . . . . . . 270
SERVICE PRODUCTS
CLUTCH AND PULLEY FLANGE CLEANER PRO S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

DIELECTRIC GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
LOCTITE 271 (RED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
LOCTITE 406 (GLUE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
LOCTITE 767 (ANTI-SEIZE LUBRICANT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280, 284–285, 295
XPS BRAKES AND PARTS CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325, 336
XPS SYNTHETIC GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280, 285, 323, 335
XPS SYNTHETIC SUSPENSION GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Outlander 450 and 570 Without DPS
266
CHASSIS
Steering System
Loctite
406
Europe
Loctite
406
XPS NEW
Synthetic
grease NEW
NEW
31.5 ± 3.5 N•m
(23 ± 3 lbf•ft)
Loctite
243
NEW
NEW
72.5 ± 7.5 N•m

(53 ± 6 lbf•ft) 09
Loctite 767
72.5 ± 7.5 N•m

(53 ± 6 lbf•ft)
NEW
57.5 ± 7.5 N•m
(42 ± 6 lbf•ft)
267
CHASSIS
Steering System
Outlander 650/850 and Renegade 570 Without

DPS
Outlander
Renegade
Europe
Loctite
406
24.5 ± 3.5 N•m

XPS (18 ± 3 lbf•ft)
Synthetic
grease NEW Loctite
NEW 406
NEW
31.5 ± 3.5 N•m
(23 ± 3 lbf•ft)
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
Loctite
243
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft) NEW
NEW
72.5 ± 7.5 N•m NEW
(53 ± 6 lbf•ft)
XPS
Synthetic
NEW grease
72.5 ± 7.5 N•m 72.5 ± 7.5 N•m

NEW (53 ± 6 lbf•ft) (53 ± 6 lbf•ft)
72.5 ± 7.5 N•m

(53 ± 6 lbf•ft)
NEW = Component must be replaced when removed. NEW
268
CHASSIS
Steering System
All models with DPS
Europe
Loctite
406
Loctite
406
NEW
XPS
Synthetic NEW
grease
NEW
31.5 ± 3.5 N•m
(23 ± 3 lbf•ft)
NEW
NEW
43.3 ± 3 N•m
72.5 ± 7.5 N•m

(53 ± 6 lbf•ft)
NEW
72.5 ± 7.5 N•m
NEW 72.5 ± 7.5 N•m (53 ± 6 lbf•ft)
(53 ± 6 lbf•ft)
09
72.5 ± 7.5 N•m

NEW = Component must be replaced when removed. NEW (53 ± 6 lbf•ft)
269
CHASSIS
Steering System
General
The procedures described below are the same for
the RH and LH sides, unless otherwise instructed.
Aligning the Wheels

1. Place vehicle on a level surface.
2. Check pressure in each tire. Adjust to recom-
mended pressure.
3. Lift and secure vehicle off the ground so that
the suspension is fully extended. 1. Steering adjustment tool
2. Angle gauge or level
4. Remove both inner fenders to have easy ac-
cess to pitman arm. 10. At the LH front of wheel, near the front of the
5. Center pitman arm by measuring equal distan- rim, pull on the rope so that it does not touch
ces, ±1mm, between the edges as per the fol- the first spacer block on the alignment tool.
lowing illustration, on both sides of the pitman
arm.
A. Equal distance ± 1 mm (1/32 in) on both sides

1. Steering column lower attach
TYPICAL
2. Pitman arm
6. Secure handlebar without moving steering 11. Slowly move rope back until it just makes con-
column. tact with both spacers.
7. Remove two wheel nuts on the LH rear wheel N O T E : Ensure rope remains in this position as
and install the steering alignment tool. you carry out the following steps.
Steering alignment
tool (P/N 529036059)
8. Place a rope around all four tires using an elas-

tic, link both ends together.
N O T E : The rope must be placed at the center of

the wheels.
9. Rotate the front wheel to position the alignment
TYPICAL
tool level with the rope. Ensure rope passes
over the spacer blocks on the alignment tool. 12. Measure the distance between the rope and
the rim, at the front and at the rear of the wheel
rim.
270
CHASSIS
Steering System
i. Maximum tie-rod end length
3. Tighten tie-rod end lock nuts to

specification.
TYPICAL — FRONT OF WHEEL
Tightening Torque
34 ± 2 Nm
Tie-rod end locking nut
(25 ± 1 lbf-ft)
15. Repeat procedure for other front wheel.

16. Put the vehicle back on the ground.
17. Remove the handlebar securing device.
18. Place the front wheels in straight ahead posi-
tion and adjust the handlebar in its center posi-
tion by loosening the 4 bolts clamping the
handlebar on the steering column.
TYPICAL — REAR OF WHEEL
13. Calculate the difference between the front and

Procedures
rear measurements and compare with follow- Handlebar Grip
ing specifications. Removing the Handlebar Grip
Specification 1. Loosen the screw at the end of handlebar grip.
Models
2. Remove the handlebar grip cap.
0 to 3 mm (0 to .118 3. Cut and remove the handlebar grip.
All Outlanders in)tto e - i n Installing the Handlebar Grip 09
3 to 5.6 mm (.118 to 1. Remove all rubber residues of the old grip be-
All Renegades fore installing the new.
.22 in)tto e - i n
2. Clean the handlebar with recommended
14. If the wheel toe measurement is out of specifi- cleaner or alcohol to remove any greasy matter
cation, carry out the following: on it.
1. Loosen tie-rod end lock nuts.
Clutch and pulley flange cleaner PRO S1
2. Adjust tie-rod length.
N O T E : For a toe-in adjustment, the distance 3. Install handlebar grip by blowing compressed
must be longer at the front of the wheel. Lengthen air between handle grip and handlebar.
tie-rod to increase toe-in, and vise-versa. 4. Install a Smoothflow™ tapered tip16 ga from
Nordson EFD Inc on a bottle of glue.
WARNING
Loctite 406 (glue)
The maximum unengaged tie-rod length must
not exceed 32 mm (1.26 in) Tie rod unen-
gaged length must be the same at both ends 5. Lift a part of the grip using a small screwdriver
of the tie-rod. and inject glue (about 4 spots per side).
N O T E : The glue dries quickly. Do not apply it be-
fore installing grip.
6. Apply pressure on the grip for approximately

30 seconds to set the glue.
271
CHASSIS
Steering System
7. Install the handlebar grip cap and tighten 1. Remove handlebar cover.
screws to specification.
N O T E : Remove handlebar grips, throttle handle,
Tightening Torque brake handle and multifunction switch only if the
handlebar is defective and requires replacement.
Handlebar grip cap 0.4 Nm
screw (3.5 lbf-in) 2. Remove handlebar mounting bolts, stiffener
and handlebar clamps.
Handlebar Cover
Removing the Handlebar Cover
Outlander
1. Pull on plastic handlebar cover to remove it
from the handlebar.
Outlander XT
2. Unscrew both plastic U-clamps that attach
handlebar cover to the handlebar.
TYPICAL
1. Stiffeners
2. Handlebar clamps
3. Remove the handlebar.

Renegade Models
1. Remove fabric steering cover.
2. Pull foam protector from handlebar.
TYPICAL 3. Remove the four socket screws, then remove
1. Plastic U-clamp
the handlebar clamps.
Renegade
3. Remove the fabric steering cover, then pull the
protective foam from the handlebar.
Inspecting the Handlebar Cover
Check covers for cracks or other damages. Re-
place if necessary.
Installing the Handlebar Cover
The installation is the reverse of removal
procedure.
Renegade X xc 1000
N O T E : Ensure handlebar "U" clamps in handle-
bar cover are tightened equally (equal distance on
each side of clamps). 1. Socket screws
2. Handlebar clamps
Handlebar
Inspecting the Handlebar
Removing the Handlebar
Inspect the handlebar for damage, cracks or bend-
All Outlander Models ing. Replace if any of these problems is detected.
272
CHASSIS
Steering System
Installing the Handlebar Steering Connector Identification

For the installation, reverse the removal
procedure.
N O T E : Ensure handlebar "U" clamps are tight-

ened equally (equal distance on each side of
clamps).
Steering Connectors
Steering Connector Access
1. Remove gauge support, refer to gauge
subsection.
STEERING CONNECTOR IDENTIFICATION

1. MG1 (LH multifunction switch)
4. DC3 (DC power connector)
5. HIC (Engine interconnect)
6. DC5 (DC Power Interconnect)
7. SWW (Switch winch, if equipped)
Multifunction Switch
1. Gauge support
Models Outside North America, no T-
2. Remove front body module, refer to body Category
subsection.
3. Remove dash board support.
09
MUL TI FUNCTION SWITCH
WITH SPEED LIMITER –
WITHOUT WINCH
1. START/DPS/OVERRIDE
button
2. Headlight switch
3. Engine stop switch
4. ON/OFF Speed Limiter
1. Dash board support button
5. Set/Reset Speed Limiter
button
273
CHASSIS
Steering System
3. Separate both parts of the multifunction switch.

T-Category Models 4. Disconnect multifunction switch steering con-
nectors, refer to Steering System for connector
identification.
– MG1
– MG2
– MG3
5. Take note of the positions of the locking ties
securing the steering harness, then cut them
MULTIFUNCTION SWITCH MULTIFUNCTION SWITCH and remove the multifunction switch steering
WITH SPEED LIMITER AND WITH SPEED LIMITER – harness from the vehicle.
WITH WINCH WITHOUT WINCH
1. START/DPS/OVERRIDE 1. START/DPS/OVERRIDE Installing the Multifunction Switch
button button 1. The installation is the reverse of the removal
2. Headlight switch 2. Headlight switch procedure. However, pay attention to the
3. Engine stop switch 3. Engine stop switch following.
4. Horn button 4. Horn button
5. Flasher signal switch 5. Flasher signal switch NOTICE
6. Hazard switch 6. Hazard switch Be sure to route and secure the multifunction
7. OFF/ACCEL button 7. OFF/ACCEL button switch steering harness as noted during
8. Set (ON)/DECEL button 8. Set (ON)/DECEL button removal.
9. Winch switch
2. Tighten fasteners to specifications.
Tightening Torque
Multifunction switch 3.5 ± 0.5 Nm

Testing the Multifunction Switch

MULTIFUNCTION SWITCH
MULTIFUNCTION SWITCH Testing the Engine Stop Switch
WITHOUT SPEED L IMITER
– WITH WINCH WITHOUT SPEED LIMITER 1. Disconnect multifunction switch connector
AND WITHOUT WINCH
1. START/DPS/OVERRIDE (MG1).
1. START/DPS/OVERRIDE
button 2. Install the D.E.S.S. key on the D.E.S.S. post.
button
2. Headlight switch 3. Test the engine stop switch ground.
2. Headlight switch
3. Engine stop switch
3. Engine stop switch HARNESS
4. Horn button SPECIFICATION
4. Horn button CONNECTOR PIN
5. Flasher signal switch
5. Flasher signal switch
6. Hazard switch 1 to chassis ground
6. Hazard switch Close to 0 V
7. Winch switch
If voltage is not to specification, perform engine

Removing the Multifunction Switch stop switch continuity test.
1. Remove gauge support, refer to appropriate If voltage is within specification, test continuity
subsection. of wiring. Refer to WIRING DIAGRAM.
2. Remove following fasteners. 4. Test the engine stop switch continuity on the
switch connector side.
Engine Stop Switch Continuity Test
ENGINE
STOP
SWITCH SPECIFICA
SWITCH
POSITION TION
CONNECTOR
PIN
274
CHASSIS
Steering System
RUN Close to 0 Ω If the result is within specification, test head-

1 to 2 lights. Replace as required.
STOP Open circuit
Testing the Hazard Switch
If the result is not within specifications, replace 1. Disconnect multifunction switch flasher con-
the multifunction switch. nector (MG3).
2. Test the hazard switch voltage.
If the result is within specification, test D.E.S.S.
key. Replace as required. Hazard Switch Voltage Test
Testing the Headlight Switch MG3
SPECIFICA
1. Disconnect multifunction switch connector CONNECTOR CHASSIS
TION
(MG2). PIN
2. Test the headlight switch voltage.
Close to
Chassis
Headlight Switch Voltage Test 1 battery
ground
voltage
MULTIFUNC
TION If voltage is not to specification, perform haz-
SWITCH SWITCH SPECIFICA ard switch continuity test.
POSITION CONNECTOR TIONS
(MG2) If voltage is to specification, test continuity of
wiring. Refer to WIRING DIAGRAM.
Close to 3. Test the hazard switch continuity.
LO Pin 6 to Pin 4 battery
voltage Hazard Switch Continuity Test
Close to MG3
SWITCH SPECIFICA
HI Pin 5 to Pin 4 battery CONNECTOR
POSITION TION
voltage PIN
Pin 3 and Pressed Close to 0 Ω

PASS/OFF Close to 0 V 1 to 2
ECMB-H3 Released Open circuit
09
If voltage is not to specification, perform head- If the resistance is not within specifications, re-
light switch continuity test. place the multifunction switch.
If voltage is to specification, test continuity of If the resistance is within specification, refer to
wiring. Refer to Wiring Diagram. TRAILER FLASHER MODULE.
3. Test the headlight switch continuity.
Testing the Flasher Signal Switch
Headlight Switch Continuity Test 1. Disconnect multifunction switch flasher con-
nector (MG3).
MULTIFUNC 2. Test the flasher signal switch voltage.
TION
SWITCH SWITCH SPECIFICA
POSITION TIONS Flasher Signal Switch Voltage Test
CONNECTOR
(MG2) MG3
SPECIFICA
CONNECTOR CHASSIS
LO Pin 6 to Pin 4 Close to 0 Ω TION
PIN
HI Pin 5 to Pin 4 Close to 0 Ω Close to
Chassis
Pin 3 and Close to 0 Ω 5 battery
PASS/OFF ground
MG1-1 voltage
If the continuity is not within specifications, re- If voltage is to specification, perform the flasher
place the multifunction switch. signal switch continuity test.
275
CHASSIS
Steering System
If voltage is not to specification, test continuity If the results are within specification and the
of wiring. Refer to WIRING DIAGRAM. voltage and ground to the button are also
3. Test the flasher signal switch continuity. good, replace the horn.
Flasher Signal Switch Continuity Test Testing the START/DPS/OVERRIDE Button

1. Disconnect multifunction switch connectors
MG3 (MG1 and MG2).
SWITCH SPECIFICA
CONNECTOR 2. Test the START/DPS/OVERRIDE button
POSITION TION
PIN voltage.
Right 4 to 5 Close to 0 Ω The D.E.S.S. key must be installed for the MG1-1
Left 6 to 5 Close to 0 Ω test.
4 to 5 START/DPS/OVERRIDE Button Voltage Test

Middle and Open circuit
Connector Specifications
6 to 5 Chassis
PIN
If the results are not within specifications, re- Close to
place the multifunction switch. Chassis
MG2-1 battery
ground
voltage
If the results are within specification, refer to
TRAILER FLASHER MODULE. Chassis
MG1-1 ground Close to 0 V
Testing the Horn Button
1. Disconnect multifunction switch connector
(MG3). If voltage is not to specification, perform
2. Test the horn button voltage. START/DPS/OVERRIDE button test.
If voltage is to specification, test continuity of
Horn Button Voltage Test wiring. Refer to WIRING DIAGRAM.
3. Test the START/DPS/OVERRIDE button
MG3
SPECIFICA continuity.
CONNECTOR CHASSIS
TION
PIN
START/DPS/OVERRIDE Button Continuity Test
Close to
Chassis Multifunction
1 battery
ground SWITCH Switch SPECIFICA
voltage
POSITION Connector TIONS
PIN
If voltage is not to specification, perform the
horn button continuity test. MG2-1 and
Close to 0 Ω
MG2-2
If voltage is to specification, test continuity of Pressed
wiring. Refer to WIRING DIAGRAM. MG1-1 and
3. Test the horn button continuity. MG1-3
Open circuit
Horn Button Continuity Test MG2-1 and
MG2-2
MG3 Released
SWITCH SPECIFICA MG1-1 and
CONNECTOR Close to 0 Ω
POSITION TION MG1-3
PIN
Pressed Close to 0 Ω If the results are not within specifications, re-
1 to 3 place the multifunction switch.
Released Open circuit
If the results are within specification and the
If the results are not within specifications, re- voltage and ground to the button are also
place the multifunction switch. good, test the continuity between MG1-3 and
ECMB-F3 and the continuity between MG2-2
and ECMB-D1.
276
CHASSIS
Steering System
If the results are still good, test the Dynamic If voltage is not to specification, test continuity
Power Steering (DPS) (if equipped). of wiring. Refer to WIRING DIAGRAM.
3.
Testing the OFF/ACCEL Button 4. Test the Set (ON)/DECEL button continuity.
1. Disconnect multifunction switch connector
(MG1). Set ON/DECEL Button Continuity Test
2. Test the OFF/ACCEL button voltage.
MG1
SWITCH SPECIFICA
OFF/ACCEL Button Voltage Test CONNECTOR
POSITION TIONS
PIN
MG1
SPECIFICA Pressed Close to 0 Ω
CONNECTOR CHASSIS
TION 4 to 5
PIN Released Open circuit
Close to
Chassis If the results are not within specifications, re-
4 battery
ground place the multifunction switch.
voltage
If voltage is not to specification, perform OFF/ voltage and ground to the button are also
ACCEL button continuity test. good, replace the digital display.
If voltage is to specification, test continuity of Testing the Winch Switch
wiring. Refer to WIRING DIAGRAM..
3. Test the OFF/ACCEL button continuity. 1. Disconnect winch switch connector (SWW).
2. Test the winch switch voltage.
OFF/ACCEL Button Continuity Test
Winch Switch Voltage Test
MG1
SWITCH SPECIFICA SWW
CONNECTOR SPECIFICA
POSITION TION CONNECTOR CHASSIS
PIN TION
PIN
Pressed Close to 0 Ω
4 to 6 Close to
Chassis
Released Open circuit A ground
battery
voltage
09
place the multifunction switch. If voltage is not to specification, perform winch
switch continuity test.
voltage and ground to the button are also If voltage is to specification, test continuity of
good, replace the digital display. wiring. Refer to WIRING DIAGRAM.
3. Test the winch switch continuity.
Testing the Set (ON)/DECEL Button
1. Disconnect multifunction switch connector Winch Switch Continuity Test
(MG1).
2. Test the set (ON)/DECEL button voltage. SWW
SWITCH SPECIFICA
CONNECTOR
POSITION TION
Set (ON)/DECEL Button Voltage Test PIN
MG1 OUT A to B Close to 0 Ω

SPECIFICA
CONNECTOR CHASSIS IN A to C Close to 0 Ω
TIONS
PIN
A to B
Close to Released and Open circuit
Chassis
4 battery A to C
ground
voltage
If voltage is to specification, perform Set ON/ place the multifunction switch.
DECEL button continuity test.
277
CHASSIS
Steering System
If the results are within specification and the For inspection and replacement of steering col-
voltage and ground to the button are also umn half bushings, refer to steering column in this
good, replace the winch. subsection.
Intelligent Throttle control (ITC) Housing Steering Column
Removing and Installing the ITC Housing Removing the Steering Column (Without DPS)
Refer to Intelligent Throttle Control (iTC) 1. Remove gauge support, refer to gauge
subsection. subsection.
2. Refer to body subsection to remove the
Brake Lever following:
Removing the Brake Lever From the Vehicle – Front body module
1. Carry out steps in Removing the BRAKE LEV- – Inner fender panels
ER (at HANDLEBAR). 3. Remove dash board support.
NOTICE
Avoid spilling brake fluid on plastic, rubber or
painted parts.
2. Disconnect brake hose, refer to brakes

subsection.
Removing the Brake Lever (At Handlebar)
1. Remove brake lever retaining screws.
1. Dash board support
4. Remove the air intake silencer. Refer to air in-

take system subsection.
5. Remove handlebar, refer to Removing the han-
dlebar in this subsection. Also remove locking
ties and separate wiring harnesses and hoses
TYPICAL
1. Remove these retaining screws
from the steering column.
6. Disconnect the tie-rods from the pitman arm at
2. Separate brake lever from handlebar. the bottom of the steering column. Refer to
TIE-ROD in this subsection.
Installing the Brake Lever
For installation, reverse the removal procedure
however, pay attention to the following.
Tightening Torque
Brake lever mounting 6 ± 1 Nm (53 ± 9 lbf-in)
screw
WARNING
If brake hose was disconnected, bleed brake
system. Refer to brakes subsection.
Steering Column Bearing

The steering column bearing(s) used on these ve-
hicles are half bushings.
278
CHASSIS
Steering System
1. Upper steering column support

1. Steering column
2. Half bushings
2. Pitman arm
3. Half bushing retainer
3. Tie-rod end
4. Retainer mounting screws (2)
4. Cotter pin
5. Tie-rod retaining nut
9. Pull steering column from vehicle.
NOTE: When removing tie-rods from pitman Removing the Steering Column (With DPS)
arm, take note of positions of flat washers for 1. Remove gauge support, refer to gauge
installation. subsection.
2. Remove the front body module, refer to body
7. Remove lower half bushing retaining screws subsection.
and pull retainer off of half bushings. 3. O u t l a n d e r M o d e l s
4. Remove dash board support.
09
1. Lower retainer mounting screws (2) TYPICAL - OUTLANDER MODEL S

2. Lower half bushing retainer 1. Dash board support
3. Steering column
4. Pitman arm 5. A l l M o d e l s
8. Remove upper half bushing retaining screws 6. Remove the air intake silencer. Refer to air in-
and pull retainer off of half bushings. take system subsection.
7. Remove handlebar, refer to Removing the han-
dlebar in this subsection. Also remove locking
ties and separate wiring harnesses and hoses
from the steering column.
8. Remove the pinch bolt.
N O T E : Some parts in following illustration not
shown for clarity of illustration.
279
CHASSIS
Steering System
Replacing the Steering Column Lower Ball

Bearing and Seal (Outlander 450 and 570
Without DPS (Except the 570 PRO))
1. Remove the pitman arm. Refer to Pitman arm
in this subsection.
2. Remove ball bearing.
9. Remove upper half bushing retaining bolts and

pull retainer off of half bushings.
3. Remove seal.
TYPICAL
1. Upper steering column support
2. Half bushings
4. Retainer mounting screws (2)
10. Pull steering column from vehicle.

Inspecting the Steering Column 4. Install a N E W seal.
5. Install a N E W ball bearing.
1. Inspect steering column for wear, cracks or
bending. Replace if any of these problems is Installing the Steering Column
detected. The installation is the reverse of the removal pro-
2. Check steering column O-rings for brittleness, cedure. However, pay attention to the following.
hardness, wear or other damage. Replace if
necessary. 1. Lubricate O-rings and half bushings.
3. Clean and check steering column half bush-
ings. If they show signs of wear or cracking, re- XPS Synthetic grease
place them.
4. M o d e l s W i t h o u t a D P S 2. Apply anti-seize lubricant on splines of the
5. Check if steering column lower ball bearing DPS input and output shafts.
turns freely and smoothly. .
– Outlander 450 and 570 Without DPS (ex-
cept the 570 PRO) - Replace the bearing if
3. Install N E W cotter pins (as applicable per
necessary.
model). Both ends of cotter pins must be
– Outlander 570 PRO, Outlander 650/850/
folded.
1000R and Renegade Without DPS - Re-
4. Install N E W elastic nuts where used.
place steering column if necessary.
280
CHASSIS
Steering System
5. Torque all fasteners as specified in the applica-

ble exploded view.
6. Carry out a steering alignment, refer to Align-
ing the Wheels.
7. Reset the torque sensor offset, refer to Reset-
ting the Torque Offset in the appropriate Dy-
namic Power Steering (DPS) subsection.
Tie-Rod
N O T E : Use the same procedure for RH and LH
side.
Removing the Tie-Rod
1. Place vehicle on jack stands and remove the
applicable wheel. TYPICAL
2. Remove tie-rod end from steering knuckle by 1. Steering column
2. Pitman arm
removing: 3. Tie-rod end
4. Cotter pin
– Cotter pin (discard) 5. Tie-rod end retaining nut
– Retaining nut
– Hardened washers (note position). Inspecting the Tie-Rod
Inspect tie-rod for straightness, cracks and other
damages. Replace as required.
Inspect tie-rod ends for wear or excessive play. If
excessive, replace the tie-rod end.
Installing the Tie-Rod
1. For the installation, reverse the removal proce-
dure. Pay attention to the following details.
2. When installing a new tie-rod or tie-rod end,
adjust tie-rod to nominal length. 09
Tie-Rod Nominal Length
Outlander with 416.4 mm

TYPICAL - TIE ROD AT STEERING KNUCKLE metal racks (16.394 in)
1. Cotter pin Dimension "A" -
2. Elastic nut Renegade and center to center
3. Hardened washers 438.3 mm
Outlander with
(17.26 in)
3. If completely removing tie-rod from vehicle, re- plastic rack
peat previous step at pitman arm.
NOMINAL LENGTH
1. Pitman arm side
2. Knuckle side
A. Distance to measure
281
CHASSIS
Steering System
Tie-Rod Maximum Unengaged Length

Dimension "A" - Shoulder 32 mm (1.26 in)
to tie rod end face
WARNING
Maximum tie-rod unengaged length must not
exceed specification. Both tie-rod ends must
be engaged equally.
6. Detach upper suspension arm from knuckle,

refer to FRONT SUSPENSION.
MAXIMUM TIE-ROD UNENGAGED LENGTH 7. Detach lower suspension arm from knuckle, re-
A. 32 mm (1.26 in) fer to FRONT SUSPENSION.
8. Remove knuckle from vehicle.
3. Install N E W cotter pins. Both ends of cotter
pins must be folded. Inspecting the Knuckle
4. Check the steering alignment, refer to Aligning Check knuckle for cracks or other damages. Re-
the Wheels in this subsection. place if necessary.
5. Apply specified torques.
Check if wheel bearing turns freely and smoothly.
Tightening Torque See WHEEL BEARINGs in this subsection.
34 ± 2 Nm Installing the Knuckle
Tie-rod lock nut (25 ± 1 lbf-ft) The installation is the reverse of removal
procedure.
Tie rod end retaining 72 ± 7 Nm
nut (53 ± 5 lbf-ft) Wheel Bearings
Inspecting Wheel Bearing
Knuckle
1. Safely lift and support the vehicle.
Removing the Knuckle 2. Hold wheel by the top and the bottom and try
1. Safely lift and support the front of vehicle. to move it by pulling and push alternately with
2. Remove front wheel. both hands. Check for any play.
3. Detach tie-rod end from knuckle, refer to TIE- 3. If there is any looseness detected, replace the
ROD in this subsection. wheel bearing. refer to Steering System
4. Remove brake caliper, refer to BRAKES subsection.
subsection.
5. Remove wheel hub, refer to the appropriate N O T E : To properly locate play during this in-
FRONT DRIVE subsection. spection, be sure to check other components for
wear or looseness (ball joints, suspension pivots,
etc). If necessary repair or replace all defective
parts before checking the wheel bearing condition.
Be careful not to misinterpret a loose ball joint as a
loose wheel bearing.
Inspecting the Wheel Bearing (During
Component Removal)
Whenever the drive axle or knuckle is removed,
check wheel bearing as follows:
– Check if wheel bearing turns freely and
smoothly.
282
CHASSIS
Steering System
– Check seal condition. – Place bearing in a freezer for 10 minutes.

– Place knuckle in oven to 100 °C (212 °F)
Replace if necessary. for 30 minutes maximum.
Removing the Wheel Bearing 3. When knuckle is cooled down, install N E W cir-
1. Remove knuckle from vehicle, refer to Remov- clip and N E W seal.
ing the Knuckle in this subsection. Pitman Arm (Without DPS)
2. Remove the circlip.
Removing the Pitman Arm
1. Remove tie rod ends from pitman arm. Refer to
tie rod in this subsection.
2. Remove and discard cotter pin.
1. Circlip
3. Install knuckle on a press.

4. Remove bearing from knuckle using an appro-
priate bearing remover.
3. Remove pitman arm retaining nut and washer.
09
TYPICAL
N O T E : It may be necessary to heat the knuckle

to remove bearing. 4. Remove pitman arm.
WARNING
Clean all grease from outside and inside of
knuckle before heating it.
Installing the Wheel Bearing

following.
2. To ease wheel bearing installation:
283
CHASSIS
Steering System
1. Pinch bolt
Inspecting the Pitman Arm

Inspect pitman arm for cracks or other damages. N O T E : There is no need to mark the parts index-
Replace if necessary. ation. There is a master spline on the assembly.
Check pitman arm splines for excessive wear. Re- 3. Remove the pitman arm by hand or using a
place if necessary. soft hammer.
Installing the Pitman Arm NOTICE
Installation is the reverse of the removal. How- Do not pry between the DPS unit and the pit-
ever, pay attention to the following man arm to avoid damage to the output shaft
1. Apply antiseize lubricant on steering column seal.
splines.
4. Remove the half bushings.
2. Tighten the pitman arm retaining nut to

specification.
Tightening Torque
Pitman arm retaining 57.5 ± 7.5 Nm

nut (42 ± 6 lbf-ft)
3. Install a N E W cotter pin. Both ends of cotter

pins must be folded. 1. Half bushings
Pitman Arm (With DPS) 5. Inspect the O-rings and replace if required.
Removing the Pitman Arm
1. Remove tie rod ends from pitman arm. Refer to
tie rod in this subsection.
2. Remove the pinch bolt.
1. O-rings
284
CHASSIS
Steering System
Inspecting the Pitman Arm

Tightening Torque
Inspect pitman arm for cracks or other damages.
Replace if necessary. Steering column pinch 43 ± 3 Nm
bolt (32 ± 2 lbf-ft)
Check pitman arm splines for excessive wear. Re-
place if necessary.
Installing the Pitman Arm
1. Lubricate the inside of the half bushings.
A. Apply grease here
2. Lubricate the pitman arm contact surface and

"O" rings.
09
1. Apply grease here
3. Apply lubricant to the DPS outout shaft splines.
4. Install pitman arm. Tighten the pinch bolt to the

specified torque.
N O T E : Make sure to engage the pinch bolt in

the DPS input shaft groove properly.
285
CHASSIS
Dynamic Power Steering (DPS)
Dynamic Power Steering

(DPS)
SERVICE PRODUCTS

LOCTITE 271 (RED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
LOCTITE 406 (GLUE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
286
CHASSIS
24 ± 3.5 N•m
(18 ± 3 lbf•ft)
24 ± 3.5 N•m
NEW
24 ± 3.5 N•m
(18 ± 3 lbf•ft)
Loctite 767
(antiseize lubricant)
NEW
XPS Synthetic
grease
XPS Synthetic
grease NEW
22 ± 2 N•m
(16 ± 1 lbf•ft)
24 ± 3.5 N•m
(18 ± 3 lbf•ft)
NEW
09
NEW NEW
24 ± 3.5 N•m 43 ± 3 N•m
(18 ± 3 lbf•ft) (32 ± 2 lbf•ft) XPS Synthetic
grease
287
CHASSIS
General The greater the power steering assist, the greater

the load on the electrical system.
NOTICE
Never perform arc welding in the DPS area. When the electrical system is under high load (bat-
Otherwise, poor DPS operation might occur. tery not at full charge, operating the vehicle for
prolonged periods of time at slow speed and low
RPM which, requires higher power steering as-
System Description (Features)
sist), the battery power reserve will gradually de-
The Dynamic Power Steering (DPS) provides a crease. This further increases the load on the
computer controlled, variable power assist, charging system and the electrical system voltage
achieved by an electric motor to optimize the will drop. As system voltage drops, so does power
amount of steering input required by the rider. steering assist.
N O T E : It is important to maintain the battery at a

full state of charge to ensure proper DPS opera-
tion. The magneto output is 650 watts to minimize
battery drain and system voltage drop.
DPS Assist Mode
The DPS system provides three rider selectable
modes of operation.
N O T E : The system automatically adjusts to the
speed of the vehicle and driving conditions. the
modes are designed to meet the preference of the
rider.
The DPS system uses the following parameters to
determine how much steering assist it provides: The following DPS modes are preset in the
– Engine RPM vehicle.
– Battery/electrical system voltage DPS Mode
– Vehicle speed
– DPS shaft torque sensor input. DPS MAX. Maximum steering assist
– DPS internal temperature.
DPS MED. Medium steering assist
The amount of steering assist provided is depend-
ent on the handlebar effort (steering torque), elec- DPS MIN. Minimum steering assist
trical power available, and vehicle speed.
A fourth mode of operation is available as an ac-
The greater the handlebar effort (torque), the
cessory to adjust the steering assist level for oper-
greater the assist will be.
ation with an approved BRP track kit.
The slower the vehicle speed, the greater the as-
DPS System Description (Components)
sist will be.
DPS Unit
If the electrical system is activated but the engine
is not running, DPS assist will be provided for ap- The DPS unit is a self contained unit that includes
proximately 30 seconds. DPS assist will resume the steering gear, the DPS module, the DPS mo-
once the engine is started. tor, and the torque sensor.
After turning the ignition key OFF, DPS assist will

be provided for approximately 20 seconds.
When the handlebar is in the straight ahead posi-
tion, there is no steering assist.
Steering torque may also come from the wheels
due to rough terrain. Steering kickback is reduced
while providing feedback to the driver.
288
CHASSIS
Part Adjusted or
Replaced What to Do
– DPS unit
– Steering column
half bushings
– Steering column
– Tie rod
– Tie rod end Reset Torque
– Knuckle Offset
– Wheel bearing in Settings, DPS
– Ball joint
– Front suspension arm
(lower/upper)
– Pitman arm
The DPS module provides DC power to the motor. – Steering alignment
The amount and duration of that DC power is de-
termined by the inputs to the DPS module.
1. Ensure steering alignment is correct, refer to
The DPS motor does not "spin", but rather turns in Aligning the wheels in the Steering System
very small increments based on the amount, dura- subsection.
tion, and direction of DC power delivered by the 2. Connect the vehicle to the BRP diagnostic soft-
DPS module. ware (BUDS2).
3. Check if an update is available and warranted
NOTE: Should the DPS unit fail, the vehicle for the DPS. Select:.
steering is still available with moderate increase in
steering effort. – Flash page.
– DPS or Vehicle button.
Steering Torque Sensor – Flash tab.
The steering column is connected to the shaft on
If an update is available, install it before reset-
the DPS unit. A small area of the DPS shaft is
ting the torque offset.
magnetized. Inside the DPS unit, a torque sensor
surrounds the magnetized area of the DPS shaft.
Required Conditions to Allow the Reset
09
When the handlebar is turned, torque is applied to Procedure
the shaft which tends to twist the shaft slightly, de-
DPS unit temperature above freezing point.
forming the magnetic field in the shaft. The sensor
detects the torque by measuring the deviation of Steering wheel should be free and centered.
the magnetic field. There MUST NOT be any effort applied to the
The torque sensor is very sensitive and can detect steering column.
very small changes in the magnetic field. The Torque sensor value must be within offset
harder the handlebar is turned, the greater the threshold value of ± 10 Nm.
magnetic deviation, the greater the power steering
assist. Engine not running.
Resetting the Torque Offset 4. To reset the torque offset, select:

When replacing the following parts or adjusting
steering alignment, the sensor torque offset MUST – Settings page.
be reset to zero for proper system operation. – DPS or Vehicle button.
– Initialization tab.
5. Select Torque Sensor Offset.
N O T E : Torque reading must be stable and not
exceeding 2 Nm during procedure. Torque sensor
reset may not be possible if the torque value is
over the 10Nm above the original setting.
289
CHASSIS
With the steering wheel centered and no effort DPS Connector

is applied, if the indicated Torque Sensor value
is over the threshold value of 1.5Nm, a steering FUNCTION PIN COLOR
imbalance may be noticeable.
12 volt input (from
If all steering components are undamaged and fuse PF2) C RD/PK
in good working order, repeated torque offset
reset procedures will not solve the problem if 12 volt input (from
fuse PF2) D RD/PK
the torque offset is greater than ±10 Nm. DPS
unit replacement may be required.
12 volt input (from
fuse PF2) E RD/PK
NOTICE
Ensure handlebar is free and centered within 12 volt switched
±10 degrees of center position. There MUST input (from fuse F6) G OR/GN
NOT be any effort applied to the steering
column. CAN HI J WH/BE
CAN LO K WH/BK
Procedures
DPS Unit Ground A BK
DPS Unit Fuse Location Ground B BK
Ground F BK
Testing the DPS Input Voltage

1. Disconnect the DPS connector.
1. DPS (F2) fuse
DPS Wire Identification

For circuit details, refer to wiring diagram.
1. DPS connector
2. Test for 12 Vdc DPS motor power at DPS con-

E K nector as per following table.
Multimeter Probe Positions Voltage

DPS connector
pin C
A F DPS connector Battery Battery

pin D ground voltage
DPS connector
DPS CONNECTOR HARNESS SIDE pin E
If NO voltage is measured, test the 40 A DPS fuse

(PF2). If good, check wires and connector pins.
290
CHASSIS
Replace or repair defective parts and reset fault

codes.
If battery voltage is measured, test the DPS igni-
tion signal voltage.
N O T E : This test may also be carried out by con-
necting a 12 Vdc test light between connector pins
(C, D and E), and the battery (-) negative terminal.
The test light must come on bright.
Testing the DPS Ignition Signal Voltage
1. Disconnect DPS connector.
1. DPS connector
2. Test for continuity between DPS connector

and battery ground.
Multimeter Probe Positions Reading

DPS
connector
(harness side)
pin A
DPS
connector Battery Continuity
1. DPS connector
(harness side) ground (close to 0 Ω)
2. Set the ignition switch to ON. pin B
3. Set the engine RUN/STOP switch to RUN.
4. Test for 12 Vdc power at the DPS connector as DPS
per following table. connector
(harness side)
pin F
Multimeter probe positions Voltage 09
DPS connector If there is NO continuity or a high resistance is
Battery
(harness side) Battery ground measured, check wires and connector pins from
voltage
pin G DPS unit to chassis ground post. Replace or repair
defective parts and reset fault codes.
If NO voltage is measured, check wires and con- If there is good continuity, carry out: Testing the
nector pins from the DPS unit to the fuse (F6) in DPS unit communication link (CAN) continuity.
the front fuse box (PF1-F6). Replace or repair de-
fective parts and reset fault codes. N O T E : This test may also be carried out by con-
If battery voltage is measured, test the DPS necting a 12 Vdc test light between each GDN
ground circuit. connector pin and the battery (+) positive terminal.
The test light must come on bright.
N O T E : This test may also be carried out by con- Testing the DPS Communication Link (CAN)
necting a 12 Vdc test light between the DPS con- Continuity
nector (pin G), and the battery (-) negative
terminal. The test light must come on bright. N O T E : DPS unit must receive an RPM signal to
Testing the DPS Ground Circuit provide power steering assist.
1. Disconnect the DPS connector. 1. Disconnect the DPS connector and the diag-
nostic connector.
2. Test continuity of CAN Bus Wires as per fol-
lowing table.
291
CHASSIS
Multimeter Probe Positions

DPS Resistance
CONNEC @ 20°C
TOR DIAGNOSTIC
CONNECTOR (68°F)
(HARNESS
SIDE)
Pin J Pin 1 Less than 1
Pin K Pin 2 Ω
If resistance measured is out of specification,

check wires and connector pins. Carry out re-
pairs as required and reset fault codes using
the BRP diagnostic software (BUDS2)
software.
If resistance measured is good, replace the
DPS unit and reset fault codes using BUDS2 VDC SELECTED TO MANUAL RANGE 6 0
software.
6. Press the MIN MAX button on the multimeter
Testing the DPS System Load to engage the MIN function.
If the charging system cannot sustain normal volt-
age when the DPS is operating, DPS ASSIST
may be greatly reduced or nonexistent. Carry out
the following steps.
1. Measure the battery voltage.
NOTE: If battery voltage is low, recharge

battery.
2. Ensure the vehicle transmission is set to
PARK.
3. Start the engine.
4. Note the voltage on the multimeter with the en-
gine running (charging system voltage).
5. Press the RANGE button repeatedly to select
Manual Range 6 0.
1. MIN function selected
7. Turn the handlebar momentarily against the

steering frame stops to each side.
N O T E : Do not hold steering against frame stops

for an extended period of time.
8. Read the MIN charging system voltage re-

corded while the handlebar was turned against
each stop.
292
CHASSIS
DPS System Load Test Torque Sensor DPS Current

Steering Voltage 0 ± 1 Nm (0 ± 9 lbf-in) 0 Amp
Probe positions
position reading
4. Turn the steering wheel side to side, momen-
Battery(- DPS fuse LH stop tarily against each steering hard stop and ob-
At least
) holder pin serve the DPS Torque Sensor value. The
RH stop 12 Vdc
terminal B torque value should increase with steering ef-
fort applied to the steering wheel.
NOTE: Turning the handlebar momentarily
against the frame stops generates maximum DPS The DPS Current value should increase pro-
load (maximum current draw on electrical system). portionately to the torque applied, and de-
Electrical system must sustain at least 12 Vdc for crease with the torque as steering assist is
proper DPS operation. provided.
N O T E : The increase and decrease in torque and
current readings is very brief as steering assist is
quickly provided. Current draw should remain
within green scale but may momentarily peak to or
exceed 60 amps, then drop off close to 0 amps as
torque applied is nulled out by steering assist. If
steering is held against hard stops the torque and
current readings will remain high.
If current draw tends to remain high, carry out

the following:
– Resetting the torque offset
– DPS unit replacement.
5. Turn steering to LH stop and hold at least 8
Nm. Note DPS current value.
6. Turn steering to RH stop and hold at least 8
If the electrical system cannot sustain at least
Nm. Note DPS current value. 09
7. Repeat previous two steps while holding at (+
12 Vdc, check the following: or -) 5 Nm. Note DPS current value.
– Battery
– Battery connections LH and RH DPS current readings should be
– DPS unit power and ground connections the same for the same applied torque.
– Charging system If the Resetting the torque offset procedures
– Chassis and engine ground studs. has been carried out, and the current or steer-
If the previously listed items are correct, carry ing imbalance is too great, the DPS unit will re-
out: Testing the DPS unit current. quire replacement to resolve the problem.
Testing the DPS Unit Current Removing the DPS Unit

1. Connect the vehicle to the BRP diagnostic soft- 1. Lift and support the front of the vehicle.
ware (BUDS2). 2. Remove the front wheels.
2. Go to: 3. Remove both inner fender panels.
4. Disconnect DPS electrical connector.
– Measurements page.
– DPS button.
– Custom tab.
3. With the vehicle engine running in PARK and
without any steering effort, the reading should
be as per following table.
293
CHASSIS
1. DPS electrical connector 1. Retaining screws

2. ABS module mounting bracket
5. Remove DPS mounting bracket retaining
screws. All models except ABS equipped
9. Remove DPS mounting bracket retaining
screws.
1. Retaining screws
2. DPS mounting bracket
1. Retaining screws
ABS equipped models 2. DPS mounting bracket
6. Disconnect ABS module.
7. Remove retaining screws and set aside ABS 10. Remove the steering column and pitman arm
module. pinch bolts.
1. Retaining screw 1. Steering column pinch bolt

2. Pitman arm pinch bolt
8. Remove ABS module mounting bracket. 3. DPS
N O T E : There is no need to mark the parts index-

ation. There is a master spline on the assembly.
294
CHASSIS
11. Remove the half bushing retainer that secures Loctite 767 (anti-seize lubricant)
the pitman arm to the chassis.
Loctite 767
Loctite 767
3. Engage the steering column on the input shaft.
12. Disconnect the pitman arm from the DPS by 4. Install the N E W pinch bolt and N E W flanged
lowering it, then remove the DPS from the elastic nut. Hand tight only.
steering column.
NOTICE
N O T E : Remove the unit by the left hand side of Make sure to properly engage the pinch bolt
the vehicle. in the groove of the DPS shaft.
If DPS unit is to be replaced, remove the lower
support from it.
Installing the DPS
1. Install the lower support on DPS unit using
N E W bolts.
09
TYPICAL - DPS SHAFT GROOVE
Tightening Torque
22 ± 2 Nm
Lower support screws
(16 ± 1 lbf-ft)
2. Apply lubricant to the entire visible portion of

the DPS shafts. 5. Position the DPS unit in the chassis and en-
gage the output shaft in the pitman arm.
295
CHASSIS
6. Install the N E W pitman arm pinch bolt and

N E W flanged elastic nut. Hand tight only.
NOTICE
Make sure to properly engage the pinch bolt
in the groove of the DPS shaft.
8. Install lateral mounting brackets.
NOTICE
TYPICAL - DPS SHAFT GROOVE Tightening sequence must strictly be ad-
hered to.
1. Install all bolts loosely.
7. Install the half bushings retainer bolts and

LH SIDE SHOWN, RH SIDE SIMILAR
N E W flanged elastic nuts. Hand tight only.
2. On both sides, tighten lateral bolts then un-
screw them (1/4 turn), just enough so the
support can move slightly into the slotted
bracket.
296
CHASSIS
2
1
1/4 3
TIGHTENING SEQUENCE
9. Tighten bolts as per the following sequences.
Tightening Torque
1 Front bolts 24.5 ± 3.5 Nm
Lateral bolts (18 ± 3 lbf-ft)
10. Apply dielectric grease on harness connector

terminals.
Dielectric grease
11. Connect the electrical connector.

2
Models with ABS
3 12. Reinstall ABS module. Ensure the rubber stop-
per is correctly installed.
09
TIGHTENING SEQUENCE
N O T E : Tightening torque must be applied on the

nut only.
Tightening Torque
43 ± 3 Nm
Pinch bolt nut (32 ± 2 lbf-ft)
Half bushings retainer 24.5 ± 3.5 Nm

bolts (18 ± 3 lbf-ft)
Tightening Torque
ABS module retaining 8 ± 2 Nm

screw (71 ± 18 lbf-in)
All Models
13. Install previously removed parts.
14. Perform Updating the Electronic Module.
297
CHASSIS
Updating the Electronic Module

New DPS units do not come with the required soft-
ware programmed into the unit. A DPS unit fault
will be generated when the vehicle is powered up.
The check engine light will come on and a DPS
FAULT message will appear in the multifunction
gauge.
The new DPS unit will require 2 mandatory up-
dates. The first update is required for the DPS to
recognize what type of vehicle it is installed in, the
second to upload the software required for proper
operation on that vehicle.
When DPS unit installation is complete, carry out
the following steps.
ware (BUDS2).
2. Select the Flash page.
3. A message window will appear asking you if
you would like to update the DPS module; se-
lect YES and follow the instructions. When a
second window appears asking you the same
question, select YES again.
4. Once the correct DPS software file is installed,
go to the Faults page and clear the fault codes.
5. Carry out: Resetting the torque offset (if re-
quired) as described in this subsection.
6. Test drive the vehicle to ensure proper DPS
operation.
298
CHASSIS
Suspension Adjustments
Choice of suspension adjustments vary with ve-
hicle load, personal preference, riding speed and
terrain condition.
The best way to set up the suspension, is to start
from factory settings, then customize each adjust-
ment one at a time.
Front and rear adjustments are interrelated. It may
be necessary to readjust the rear shock absorbers
after adjusting front shock absorbers for instance.
Test run the vehicle under the same conditions;
trail, speed, load, etc. Change one adjustment and
TYPICAL
retest. Proceed methodically until you are 1. Adjustment cam
satisfied. 2. Softer adjustment
3. Firmer adjustment
Following are guidelines to fine-tune suspension.
Shock Absorber With Adjustment Ring
General Adjust spring preload by turning the adjuster ring.
The procedure described below is the same for
the RH and LH sides, unless otherwise instructed. N O T E : Do not increase preload on FOX shocks.
WARNING
The left and right shock adjustment on front
or rear suspension must always be set to the
same position. Never adjust one shock only.
Uneven adjustment can cause poor handling
and loss of stability, which could lead to an
accident.
09
Spring Preload
N O T E : Spring preload affects ground clearance.
Shorten the spring for a firmer ride and rough rid-
TYPICAL
ing condition or when pulling a trailer (if equipped Step 1. Loosen top locking ring
with hitch). Step 2. Turn adjusting ring accordingly
Step 3. Tighten top locking ring
Lengthen the spring for a softer ride and smooth
riding condition. Shock Damping Adjustments (if
Equipped)
Lift the vehicle. Spring length should be measured
without load on the wheels. Adjusting the Compression Damping (With
Single Adjustment)
Do not increase the front/rear spring preload by Compression damping controls how the shock ab-
more than 15 mm (.59 in) over the factory setting. sorber reacts in compression when hitting a bump
Shock Absorber With Adjustment Cam
Adjust spring preload by turning adjustment cam.
299
CHASSIS
Result on big Action Result

Position Setting
bumps
Increasing Firmer compression
Softer compression damping damping
1 Soft compression force
damping Decreasing Softer compression
Medium compression damping damping
Medium force
2 compression
(Factory)
damping
Adjusting the Compression Damping (With
Firmer Dual Adjustments)
3 Hard compression Perform adjustments o n e position (click) at a time.
damping Test run the vehicle under the same conditions.
Proceed methodically until you are satisfied.
To adjust compression and rebound to factory set-
tings, proceed as follows:
1. Turn adjuster clockwise until it stops.
2. Turn adjuster counterclockwise by the speci-
fied amount, see Suspension Factory Settings
table in appropriate Technical specification
section.
Low Speed Compression Damping
Low speed compression damping controls how
1. Position 1 the shock absorber reacts to a low suspension ve-
2. Position 2
3. Position 3
locity (slow compression strokes, in most cases
when riding at lower speeds).
Action Result on Big Bumps
Increasing low speed Firmer compression

compression damping damping (slow
force compression)
Decreasing low speed Softer compression

compression damping damping (slow
force compression)
COMPRESSION DAMPI NG
1. I n c r e a s e s damping (firmer)
2. D e c r e a s e s damping (softer)
Turn adjuster clockwise to i n c r e a s e shock damp-

ing action (firmer).
Turn adjuster counterclockwise to d e c r e a s e
shock damping action (softer). TYPICAL - LOW SPEED COMPRESSION DAMPING
1. Adjustment screw
300
CHASSIS
High Speed Compression Damping

High speed compression damping controls how
the shock absorber reacts to a high suspension
velocity (quick compression strokes, in most cases
when riding at higher speeds).
Result on Small
Action Bumps
Increasing high speed Firmer compression

compression damping damping (fast
force compression)
Decreasing high speed Softer compression

compression damping damping (fast
force compression)
TYPICAL
1. Rebound adjuster
2. I n c r e a s e s damping (slower extension)
3. D e c r e a s e s damping (faster extension)
TYPICAL - HIGH SPEED COMPRESSION DAMPING (USE A 17

MM WRENCH)
1. Adjustment screw
Rebound Damping 09
Rebound damping controls how the shock absorb-
er reacts in extension after hitting a bumps.
Action Results
Increasing rebound
damping Slower Extension
Decreasing rebound
damping Faster extension
301
CHASSIS
Front Suspension
Front Suspension
NEW
73 ± 7 N•m
(54 ± 5 lbf•ft)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
NEW
4.5 ± 0.5 N•m

(40 ± 4 lbf•in) Suspension
NEW Grease
4.5 ± 0.5 N•m 3 ± 0.5 N•m
NEW (40 ± 4 lbf•in) (27 ± 4 lbf•in)
Suspension
Grease
3 ± 0.5 N•m
(27 ± 4 lbf•in)
Suspension
Grease
2.5 ± 0.5 N•m NEW
(22 ± 4 lbf•in)
NEW
Suspension 65 ± 5 N•m
Grease (48 ± 4 lbf•ft) 65 ± 5 N•m
2.5 ± 0.5 N•m (48 ± 4 lbf•ft)
(22 ± 4 lbf•in)
NEW
65 ± 5 N•m
4.5 ± 0.5 N•m (48 ± 4 lbf•ft) NEW
65 ± 5 N•m (40 ± 4 lbf•in)
(48 ± 4 lbf•ft)
45 ± 5 N•m
(33 ± 4 lbf•ft)
NEW
302
CHASSIS
Front Suspension
General 4. Check the following conditions that will denote

The procedure explained below is the same for a defective shock:
the RH and LH sides unless otherwise noted. – A skip or a hang back when reversing
stroke at mid travel.
Procedures – Seizing or binding condition except at ex-
Shock Absorber treme end of either stroke.
– Oil leakage.
Removing the Shock Absorber – A gurgling noise, after completing one full
1. Safely lift and support the vehicle off the compression and extension stroke.
ground. 5. Replace if any faults are present.
2. Remove screws and nuts retaining the shock
absorber. Installing the Shock Absorber
following.
2. Install shock absorber screws from front to-
wards rear of vehicle.
3. Tighten shock absorber nuts to specification.
Refer to exploded views.
Shock Absorber Bushings
Refer to SHOCK ABSORBER BUSHINGS in
REAR SUSPENSION subsection for complete
procedures.
Springs
Refer to Springs in REAR SUSPENSION subsec-
TYPICAL tion for complete procedures.
3. Remove shock absorber. Lower Suspension Arm
Removing the Lower Suspension Arm
Inspecting the Shock Absorber
1. Remove spring from shock absorber. Refer to 1. Safely lift and support the vehicle off the
09
springs in this subsection. ground.
2. Secure the end of shock eyelet in a vise with 2. Remove wheel, refer to WHEELS AND TIRES
its rod upward. subsection.
3. Remove screw and nut securing lower ball joint
to knuckle.
TYPICAL
NOTICE
Do not clamp directly on shock body.
3. Extend and compress the piston several times

over its entire stroke. Check that it moves
TYPICAL
smoothly and with uniform resistance with its
rod upward. 4. Remove screws and nuts securing suspension
arm to frame.
303
CHASSIS
Front Suspension
TYPICAL
1. Suspension arm screws TYPICAL
5. Remove suspension arm. 4. Remove and discard cotter pin retaining ball
joint.
TYPICALMOVE OUTWARDS
Installing Lower Suspension Arm TYPICAL

5. Remove ball joint nut and washer.
following.
2. Lubricate suspension arm. Refer to PERIODIC
MAINTENANCE PROCEDURES subsection.
3. Tighten ball joint nut to specification. Refer to
exploded views.
4. Perform steering alignment procedure. Refer
to steering alignment subsection.
Upper Suspension Arm
Removing the Upper Suspension Arm
1. Safely lift and support the vehicle off the
ground.
2. Remove wheel, refer to WHEELS AND TIRES
subsection.
3. Remove fasteners retaining brake hose to TYPICAL
vehicle.
6. Carefully move brake hose aside.
7. Using a plastic hammer, carefully hit on the
knuckle side to separate ball joint from
knuckle.
304
CHASSIS
Front Suspension
N O T E : A ball joint remover can be used if the

ball joint is jammed into knuckle.
NOTICE
Never hit on suspension arm to avoid damag-
ing it permanently.
TYPICAL
10. Remove screws and nuts securing suspension

arm to frame.
TYPICAL - CAREFULLY HIT ON KNUCKLE SIDE
8. Remove stabilizer bar link nut on both sides

than move back the stabilizer bar from upper
suspension arms.
TYPICAL
09
11. Remove suspension arm.
Installing the Upper Suspension Arm
following.
9. Remove screw and nut securing suspension 2. Lubricate suspension arm. Refer to PERIODIC
arm to shock absorber. MAINTENANCE PROCEDURES subsection.
3. Install a N E W cotter pin to secure ball joint nut.
Both end of cotter pin must be folded.
4. Tighten shock absorber nut to specification.
Refer to exploded views.
5. Tighten ball joint nut to specification. Refer to
exploded views.
6. Perform steering alignment procedure. Refer
to steering alignment subsection.
Suspension Arm Bushings
Removing the Suspension Arm Bushings
1. Remove wear plates, bushings and sleeves
from suspension arm.
305
CHASSIS
Front Suspension
TYPICAL - LOWER SUSPENSION ARM

1. Wear plates
2. Bushings
3. Sleeves LOWER BALL JOINT
UPPER BALL JOINT
3. Install suspension arm on a press.

TYPICAL - UPPER SUSPENSION ARM
1. Wear plates
2. Bushings NOTICE
3. Sleeves Pressing on the center or on the lip of the ball
joint will damage it.
Installing Suspension Arm Bushings
Lubricate suspension arm. Refer to PERIODIC
MAINTENANCE PROCEDURES subsection.
Ball Joints
Removing the Ball Joint
1. Remove suspension arm from vehicle. Refer to
Removing Suspension Arm in this subsection.
2. Remove circlip from ball joint.
DO NOT PRESS THERE
N O T E : The ball joint removal tool is design to

apply force only on the outside edge of the ball
joint.
306
CHASSIS
Front Suspension
09
CONTACT BETWEEN TOOL AND BALL JOINT ON THE OUT-

SIDE EDGE ONLY
4. Remove ball joint from suspension arm.

NOTICE
Make sure that suspension arm is properly
supported on the press during ball joint
removal.
Installing Ball Joint

Install a N E W circlip to secure ball joint.
307
CHASSIS
Rear Suspension
Rear Suspension
SERVICE TOOLS
SPRING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . (P/N 529036184) . . . . . . . . . . . . . . . . . . . . . . . 313

STEERING ALIGNMENT TOOL . . . . . . . . . . . . . . . . . . . . . . (P/N 529036059) . . . . . . . . . . . . . . . . . . . . . . . 270
SERVICE PRODUCTS

LOCTITE 271 (RED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
LOCTITE 406 (GLUE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
308
CHASSIS
Rear Suspension
NEW
53 ± 3 N•m
(39 ± 2 lbf•ft)
09
NEW
309
CHASSIS
Rear Suspension
All models except 6x6
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
Suspension
53 ± 3 N•m Grease
(39 ± 2 lbf•ft)
NEW 3.0 ± 0.5 N•m
(27 ± 4 lbf•ft)
Suspension
Grease
61 ± 9 N•m
(45 ± 7 lbf•ft)
3.0 ± 0.5 N•m

(27 ± 4 lbf•ft)
Suspension NEW
Grease
Suspension
Grease
Loctite 271
3.0 ± 0.5 N•m
(27 ± 4 lbf•ft)
NEW
NEW
255 ± 10 N•m
(188 ± 7 lbf•ft)
310
CHASSIS
Rear Suspension
6x6 models
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
NEW
Suspension
grease
Suspension 90º from
grease arm axis
NEW
24.5 ± 3.5 N•m
Suspension (18 ± 3 lbf•ft)
grease
NEW
Suspension
grease
NEW
NEW
Suspension
grease
NEW
255 ± 10 N•m
(188 ± 7 lbf•ft)
NEW 4.5 ± 0.5 N•m

(188 ± 7 lbf•ft)
Suspension
NEW
255 ± 10 N•m
09
grease
(188 ± 7 lbf•ft)
4.5 ± 0.5 N•m

(188 ± 7 lbf•ft)
311
CHASSIS
Rear Suspension
General 4. Check the following conditions that will denote

The procedure described below is the same for a defective shock:
the RH and LH sides, unless otherwise instructed. – A skip or a hang back when reversing
stroke at mid travel
Procedures – Seizing or binding condition except at ex-
Shock Absorbers treme end of either stroke
– Oil leakage
Removing the Shock Absorber – A gurgling noise, after completing one full
1. Safely lift and support the vehicle off the compression and extension stroke.
ground. 5. Replace if any faults are present.
2. Remove screws and nuts retaining shock
absorber. Installing the Shock Absorber
Tightening Torque
61 ± 9 Nm
Shock absorber nuts (45 ± 7 lbf-ft)
Shock Absorber Bushings

Replacing the Shock Absorber Bushing
1. Remove shock absorber from vehicle. Refer to
shock absorbers in this subsection.
2. Install shock absorber on a press.
3. Use an appropriate socket to push bushing.
TYPICAL
3. Remove shock absorber.

Inspecting the Shock Absorber
1. Remove spring from shock absorber. Refer to
springs in this subsection.
2. Secure the end of shock body in a vise with its
rod upward.
TYPICAL
4. Remove bushing from shock absorber.
TYPICAL
NOTICE
Do not clamp directly on shock body.
3. Extend and compress the piston several times

over its entire stroke. Check that it moves
smoothly and with uniform resistance with its
rod upward.
312
CHASSIS
Rear Suspension
Stabilizer Bar
Removing the Stabilizer Bar
1. Safely lift and support the vehicle off the
ground.
2. Remove rear wheels. Refer to WHEELS AND
TIRES subsection.
3. Detach stabilizer bar from link arm (both
sides).
4. Remove bolts and nuts securing stabilizer bar
to frame (both sides).
TYPICAL
5. Install a NEW bushing as the reverse of

removal.
6. Install shock absorber on vehicle.
Springs
Removing the Spring
1. Install the spring compressor in a vice.
Spring compressor
(P/N 529036184)
TYPICAL
2. Position the shock absorber in the tool. 5. Remove rear propeller shaft screw from the
3. Install the spring compressor pins. middle drive yoke. Refer to propeller shaft
4. Tighten spring remover screw until the spring subsection.
is sufficiently compressed to remove spring 6. Remove rear final drive. Refer to REAR FINAL
cap. DRIVE subsection
5. Remove spring cap from shock absorber. 7. Remove stabilizer bar.
6. Release spring remover screw.
7. Remove spring from shock absorber. Inspecting the Stabilizer Bar 09
Check stabilizer bar for cracks, bending or other
Inspecting the Spring
damages.
Inspect the spring for damage.
Installing the Stabilizer Bar
Installing the Spring
The installation is the reverse of the removal pro- procedure. However, pay attention to the
cedure. However, pay attention to the following. following.
On applicable models, install spring cap opening 2. Install all retaining screws of stabilizer bar
at 180° from spring stopper opening. loosely first.
3. Position link arm screws with their heads to-
wards inside.
TYPICAL - CAP OPENING AT 180°
313
CHASSIS
Rear Suspension
4. Remove nut and washer securing trailing arm

pivot shaft.
4. Tighten stabilizer bar retaining screws to

specification.
Tightening Torque 5. Detach trailing arm from link arm and remove
lower nut retaining shock absorber.
Screws securing 24.5 ± 3.5 Nm
stabilizer bar to frame (18 ± 3 lbf-ft)
Screws securing 61 ± 9 Nm
stabilizer bar to link (45 ± 7 lbf-ft)
arm
5. Lubricate stabilizer bar. Refer to Periodic Main-

Trailing Arm
Removing the Trailing Arm
1. Safely lift and support the vehicle off the TYPICAL
ground.
2. Remove wheel hub. Refer to REAR DRIVE 6. Firmly hold trailing arm then remove:
subsection.
– Shock absorber lower screw
3. Remove protective plate from trailing arm.
– Trailing arm pivot shaft (pull from opposite
side).
N O T E : If only one trailing arm is removed, pull

pivot shaft just enough to clear trailing arm.
N O T E : If applicable, remove fasteners retaining TYPICAL

brake hose to vehicle.
7. Remove trailing arm from vehicle.
314
CHASSIS
Rear Suspension
Disassembling the Trailing Arm 2. Remove bearing with an appropriate bearing

Removing the Drive Shaft Bearing remover.
1. Remove circlip securing bearing into trailing
N O T E : Remove one bearing at a time.
arm.
3. Remove inner spacer from trailing arm.
1. Pivot bearings
2. Inner spacer
2. Install trailing arm on a press.
3. Use an appropriate bearing remover. Inspecting the Trailing Arm
4. Remove drive shaft bearing from trailing arm. 1. Check trailing arms for:
Removing the Link Arm Inner Sleeve and – Cracks
Bushing
– Bending.
1. Remove both bushings and sleeve from trailing
2. Check seals condition.
arm.
3. Check inner race of each pivot bearing with
your finger. Bearings should turn smoothly and
quietly.
4. Replace all damaged parts.
Assembling and Installing the Trailing Arm
1. The installation is the reverse of the removal 09
following.
2. Install the following N E W parts:
– Trailing arm pivot nuts
1. Bushings – Pivot bearings
2. Sleeve – Pivot seals
Removing the Trailing Arm Pivot Bearing – Circlip.
1. Remove both spacers and seals from trailing 3. Use an appropriate shaft to center trailing arm
arm pivot. inner spacer during pivot bearings installation.
4. Install pivot bearings and inner spacer as per
the following sequence.
1. Spacer
2. Seal
315
CHASSIS
Rear Suspension
TYPICAL
TYPICAL - LH TRAILING ARM
Step 1. Insert bearings on RH side 12. Tighten trailing arm fasteners to specification.
Step 2. Center inner spacer with RH side bearing using a shaft
Step 3. Insert bearings on LH side Tightening Torque
5. Lubricate trailing arm pivot seals. 61 ± 9 Nm
Bolts securing trailing
arm to link arm (45 ± 7 lbf-ft)
XPS Synthetic suspension grease
53 ± 3 Nm
6. Install trailing arm pivot seal with its cavity fac- Shock absorber nuts (39 ± 2 lbf-ft)
ing inwards.
Protective plate 4.5 ± 0.5 Nm
retaining nuts (40 ± 4 lbf-in)
1. Seal cavity
2. Trailing arm
7. Center trailing arm pivot shaft.

8. Apply threadlocker on threads of the RH trail-
ing arm nut.
Loctite 271 (red)
9. Tighten the RH trailing arm nut until it reaches

end of threads.
10. Tighten the LH trailing arm nut.
Tightening Torque
255 ± 10 Nm
LH trailing arm nut
(188 ± 7 lbf-ft)
11. Position link arm bolts with their heads towards

inside.
316
CHASSIS
Brakes
Brakes
SERVICE PRODUCTS

LOCTITE 271 (RED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
LOCTITE 406 (GLUE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
09
317
CHASSIS
Brakes
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
NEW
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
To rear circuit
5.5 ± 1.5 N•m NEW

(49 ± 13 lbf• in )
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
NEW
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)

FRONT CIRCUIT
318
CHASSIS
Brakes
NEW
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
0.7 ± 0.1 N•m

(6 ± 1 lbf• in )
28.5 ± 1.5 N•m
(21 ± 1 lbf•ft)
NEW
NEW
28.5 ± 1.5 N•m
(21 ± 1 lbf•ft)
To front circuit
NEW
09
27.5 ± 2.5 N•m

(20 ± 2 lbf•ft)
See tightening sequence

REAR CIRCUIT
319
CHASSIS
Brakes
FRONT REAR
Brake caliper 8.5 ± 1.5 N•m
synthetic grease (75 ± 13 lbf• in )
Brake caliper
synthetic
grease
8.5 ± 1.5 N•m
(75 ± 13 lbf• in )
LH SIDE
1.3 ± 0.1 N•m
(12 ± 1 lbf• in )
Cover +
gasket
8.5 ± 1.5 N•m

(75 ± 13 lbf• in )
XPS synthetic
grease
CALI PERS AND BRAKE LEVERS
320
CHASSIS
Brakes
General 3. Push brake lever at distance A from handlebar

grip using force gauge.
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 re-
placed with new ones every time a Banjo bolt
is unscrewed. A. Distance from handlebar (refer to table)
4. Read load recorded by the force gauge.

NOTICE 5. Load reading must be as per the following
Always clean the area around a brake com- table.
ponent before servicing. Brake Lever Verification
System Description Distance
Minimum Load
A disc brake system with twin-piston sliding cali- A
pers is used. 25 mm (1 in) 150 N (34 lbf)
Disc Brake Configurations
6. If load reading is not in accordance with the
Number of Disc Brakes specification:
1. Perform a brake system inspection and
FRONT REAR cleaning.
2 1 2. Bleed brake system. Refer to Periodic
maintenance Procedures subsection.
09
Brake Controls and Circuit Configurations Brake Pedal Verification
LH Brake Lever Brake Pedal N O T E : Do not pump up the brakes repeatedly
before doing the validation.
Controls front and rear
Controls rear brake
brakes 1. Position force gauge perpendicularly on brake
pedal edge.
Inspection 2. Position a ruler perpendicularly to brake pedal.
Brake System Pressure Validation 3. Push brake pedal from distance A using force
gauge.
Required Tools
Use an appropriate compression force gauge and
a ruler.
Brake Lever Verification
N O T E : Do not pump up the brakes repeatedly
1. Position force gauge perpendicularly on brake

lever edge.
2. Position a ruler perpendicularly to handlebar
grip.
321
CHASSIS
Brakes
Testing the Brake Light Switch Resistance

1. Disconnect brake light switch connector.
2. Check switch operation as follows.
Brake Light
Pin Resistance
Switch Position
Firmly pushed Close to 0 Ω
1 2
Released Infinite (OL)
If switch is defective, replace with a new one.

A. Distance to push (refer to table) If the switch tests good, verify wire continuity
4. Read load recorded by the force gauge. between harness connector and ECM connec-
5. Load reading must be as per the following tor. Refer to the appropriate wiring diagram.
table. Replacing the Brake Light Switch
Brake Pedal Verification Brake Light Switch Located on Master
Cylinder
Distance 1. Disconnect brake light switch connector.
Minimum Load
A 2. Drain brake line.
35 mm (1-3/8 in) 180 N (40 lbf) 3. Remove brake light switch.
N O T E : Use shop rags to catch any spilled brake

6. If load reading is not in accordance with the fluid.
specification:
1. Perform a brake system inspection and 4. Install N E W sealing washers.
cleaning. 5. Install brake light switch.
2. Bleed brake system.
Tightening Torque
N O T E : Refer to Periodic maintenance Proce-
dures subsection. 28.5 ± 1.5 Nm
Brake light switch
(21 ± 1 lbf-ft)
Procedures
Brake Light Switch 6. Connect brake light switch connector.
7. Refill and bleed brake system, refer to Periodic
Brake Light Switch Location Maintenance Procedures subsection.
The brake switch is located on the brake pedal
master cylinder. Brake Pedal
Removing the Brake Pedal
1. Drain brake system, refer to Periodic Mainte-
2. Remove RH footrest panel. Refer to BODY
subsection.
N O T E : Loosen brake pedal bolt before removing

support from frame.
3. Remove master cylinder support from frame.
1. Brake light switch

2. Brake light switch connector
322
CHASSIS
Brakes
4. Tighten brake pedal nut as per the following

sequence.
Tightening Sequence
STEP Brake pedal 10 ± 2 Nm

1 bolt (pivot) (89 ± 18 lbf-in)
STEP Brake pedal 27.5 ± 2.5 Nm

2 nut (20 ± 2 lbf-ft)
1. Master cylinder support
4. Remove brake pedal spring.
TIGHTENING SEQUENCE
Step 1. Tighten bolt
Step 2. Hold bolt then tighten nut
Master Cylinder
1. Brake pedal spring
5. Remove brake pedal.

Removing the Master Cylinder
1. Remove brake pedal. See procedure in this
09
subsection.
2. Remove master cylinder from support.
1. Brake pedal pivot bolt
Installing the Brake Pedal

1. Master cylinder
following. 3. Remove hoses and bleeder from master
2. Install N E W brake pedal O-ring. cylinder.
3. Lubricate brake pedal pivot.
323
CHASSIS
Brakes
Inspecting the Master Cylinder

1. Check boot for crack.
2. Check rod for wear and scratch.
3. Check master cylinder housing for leak or
damage.
Installing the Master Cylinder
following.
2. Tighten brake hoses and bleeder to
specification.
Tightening Torque
TYPICAL
1. Caliper screws
Brake hose screw 28.5 ± 1.5 Nm
(banjo fitting) (21 ± 1 lbf-ft) 6. Place caliper assembly onto a support.
8.5 ± 1.5 Nm NOTICE
Bleeder (75 ± 13 lbf-in)
Do not let caliper hangs by the hose and do
not stretch or twist hose.
3. Install N E W sealing washers.
4. Refill and bleed brake system, refer to Periodic Installing the Caliper
Maintenance Procedures subsection. 1. The installation is the reverse of the removal
Caliper procedure. However, pay attention to the
following.
Removing the Caliper 2. If caliper was removed for replacement:
1. Safely lift and support the vehicle.
2. Remove wheel, refer to WHEELS AND TIRES – Refill and bleed brake system, refer to Peri-
subsection. odic Maintenance Procedures subsection.
3. If caliper is removed from vehicle for – Install N E W sealing washers.
replacement: 3. Install N E W caliper retaining screws.
1. Drain brake system, refer to Periodic Main- 4. Tighten caliper retaining screws to
tenance Procedures subsection. specification.
2. Unscrew brake hose from caliper.
Tightening Torque
Caliper retaining 61 ± 9 Nm
Brake Pads
Replacing the Brake Pads
1. Remove caliper, refer to Removing the Caliper
in this subsection.
2. Remove pin retainer securing brake pad pin.
TYPICAL
i. Brake hose
ii. Sealing washers
4. Remove fasteners retaining brake hose.

5. Remove screws securing caliper support.
324
CHASSIS
Brakes
1. Pin retainer
BRAKE PAD SPRING
3. Remove brake pad pin from caliper. 8. Ensure pad stopper is properly aligned with
caliper support protrusion.
TYPICAL 09
1. Brake pad pin
1. Pad stopper
4. Carefully remove brake pads. 2. Caliper support protrusion
5. Clean pistons end using the following product
or and equivalent. NOTICE
Prior to installing brake pads, pad stopper
XPS Brakes and Parts cleaner must be properly positioned and not
damaged.
6. Push caliper pistons inward.
9. Install N E W brake pads.
N O T E : To avoid damaging pistons, use an old 10. Clean and install brake pad pin on caliper.
pad to push it into the caliper using a C-clamp. 11. Install pin retainer to secure brake pad pin.
7. Ensure brake pad spring is properly positioned 12. Slide caliper support completely into caliper.
onto caliper and not damaged.
325
CHASSIS
Brakes
1. Caliper support 1. Brake disc screw
13. Install caliper, refer to Installing the Caliper. 4. Replace brake disc.
5. Install N E W brake disc screws.
Brake Disc 6. Tighten brake disc screws to specification.
Inspecting the Brake Disc
Tightening Torque
1. Check disc surfaces for scratches or grooves
on both sides. 33.5 ± 3.5 Nm
2. Measure thickness of the disc. Brake disc screws (25 ± 3 lbf-ft)
Disc Minimum Thickness
7. Install wheel hub then caliper.
Front 4.0 mm (.157 in) 8. Install N E W cotter pin to secure wheel hub
nut.
Rear 4.0 mm (.157 in)
NOTICE
Brake discs must never be machined.
3. Check warpage of the disc.
Maximum Disc Warpage

Front
0.2 mm (.01 in)
Rear
Replacing the Brake Disc

in this subsection.
2. Remove wheel hub, refer to Front Drive or
Rear Drive subsection.
3. Remove screws securing brake disc to wheel
hub.
326
CHASSIS
Brakes (ABS)
Brakes (ABS)
SERVICE PRODUCTS

LOCTITE 271 (RED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
LOCTITE 406 (GLUE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
NEW
28.5 ± 1.5 N•m
(21 ± 1 lbf•ft)
NEW
16 ± 2 N•m
( 142 ± 18 lbf•in)
NEW
NEW
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft) 09
61 ± 9 N•m
(45 ± 7 lbf•ft)
NEW
28.5 ± 1.5 N•m
(21 ± 1 lbf•ft) NEW
FRONT BRAKES
327
CHASSIS
Brakes (ABS)
28.5 ± 1.5 N•m

(21 ± 1 lbf•ft)
NEW
NEW 61 ± 9 N•m
(45± 7 lbf•ft)
Brake fluid
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)
28.5 ± 1.5 N•m
(21 ± 1 lbf•ft)
16 ± 2 N•m NEW
(142 ± 18 lbf•in) 27.5 ± 2.5 N•m NEW
33.5 ± 3.5 N•m
(20 ± 2 lbf•ft) (25 ± 3 lbf•ft)
9 ± 1 N•m
(80 ± 9 lbf•in)
16 ± 2 N•m NEW
(142 ± 18 lbf•in)
Synthetic grease

REAR BRAKES
328
CHASSIS
Brakes (ABS)
FRONT REAR
Brake caliper 8.5 ± 1.5 N•m
synthetic grease (75 ± 13 lbf• in )
Brake caliper
synthetic
grease
8.5 ± 1.5 N•m
(75 ± 13 lbf• in )
LH SIDE
1.3 ± 0.1 N•m
(12 ± 1 lbf• in )
Cover +
gasket
8.5 ± 1.5 N•m

(75 ± 13 lbf• in )
XPS synthetic
grease
09
CALIPERS AND BRAKE LEVERS
329
CHASSIS
Brakes (ABS)
General Fault Codes

WARNING For any replacement of parts that involves brake
bleeding, it is important to reset the fault codes us-
Always check brake system operation after ing the BRP diagnostic software (BUDS2). Refer
removing or servicing a brake component. to DIAGNOSTIC and fault codes subsection.
System Components Description
NOTICE
Avoid spilling brake fluid on plastic, rubber or ABS Module
painted parts. Protect these parts with a rag The ABS module is the heart of the vehicle anti-
when servicing brake system. lock braking system (ABS). It contains 2 micro-
processors, 2 hydraulic pumps, several solenoids
and passageways to the 3 brake calipers.
NOTICE
Sealing washers must be discarded and re-
placed with new ones every time a Banjo bolt
is unscrewed.
NOTICE
Always clean the area around a brake com-
ponent before servicing.
System Description
A disc brake system with twin-piston sliding cali-
pers is used.
The ABS module receives inputs from wheel sen-
Anti-Lock Braking System (ABS) sors (WSS) and performs calculations to cycle the
The ABS prevents the wheels to lock while brak- pump and solenoids to apply or relieve hydraulic
ing. The vehicle configuration allows a single pressure to or from the vehicle brake calipers.
brake point at the right foot or the left lever, to pro-
vide the optimal amount of hydraulic brake pres- Wheel Speed Sensor (WSS)
sure on all brake discs, under a multitude of
braking conditions. The result is maximizing ve-
hicle control while allowing the wheels to remain
available to generate steering control force in re-
sponse to the rider’s input.
Disc Brake Configurations
Number Of Disc Brakes

Front 2
Rear 1
Brake Controls and Circuit Configurations FRONT WHEEL SPEED SENSOR
Brake Controls
Controls front and rear
LH brake lever
brakes
Brake pedal Controls front and rear

brakes
330
CHASSIS
Brakes (ABS)
REAR WHEEL SPEED SENSOR BRAKE PRESSURE SENSOR
There are 3 speed sensors on the vehicle, two on

the front and one on the rear. The speed sensors Brake Light Switch (BLS)
are hall effect type sensors that send a digital sig- The brake light switches (BLS) are located close
nal to the ABS module. to the master cylinder. They are activated by the
brake pedal or the brake lever.
As the wheel rotates, the teeth on the encoder
wheel pass in front of the sensor. The output fre-
quency of the sensor is proportional to the wheel
rotation speed.
09
BRAKE LIGHT SWITCH
TYPICAL - PARTS REMOVED FOR CL ARITY

1. Extrusions on encoder wheel
2. Wheel speed sensor
The signal from the wheel speed sensors are the

main inputs looked at by the ABS module for the
activation of ABS and other functions.
Brake Pressure Sensor (BPS)
The brake pressure sensor reads the pressure ap-
plied on the brake pedal by the user. It sends the
value directly to the ABS module. This input is BRAKE LEVER MASTER CYLINDER
used for precise control. 1. Brake light switch
The BLS turns on the brake lights and supplies the

ECM a signal that the operator is applying the
brakes. Brake light switches are hard wired to the
ABS module. When the ABS module detect either
one of the BLS, it sends a signal to the brake light
relay to light up the brake light.
331
CHASSIS
Brakes (ABS)
Maintenance 2. Position a ruler perpendicularly to handlebar

Bleeding the Brake fluid grip.
3. Push brake lever at distance A from handlebar
WARNING grip using force gauge.
Failure to correctly bleed the braking system
may reduce its performance and lead to a
loss of control.
Anytime the brake system is opened, the bleeding

procedure must be performed.
1. Ensure brake fluid is present in the entire sys-
tem by topping off the front and rear master
cylinders and:
–
Open the bleeder of the rear caliper until
fluid drips out and close it. A. Distance from handlebar (refer to table)
– Open the bleeder of the front RH caliper un- 4. Read load recorded by the force gauge.
til fluid drips out and close it. 5. Load reading must be as per the following
– Open the bleeder of the front LH caliper un- table.
til fluid drips out and close it.
2. Connect the vehicle to the BRP diagnostic soft- Brake Lever
ware (BUDS2) and go to: Distance Minimum
Lever
– S e t t i n g s page A Load
– A B S button 25 mm (1 in) 150 N (34 lbf)
LH side lever
– S e t t i n g s tab
– Initializations - Execute bleeding
3. Follow the on-screen instructions. specification:
4. Ensure brake fluid is present in the entire sys- 1. Perform a brake system inspection and
tem by topping off the front and rear master cleaning.
cylinders and: 2. Bleed brake system, refer to Bleeding the
– Open the bleeder of the rear caliper until Brake fluid in this subsection.
fluid drips out and close it. Verifying the Brake Pedal Compression Force
– Open the bleeder of the front RH caliper un-
til fluid drips out and close it. I M P O R T A N T : : Do not pump up the brakes re-
– Open the bleeder of the front LH caliper un- peatedly before doing the validation.
til fluid drips out and close it. 1. Position force gauge perpendicularly on brake
pedal edge.
Inspection 2. Position a ruler perpendicularly to brake pedal.
Verifying the Compression Force 3. Push brake pedal from distance A using force
gauge.
Required Tool
Compression force
gauge
Verifying the Brake Lever Compression Force

I M P O R T A N T : : Do not pump up the brakes re-
peatedly before doing the validation.
1. Position force gauge perpendicularly on brake
lever edge.
332
CHASSIS
Brakes (ABS)
In BUDS2, the ABS module will not show up in the

left menu if the ABS module does not communi-
cate through CAN bus.
Carry out the tests in this subsection according to
the fault codes informations. Refer to Diagnostic
and fault codes subsection.
Procedures
Brake Light Switches
Brake Light Switch Location
A. Distance to push (refer to table)
4. Read load recorded by the force gauge.

5. Load reading must be as per the following
table.
Brake Pedal
Distance
Minimum Load
A
35 mm (1-3/8 in) 180 N (40 lbf)

specification: BRAKE PEDAL - -MASTER CYL INDER
1. Perform a brake system inspection and 1. Brake light switch
cleaning.
2. Bleed brake system, refer to Bleeding the
Brake fluid in this subsection.
Troubleshooting
Refer to Power distribution and grounds for fuses 09
and relays information.
Always refer to the wiring diagram when trouble-
shooting an electrical circuit.
Install a battery charger on battery terminals
(under seat) for any tests that involve a prolonged
"key ON" period. If battery voltage gets too low,
the ABS module shuts off, some accessories are
shut off by the ECM and test results can be BRAKE LEVER - -MASTER CYL INDER
altered. 1. Brake light switch
NOTICE
Never force a multimeter probe into an elec- Testing the Brake Light Switch
trical terminal. 1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2) and go to:
Troubleshooting Tips
– F u n c t i o n s page
Start troubleshooting by checking fault codes us- – A B S button
ing the BRP diagnostic software (BUDS2). Make – F u n c t i o n s tab
sure fuses are good; follow the service actions in
the fault codes section. Refer to Diagnostic and Do the R o u t i n e s - B r a k e L i g h t R e l a y T e s t to
fault codes. ensure the proper working of the system. If the
brake lights don't light-up, continue testing.
333
CHASSIS
Brakes (ABS)
3. Check switch operation as follows. Tightening Torque

Brake Light 28.5 ± 1.5 Nm
Pin Resistance Brake light switch
Switch Position (21 ± 1 lbf-ft)
Firmly pushed Close to 0 Ω
1 2 5. Connect brake light switch connector.
Released Infinite (OL) 6. Refill and bleed brake system, refer to Bleed-
ing the Brake fluid in this subsection.
If switch is defective, replace with a new one.
Brake Pedal
If the switch tests good, verify wire continuity
Removing the Brake Pedal
between harness connector and ECM connec-
tor. Refer to the appropriate wiring diagram. 1. Drain brake system, refer to Periodic Mainte-
Replacing the Brake Light Switch 2. Remove RH footrest panel. Refer to BODY
Brake Light Switch Located on Brake Lever subsection.
2. Drain master cylinder. N O T E : Loosen brake pedal bolt before removing
support from frame.
fluid. 3. Remove master cylinder support from frame.
3. Replace brake light switch by a new one using

N E W sealing washers.
4. Connect brake light switch connector.
5. Refill and bleed brake system, refer to Bleed-
Brake Light Switch Located on Master
Cylinder
2. Drain brake line.
3. Remove brake light switch.
fluid. TYPICAL
1. Master cylinder support
4. Install the brake light switch using N E W seal-
ing washers. 4. Remove brake pedal spring.
1. New sealing washer

2. Brake line banjo fitting 1. Brake pedal spring
3. Pressure sensor banjo fitting
4. Brake light switch 5. Remove brake pedal.
334
CHASSIS
Brakes (ABS)
2. Remove master cylinder from support.
1. Brake pedal pivot bolt
Installing the Brake Pedal

1. Master cylinder
procedure. However, pay attention to the 3. Remove hoses and bleeder from master
following. cylinder.
2. Install N E W brake pedal O-ring. 4. Discard sealing washers.
3. Lubricate brake pedal pivot.
Inspecting the Master Cylinder
XPS Synthetic grease 1. Check boot for crack.
2. Check rod for wear and scratch.
4. Tighten brake pedal nut as per the following 3. Check master cylinder housing for leak or
sequence. damage.
Tightening Sequence Installing the Master Cylinder

STEP Brake pedal bolt 10 ± 2 Nm procedure. However, pay attention to the
1 (pivot) (89 ± 18 lbf-in) following.
STEP 27.5 ± 2.5 Nm
2. Install N E W sealing washers. 09
Brake pedal nut 3. Tighten brake hoses and bleeder to
2 (20 ± 2 lbf-ft) specification.
Tightening Torque
Brake hose screw 28.5 ± 1.5 Nm
(banjo fitting) (21 ± 1 lbf-ft)
8.5 ± 1.5 Nm
Bleeder (75 ± 13 lbf-in)

Caliper
Removing the Caliper
TIGHTENING SEQUENCE 1. Safely lift and support the vehicle.
Step 1. Tighten bolt
Step 2. Hold bolt then tighten nut 2. Remove wheel, refer to WHEELS AND TIRES
subsection.
Master Cylinder 3. If caliper is removed from vehicle for
Removing the Master Cylinder replacement:
1. Drain brake system, refer to Periodic Main-
1. Remove brake pedal. See procedure in this
subsection.
335
CHASSIS
Brakes (ABS)
2. Unscrew brake hose from caliper and dis- 4. Tighten caliper retaining screws to
card sealing washers. specification.
Tightening Torque
Caliper retaining 61 ± 9 Nm
Brake Pads
Replacing the Brake Pads
in this subsection.
2. Remove pin retainer securing brake pad pin.
TYPICAL
i. Brake hose
ii. Sealing washers (discard)
4. Remove fasteners retaining brake hose.

5. Remove and discard screws securing caliper
support.
1. Pin retainer
3. Remove brake pad pin from caliper.
TYPICAL
1. Caliper screws (discard)
6. Place caliper assembly onto a support.
NOTICE
Do not let caliper hangs by the hose and do
not stretch or twist hose.
Installing the Caliper

1. The installation is the reverse of the removal TYPICAL
procedure. However, pay attention to the 1. Brake pad pin
following.
2. If caliper was removed for replacement: 4. Carefully remove brake pads.
5. Clean pistons end using the following product
–Install N E W sealing washers. or and equivalent.
–Refill and bleed brake system, refer to
Bleeding the Brake fluid in this section. XPS Brakes and Parts cleaner
3. Install N E W caliper retaining screws.
336
CHASSIS
Brakes (ABS)
6. Using an old pad and a C-clamp, push the cali-

per piston into the caliper.
7. Ensure brake pad spring is properly positioned
onto caliper and not damaged.
1. Caliper support
13. Install caliper, refer to Installing the Caliper in

this subsection.
Brake Disc
Inspecting the Brake Disc
BRAKE PAD SPRING 1. Check disc surfaces for scratches or grooves
on both sides.
8. Ensure pad stopper is properly aligned with
2. Measure thickness of the disc.
caliper support protrusion.
Disc Minimum Thickness
Front
4.0 mm (.157 in)
Rear
NOTICE
Brake discs must never be machined.
3. Check warpage of the disc.

09
Maximum Disc Warpage
Front
0.2 mm (.01 in)
1. Pad stopper Rear
2. Caliper support protrusion
Replacing the Brake Disc
NOTICE 1. Remove caliper, refer to Removing the Caliper
Prior to installing brake pads, pad stopper in this subsection.
must be properly positioned and not 2. Remove wheel hub, refer to Front Drive or
damaged. Rear Drive subsection.
3. Remove screws securing brake disc to wheel
9. Install N E W brake pads. hub.
10. Clean and install brake pad pin on caliper.
11. Install pin retainer to secure brake pad pin.
12. Slide caliper support completely into caliper.
337
CHASSIS
Brakes (ABS)
1. Brake disc screw

REAR WHEEL SPEED SENSOR
1. Speed sensor
4. Replace brake disc.
5. Install N E W brake disc screws. Make sure that wheel sensors:
Tightening Torque – Are securely fastened and undamaged.
– Are clean and free from debris.
33.5 ± 3.5 Nm – Support for the front speed sensors are se-
Brake disc screws (25 ± 3 lbf-ft) curely fastened and undamaged.
Testing the WSS with BUDS2
6. Install wheel hub then caliper.
7. Install N E W cotter pin to secure wheel hub
ware (BUDS2).
nut.
2. Go to:
Wheel Speed Sensor (WSS)
– M e a s u r e m e n t s page
– A B S button
3. Lift each wheel one at a time and manually ro-
tate wheel.
4. Look in BUDS2 to see if the corresponding
sensor needle moves.
Otherwise, perform the electrical tests.
If one of the sensor gauges does not respond
to wheel rotation, refer to Testing the WSS Wir-
ing Continuity .
Testing the WSS Wiring Continuity
FRONT WHEEL SPEED SENSOR 1. Disconnect the wheel speed sensor connector
1. Speed sensor to be tested.
2. Speed sensor support 2. Disconnect ABS module connector, refer to
ABS module connector Access in this
subsection.
4. Measure wiring resistance as follows.
NOTICE
To avoid damaging the connector, probe only
the terminal tip.
338
CHASSIS
Brakes (ABS)
ABS
Sen Sensor Module
Measurement
sor Terminal Connec
tor Pin
Front 1 19
LH 2 8
Front 1 16 Close to 0 Ω
RH 2 4 (continuity)
1 17
Rear
2 29 REAR DIFFERENTIAL
1. WSS
If continuity test failed, repair wiring or 2. WSS retaining screw
connectors. ABS Module
If continuity test succeeded, try a new sensor.
If problem persists, try a new ABS module.
Replacing the WSS
1. Unplug the WSS connector.
2. Remove screw securing the WSS on its sup-
port (front) or on the differential (rear).
3. Pull the WSS upwards to remove it.
TYPICAL
Tightening Torque
WSS retaining screw

4.5 ± 0.5 Nm Troubleshooting the ABS Module 09
(40 ± 4 lbf-in) A ABS module failure is not likely to occur. These
modules have proven to be very reliable. Prior to
13.5 ± 1.5 Nm replacing a suspected ABS module, take the fol-
WSS support screw
(119 ± 13 lbf-in) lowing into account.
The problem can be related to a hydraulic func-
tion, check the following:
– Brake fluid level
– Brake line leaking, bent or pinched
– Brake caliper
– Master cylinder (including piston rod position).
The problem can be related to an electric function,
check the following:
– Fault codes
– ABS module electrical connector.
– Wiring harness condition.
If pins or terminals are not clean, check ABS mod-
FRONT DIFFERENTIAL ule harness connector seal condition and ensure
1. WSS
2. WSS retaining screw connector mechanism properly locks connector
3. WSS support seal against ABS module.
4. WSS support screw
339
CHASSIS
Brakes (ABS)
Try cleaning terminals with Deoxit lubricant (P/N

293 550 034) before reconnecting the ABS mod-
ule connector to see if it “cures” the problem.
As a final test, try a new ABS module w i t h o u t dis-
connecting brake lines from the old ABS module.
Proceed as follows:
I M P O R T A N T : Disconnecting brake lines would
require the system bleeding.
1. Connect ABS module connector to a new ABS

module.
2. Turn ignition switch ON.
LH SIDE
1. Connector
N O T E : It is normal that some fault codes appear 2. ABS module
at this time.
3. Reset learned vehicle variant using BUDS2. ABS Module Power Supply Pinout
– S e t t i n g s page ABS Module

Function
– A B S button Connector Terminal
– S e t t i n g s tab
Power from ignition
4. Turn ignition switch OFF for 30 seconds. 28
switch
5. Turn ignition switch ON.
6. If problem persists, the trouble is elsewhere. Hydraulic pump power 1
7. If problem is now solved, the ABS module in
the vehicle is faulty. Install the new ABS mod- Hydraulic valves
power 25
ule in the vehicle.
WARNING Hydraulic pump

ground 13
Never ride a vehicle with a ABS module tem-
porarily installed. ECM ground 38
ABS Module Connector Access Can high 26
WARNING Can low 14
The ABS module motor and valves are al-
Brake Light Output (to
ways powered. Always disconnect the battery 3
brake relay)
prior to disconnecting ABS module
connector. 5V Output 5
Connector can be accessed from the front LH side Pressure Signal 37
behind the inner fender as illustrated.
Analog Ground 6
ABS MODULE HARNESS CONNECTOR PINOUT
340
CHASSIS
Brakes (ABS)
Testing the ABS Module Input Voltage Testing the ABS Module Ground Circuit
1. Disconnect ABS module connector. 1. Connect multimeter RED probe to a positive
2. Turn ignition switch ON. source such as the battery terminal of the start-
3. Test for input voltage as follows. er solenoid.
2. Probe pin 13, then pin 38 of the ABS module
NOTICE connector with the BLACK (COM) probe of the
To avoid damaging the connector, probe only multimeter.
the tip of the terminal.
N O T E : Refer to ABS module Power Supply Pin-
out in this subsection for pin identification.
N O T E : Refer to ABS module Power Supply Pin-
out in this subsection for pin identification. ABS Module Battery Voltage
Connector
ABS Module Battery Voltage
Connector Positive
Pin 13
source Battery
Battery
Pin 28 Ground voltage voltage
Positive
Pin 38
source
09
If voltage is not good, check wiring/connectors
from battery through ignition switch to ABS If ground circuits are not good, check wiring
module harness connector. Refer to wiring from ABS module harness connector to chas-
diagram. sis ground located on the front part of the
frame. Refer to wiring diagram.
If voltage is good, test for input voltage as
follows. If ground circuits are good, carry out the Test-
ing the ABS module CAN line resistor in this
N O T E : Ignition switch can be either ON or OFF. subsection.
ABS Module Testing the ABS Module CAN Line Continuity

Battery Voltage
Connector 1. Read wiring resistance between diagnostic link
connector and ABS module.
Pin 1 Ground Battery
Pin 25 Ground voltage N O T E : Refer to ABS module Power Supply Pin-
out in this subsection for pin identification.
If voltage is not good, check wiring/connectors
from battery to ABS module harness connec- NOTICE
tor. Refer to wiring diagram. To avoid damaging the connector, probe only
the terminal tip.
If voltage is good, carry out the Testing the
ABS module Ground circuit in this subsection.
341
CHASSIS
Brakes (ABS)
ABS Module CAN Line 4. Use XPS Heavy Duty Cleaner to thoroughly
clean the parts. Blow compressed air again
CAN* Probes Result and thoroughly dry the parts.
ABS Diagnos NOTICE
module tic link
High Disconnect brake lines from the ABS module
connector connector Close to 0 only just prior to installing the new ABS mod-
pin 26 pin 1 Ω ule. The shorter the time the brake lines are
ABS Diagnos (continui open, the lesser the possibility of brake sys-
module tic link ty) tem contamination.
Low connector connector
pin 14 pin 2 5. Disconnect ABS module connector.
6. Disconnect brake lines.
* CAN: Serial data communication 7. Remove ABS module from frame.
8. Pull assembly out of position to dislodge
2. If continuity is not good, check wiring and con- grommet.
nectors from diagnostic link connector (DLC) to
ABS module connector. Refer to applicable
wiring diagram.
3. If everything tested good and ABS module
does not work, try a new ABS module.
Removing the ABS Module
WARNING
Cleanliness is critical when working with the
ABS module and brake lines. All precautions
must be taken to prevent any foreign particle
from entering the brake system.
A. Rubber gromet
N O T E : Before replacing the ABS module, make Step 1. Disconnect ABS module connector
sure electrical and hydraulic systems are in good Step 2. Remove retaining screws
condition. Step 3. Disconnect brake lines
9. Pull grommet out of ABS module support and

1. Disconnect battery. Refer to charging system pull out ABS module towards the LH side of ve-
subsection. hicle. Discard grommet.
2. Remove wheel and inner fender panel.
Installing the ABS Module
NOTICE
Keep the protective plugs on new ABS mod-
ule until brake line installation.

cedure. However, pay attention to the following:
1. Install N E W grommet.
2. Remove protective plugs from ABS module
brake line ports.
3. Make sure to reinstall brake lines as illustrated.
3. Using compressed air, clean:

– The ABS module and brake line fittings
– The area around the ABS module.
342
CHASSIS
Brakes (ABS)
3. Look at T I F r o n t P r e s s u r e S e n s o r and T I
R e a r P r e s s u r e S e n s o r for increased pres-
sure when applying the brakes.
4. If no pressure is shown, perform Testing pres-
sure sensor Wiring Continuity.
Testing the Pressure Sensor Wiring Continuity
1. Disconnect the pressure sensor connector.
2. Disconnect ABS module connector, refer to
ABS module connector Access in this
subsection.
4. Measure wiring resistance as follows.
1. To LH front brake caliper
2. To RH front brake caliper
3. To rear brake caliper NOTICE
4. From brake pedal To avoid damaging the connector, probe only
5. From brake handle
the terminal tip.
4. Tighten ABS module mounting screws to
specification. ABS
Sensor Module
Tightening Torque Measurement
Terminal Connector
Pin
ABS module mounting 8 ± 2 Nm
screw (71 ± 18 lbf-in) PSI - 5 ABS - 5 5V
PSI - 4 ABS - 37 Signal
5. Make sure the ABS module connector is prop-
erly installed and locked. PSI - 3 ABS - 6 Ground
6. Bleed the ABS module, refer to Bleeding the
Brake Fluid. If continuity test failed, repair wiring or
connectors.
WARNING
If continuity test succeeded, try a new sensor.
Brake bleeding must be performed to remove
any air trapped in the brake system. Refer to
09
If problem persists, try a new ABS module.
Bleeding the Brake fluid.
Replacing the Pressure Sensor
After bleeding, refer to Diagnostic and Fault Co- 1. Remove brake light switch, refer to Brake Light
des and do the following: Switch Located on Master Cylinder.
2. Disconnect pressure sensor electrical
– Check and clear fault codes
connector.
– Reset ABS module variant if ABS module is
3. Remove pressure sensor with its banjo fitting.
used.
4. Put banjo fitting in a vise fitted with non-mar-
Brake System Pressure Sensor ring soft jaws.
5. Apply brake fluid on tip and threads of new
NOTICE sensor and install on banjo fitting.
Do not pump up the brake pedal repeatedly 6. Tighten sensor to specification.
Tightening Torque
ware (BUDS2). 32.5 ± 2.5 Nm
Pressure sensor (24 ± 2 lbf-ft)
2. Go to:
– M e a s u r e m e n t s page 7. Remove banjo fitting from vise.
– A B S button 8. Install N E W sealing washers.
– P r e s e t s tab. 9. Install brake light switch.
343
CHASSIS
Brakes (ABS)
1. Sealing washers
2. Brake line banjo fitting
3. Pressure sensor banjo fitting
4. Brake light switch
Tightening Torque
28.5 ± 1.5 Nm
Brake light switch
(21 ± 1 lbf-ft)
10. Connect brake light switch connector.

ing the Brake Fluid in this subsection.
12. Reset the new sensor, connect the vehicle to
the BRP diagnostic software (BUDS2) and go
to:
–S e t t i n g s page
–A B S button
–S e t t i n g s tab
–Initializations - Reset Offset External
Pressure Sensor
13. Follow the on-screen instructions.
344
CHASSIS
Body
Body
1. Gauge
support
2. Console
3. Seat
4. Rear top
panel
(under rear
rack)
5. Rear rack
BODY PARTS NOMENCLATURE 6. Rear
(SHORT MODELS)
bumper
7. Rear
storage
compart
ment
8. Rear fascia
9. Rear fender
10. Rear mud
guard
11. Footrest
12. Side panel
13. Front mud
guard
14. Front
fender
15. Inner
fender
panels
16. Front
bumper 09
17. Hood
18. Front fascia
19. Front rack
345
CHASSIS
Body
1. Gauge
support
2. Console
3. Seat
4. Passenger
seat
5. Rear top
panel
(under rear
rack)
6. Rear rack
7. Rear
BODY PARTS NOMENCLATURE
(MAX MODELS) bumper
8. Rear
storage
compart
ment
9. Rear fascia
10. Rear
Fender
11. Rear mud
guard
12. Rear side
panel
extension
13. Footrest
14. Panel
extension
15. Side panel
16. Front
fender
17. Front mud
guard
18. Inner
fender
panels
19. Front
bumper
20. Front fascia
21. Hood
22. Front rack
346
CHASSIS
Body
09
FRONT AND REAR BODY MODUL ES (SHORT MODELS)
1. Front body module

2. Rear body module
347
CHASSIS
Body
FRONT AND REAR BODY MODULES (MAX MODEL S)
1. Front body module

2. Rear body module
348
CHASSIS
Body
4 ± 0.5 N•m
(35 ± 4 lbf•in)
09
BODY PARTS (SHORT MODELS)
349
CHASSIS
Body
4 ± 0.5 N•m
(35 ± 4 lbf•in)
LH side shown, RH side identical

BODY PARTS (MAX MODEL S)
350
CHASSIS
Body
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
14 ± 0.5 N•m
(124 ± 4 lbf•in)
14 ± 0.5 N•m
(124 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
5.5 ± 0.5 N•m

09
(49 ± 4 lbf•in)
T Category
RACKS AND FRONT FASCIA
351
CHASSIS
Body
4.5 ± 0.5 N•m 4.5 ± 0.5 N•m

(40 ± 4 lbf•in) (40 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
3
4
4.5 ± 0.5 N•m
(40 ± 4 lbf•in)
1
4.5 ± 0.5 N•m
2 (40 ± 4 lbf•in)
1.6 ± 0.4 N•m

(14 ± 4 lbf•in)
RACKS AND BODY PARTS
352
CHASSIS
Body
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
16 ± 2 N•m
(142 ± 18
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
09
4.5 ± 0.5 N•m
(40 ± 4 lbf•in)
BUMPERS AND BODY PARTS
353
CHASSIS
Body
X xc CU/INTER only 2.5 ± 0.5 N•m

(22 ± 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
(22 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
16 ± 2 N•m
(142 ± 18 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
BUMPERS AND BODY PARTS – XXC MODEL S
354
CHASSIS
Body
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
Outlander MAX
09
27 ± 2 N•m
(20 ± 1 lbf•in)
14 ± 1 N•m 10 ± 2 N•m
(124 ± 9 lbf•in) (89 ± 18 lbf•in)
REAR STORAGE COMPARTMENT
355
CHASSIS
Body
24.5 ± 3.5 N•m

(18 ± 2.5 lbf•ft)
If equipped
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
If equipped
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
5 ± 1 N•m
(44 ± 9 lbf•in)
25 ± 3 N•m
(18 ± 2 lbf•ft)
If equipped
PASSENGER SEAT
356
CHASSIS
Body
Procedures
Plastic Rivet
Plastic rivets are used in the riveting of the various
body parts. Plastic rivets can be reused many
times
Decals
Removing the Decal
1. Using a heat gun warm up one end of decal for
a few seconds until decal can roll off when rub-
bing with your finger.
2. Pull decal slowly and when necessary apply
more heat to ease removal on the area that 3. Remove the side panels.
has to be peeled off.
3. If decal tears while pulling off, it has to be
heated for a few seconds longer. If decal tends
to stretch while pulling off, stop heating and
wait a few seconds to let it cool, then peel it off.
Installing the Decal
Using isopropyl alcohol, clean the surface and dry
thoroughly.
Apply liquid soap to new decal and carefully posi-
tion it. Using a sponge or a squeegee, remove the
air bubbles and surplus water working from the
center toward the edges. Allow to air dry.
NOTICE 4. Remove the screw securing the fenders to the

Do not apply isopropyl alcohol or solvent di- footrest on both sides.
rectly on decals. Use these products in a well
ventilated area. 09
Front Body Module
Removing the Front Body Module
1. Remove the center panel.
5. Remove the inner fender panels.
2. Remove the gauge support.
357
CHASSIS
Body
6. Remove the front bumper. 9. Remove the headlights assemblies.
7. Disconnect the headlights connectors and oth- 10. Remove the fascia retaining screws.
er connectors if present.
11. Remove the fascia.

8. Remove the screws securing the front head-
lights assemblies.
358
CHASSIS
Body
Tightening Torque
Footrest to fenders M6 2.5 ± 0.5 Nm

nuts (22 ± 4 lbf-in)
Screws securing front 4.5 ± 0.5 Nm

fenders to frame (40 ± 4 lbf-in)
Removing the Front Fascia

1. Remove front bumper.
12. Remove the fender mounting screw.
2. Disconnect headlights connectors.
13. Pull the front fenders forward to remove.
09
3. Remove screws securing front headlights

assemblies.
Installing the Front Body Module

1. Tighten the fasteners to specification.
Tightening Torque
Front fascia upper 2.5 ± 0.5 Nm

Torx screw K50 x 16 (22 ± 4 lbf-in)1
Front fascia mid and 2.5 ± 0.5 Nm

lower M6 nuts (22 ± 4 lbf-in)
359
CHASSIS
Body
4. Remove headlights assemblies. Tightening Torque
Front fascia upper 2.5 ± 0.5 Nm

Torx screw K50 x 16 (22 ± 4 lbf-in)1
Front fascia mid and 2.5 ± 0.5 Nm

lower M6 nuts (22 ± 4 lbf-in)
Rear Body Module

Removing the Rear Body Module
1. Remove seat.
2. Remove the following panels, see procedure in
this section.
– luggage tray ( M a x M o d e l s )
5. Remove fascia retaining screws.
– side panel.
3. On S h o r t M o d e l s , remove rear top panel re-
taining screws.
6. Remove fascia.
TYPICAL
1. Rear top panel retaining screws
4. Remove both rivets located in the crescent

near previously removed retaining screws.
5. Disconnect taillights connectors.
Installing the Front Facia

1. Tighten front fender screws to specification.
LH SIDE SHOWN
1. Taillight connector
6. Move aside taillight harness from rear body

module (on both sides).
360
CHASSIS
Body
TYPICAL - LH SIDE SHOWN

1. Rear body module upper retaining bolts
TYPICAL - LH SIDE TAILL IGHT HARNESS
10. Remove rear body module lower retaining
7. Disconnect connectors from voltage regulator bolts.
rectifier.
09
LH SIDE
1. Voltage regulator rectifier connectors
1. Rear body module lower retaining bolts
8. Remove muffler upper retaining bolt.
RH SIDE - SOME PARTS REMOVED FOR CLARITY

1. Rear body module lower retaining bolts
TYPICAL
1. Muffler upper retaining bolt 11. Remove screw securing rear fender to footrest
9. Remove rear body module upper retaining panel (on both sides).
bolts.
361
CHASSIS
Body
2. Tighten rear body module retaining bolts to

specification.
Tightening Torque
Rear body module 27 ± 2 Nm (20 ± 1 lbf-
u p p e r bolts ft)
Rear body module 24.5 ± 3.5 Nm (18 ± 3

l o w e r bolts lbf-ft)
3. Tighten rear fender screws to specification.
Tightening Torque
TYPICAL Screws securing
1. Screw securing rear fender 4.5 ± 0.5 Nm (40 ± 4
footrest panels to rear lbf-in)
12. Detach rear fender from footrest panel by re- fenders
leasing retaining tabs (on both sides).
4. Tighten rear top panel screws to specification.
Tightening Torque
4.5 ± 0.5 Nm (40 ± 4
Rear top panel screws
lbf-in)
Console
Removing the Console
1. Remove seat.
2. Lift rear portion of console upwards.
TYPICAL
1. Rear fender retaining tabs

14. Place a c l e a n rag into fuel tank filler tube.
15. With the assistance of a person, pull rear body
module rearward.
16. Install rear body module on a stable and clean
support.
17. Remove rag and reinstall fuel tank cap.
WARNING TYPICAL - LIFT REAR PORTION
Fuel vapors are flammable and explosive 3. Pull console rearwards.

under certain conditions. Unless otherwise
noted, the fuel tank cap must always be in- Installing the Console
stalled on vehicle. The installation is the reverse of the removal pro-
Installing the Rear Body Module
Align console front tabs with slots, then push con-
sole forward.
following.
362
CHASSIS
Body
SOME PARTS REMOVED FOR CLARITY

1. Console front tabs TYPICAL
1. Plastic rivet securing side panel
Gauge Support
3. Remove plastic rivet securing side panel to air
Refer to GAUGE subsection. filter housing.
Inner Fender Panels
Removing and Installing the Inner Fender
Remove the following plastic rivets from inner
fender panels.
09
TYPICAL
4. Remove plastic rivet securing side panel

( S h o r t M o d e l s ) or rear side panel extension
( M A X M o d e l s ) to rear fender.

procedure.
Side Panels
Removing the Side Panel
1. Remove console. Refer to Removing the
Console.
2. Remove plastic rivet securing side panel to in-
ner fender panel.
5. Remove luggage tray. Refer to luggage tray.
363
CHASSIS
Body
6. Lift rear portion of side panel assembly then

pull it towards outside.
N O T E : For S h o r t M o d e l s , side panel assembly

includes side panel and panel extension.
N O T E : For M A X M o d e l s , side panel assembly
includes side panel, panel extension and rear side
panel extension.
1. Tabs securing panel extension to side panel

2. Side panel extension
3. Remove panel extension.

Installing the Panel Extension
procedure.
Rear Top Panel
LIFT REAR PORTION Removing the Rear Top Panel
1. Remove seat.
Installing the Side Panel 2. Remove rear body module. Refer to Rear body
The installation is the reverse of the removal pro- module.
cedure. However, pay attention to the following. 3. Remove rear rack. Refer to Removing the rear
rack.
Align side panel front tab with slot, then push side 4. Using a screwdriver, unclip retaining tabs se-
panel forward. curing rear top panel to rear storage
compartment.
Panel Extensions
Removing the Panel Extension
1. Remove the following parts. Refer to the pro-
cedures in this subsection:
– Driver and passenger seats
– Passenger seat holder
– Console
– Side panel.
2. Release the retaining tabs securing panel ex-
tension to side panel.
PARTS REMOVED FOR CLARITY

1. Retaining tab locations
5. Slide rear top panel forward to free it from rear

storage compartment retaining tab.
364
CHASSIS
Body
TYPICAL - SL IDING REAR TOP PANEL TOWARDS FRONT

TYPICAL
1. Screw securing front fender
Installing the Rear Top Panel
The installation is the reverse of the removal pro- 3. Remove both plastic rivet securing inner fender
cedure. However pay attention to the following: panel to footrest panel.
Tightening Torque
4.5 ± 0.5 Nm
(40 ± 4 lbf-in)
Footrest Panels
Removing the Footrest Panel
Short Models
1. Remove footrest panel retaining screws.
09
4. Remove screw securing rear fender to footrest

panel.
TYPICAL - FOOTREST PANEL RETAINING SCREWS
2. Remove screw securing front fender to footrest

panel.
TYPICAL
1. Screw securing rear fender
365
CHASSIS
Body
5. Remove screw securing footrest panel to

frame.
TYPICAL
TYPICAL
1. Screw securing footrest panel 8. Remove footrest panel from vehicle.
6. Detach front fender from footrest panel by re- MAX Models
leasing retaining tabs.
1. Remove footrest panel retaining screws.
TYPICAL
1. Front fender retaining tabs
TYPICAL - RH SIDE DOWN
7. Detach rear fender from footrest panel by re- 1. Footrest panel retaining screws
366
CHASSIS
Body
3. Remove plastic rivet securing footrest panel to

rear side panel extension.
frame.
TYPICAL - RH SIDE DOWN

1. Footrest panel retaining screws
TYPICAL - PARTS REMOVED FOR CLARITY

1. Plastic rivet securing footrest panel to inner fender
2. Plastic rivet securing footrest panel to rear side panel extension
3. Retaining screw securing footrest panel to frame

panel extension.
frame.
7. Remove screw securing front fender to footrest
panel.
09
TYPICAL - LH SIDE SHOWN

1. Plastic rivet securing footrest panel to panel extension
2. Plastic rivet securing footrest panel to frame
3. Retaining screw securing footrest panel to front fender
8. Detach front fender from footrest panel by re-

TYPICAL - LH SIDE SHOWN leasing retaining tabs.
2. Remove screw securing rear fender to footrest

panel.
367
CHASSIS
Body
Rack (Front and Rear)

Removing the Front Rack
1. Remove retaining bolts securing rack assem-
bly to frame.
N O T E : A small wrench will be needed to remove

the retaining screw located between the rack sup-
port and fender.
TYPICAL
1. Front fender retaining tabs
9. Detach rear fender from footrest panel by re-


1. Retaining bolts locations
2. Remove rack assembly from vehicle.

3. Remove the 4 retaining screws securing rack
moulding to rack assembly.
4. Remove both retaining screws securing rack
moulding to rack supports.
TYPICAL
10. Remove footrest panel from vehicle.

Installing the Footrest Panel
Tighten footrest panel screws to specification.
TYPICAL - LH SIDE OF ASSEM BLY SHOWN ON VEHICLE
Tightening Torque FOR CLARITY
1. LH side retaining screws securing rack moulding to rack assembly
2. LH side retaining screw securing rack moulding to rack support
Footrest panel 4.5 ± 0.5 Nm
retaining screws (40 ± 4 lbf-in) 5. Remove both retaining bolts securing rack sup-
ports to rails.
Screws securing 4.5 ± 0.5 Nm
footrest panel to (40 ± 4 lbf-in)
fenders
368
CHASSIS
Body
TYPICAL - LH SIDE OF ASSEMBLY SHOWN ON VEHICLE

FOR CLARITY 1. Retaining nuts and bolts securing rack to frame
1. Retaining bolt securing rack support to rail 2. Frame
3. Rack assembly
6. Remove retaining screws securing rack to
rails. 2. Remove rack from vehicle.
3. Remove retaining screws securing rack to rail.
Installing the Front Rack
The installation is the reverse of the removal pro- Installing the Rear Rack
cedure. However, pay attention to the following. The installation is the reverse of the removal pro-
Tightening Torque
Tightening Torque
Screws and nuts 4.5 ± 0.5 Nm
securing front rack to Screws and nuts 4.5 ± 0.5 Nm
(40 ± 4 lbf-in) securing rear rack to
rail (40 ± 4 lbf-in)
rail
Bolts securing front 4.5 ± 0.5 Nm
rack assembly to Screws and nuts
(40 ± 4 lbf-in) 4.5 ± 0.5 Nm
frame securing rear rack
(40 ± 4 lbf-in) 09
assembly to frame
Retaining screws
1.6 ± 0.4 Nm
securing fender to Rear Storage Compartment
(14 ± 4 lbf-in)
front rack assembly
Rear Storage Compartment Cover
Screws securing rack Replacing the Rear Storage Compartment
4.5 ± 0.5 Nm
moulding to rack Cover
(40 ± 4 lbf-in)
assembly
1. Open rear storage compartment cover.
2. Push rear storage compartment cover forward
Removing the Rear Rack to release it from hinges.
1. Remove retaining bolts and nuts securing rack
assembly to frame.
369
CHASSIS
Body
TYPICAL 1. Retaining screws securing RH rear storage compartment support

to RH support
3. Install a new rear storage compartment cover 2. Retaining screw securing RH fender to rear storage compartment
3. Retaining screw securing RH rear storage compartment support
as the reverse of removal. to rear storage compartment
Removing the Rear Storage Compartment 8. Remove RH rear storage compartment

1. Remove rear body module. Refer to Rear body support.
module. 9. Remove retaining screw securing top of RH
2. Remove rear rack. Refer to Removing the rear fender to top of rear storage compartment.
rack.
3. Remove rear storage compartment cover. Re-
fer to rear storage compartment cover.
4. Remove retaining screws securing bottom of
RH rear storage compartment support.
1. Retaining screw securing top of RH fender to top of rear storage

compartment
10. Remove retaining screw securing LH rear stor-

age compartment support to rear storage
compartment.
1. Retaining screws securing bottom of RH rear storage compart- 11. Remove retaining screw securing LH support
ment support
and LH rear storage compartment support to
5. Remove retaining screws securing RH rear rear storage compartment.
storage compartment support to RH support.
6. Remove retaining screw securing RH fender to
rear storage compartment.
7. Remove retaining screw securing RH rear stor-
age compartment support to rear storage
compartment.
370
CHASSIS
Body
3. Remove retaining screws securing cargo bed

1. Retaining screw securing LH rear storage compartment support
to rear storage compartment to rear storage compartment.
2. Retaining screw securing LH support and LH rear storage com-
partment support to rear storage compartment
12. Remove both retaining screws securing LH

fender to rear storage compartment.
4. Remove rear storage compartment.

09
1. Retaining screws securing LH fender to rear storage

compartment
13. Remove rear storage compartment.

Removing the Rear Storage Compartment
cedures in this subsection::
– Rear fenders
– Rear rack.
2. Remove retaining screws and plastic rivets se- Installing the Rear Storage Compartment
curing rear storage compartment to rear Installation is the reverse of removal. However
fenders. pay attention to the following:
371
CHASSIS
Body
Tightening Torque
4.5 ± 0.5 Nm
(40 ± 4 lbf-in)
Rear storage 10 ± 2 Nm
compartment retaining (89 ± 18 lbf-in)
screws
Installing the Rear Storage Compartment

cedure. However, pay attention to the following:
Tighten rear storage compartment retaining 1. Plastic rivet
screws to specification. 2. Screw securing rear fender
4. Detach rear fender from footrest panel by re-

Tightening Torque leasing retaining tabs.
Rear storage 4.5 ± 0.5 Nm
compartment retaining (40 ± 4 lbf-in)
screws
Rear Fenders
Removing the Rear Fenders
cedures in this subsection:
– Passenger seat holder
2. Remove rear top panel retaining screws and
plastic rivets.
TYPICAL

6. Place a c l e a n rag into fuel tank filler tube.
7. Remove rear fenders.
8. Remove rag and reinstall fuel tank cap.
WARNING
Fuel vapors are flammable and explosive
under certain conditions. Unless otherwise
noted, the fuel tank cap must always be in-
stalled on vehicle.
1. Plastic rivets
2. Retaining screws
3. Rear top panel Installing the Rear Fenders
3. Remove plastic rivet and the screw securing
procedure.
rear fender to footrest panel.
372
CHASSIS
Frame
Frame
Frame
Frame Inspection
Procedures Check frame for bending, cracks, weld damages
Huck Rivet Removal or any other damage. Replace frame as
Recommended Method necessary.
1. Using a cut-off tool, cut the rivet retainer with- Frame Welding
out touching the retainer's shoulder. No welding should be done on frame except if
mentioned or required on an approved BRP
Bulletin.
Frame Insert Replacement
To install a new blind threaded insert, use a blind
threaded insert installer available at any automo-
tive parts retailer.
After insert installation, ensure insert can hold the
torque applied to the screw it retains and measure
1. Rivet retainer's shoulder the compressed length of the frame insert. Other-
2. Cutter wheel
3. Rivet retainer
wise, install a new insert.
Insert Compressed Length

N O T E : Apply a thin layer of grease on cutter
wheel to increase its durability. 9 ± 0.5 mm
Insert for M6 bolt (.354 ± .02 in)
2. Break the rivet retainer's shoulder using a
chisel. 11.5 ± 0.5 mm
Insert for M8 bolt (.453 ± .02 in)
3. Use a small punch to drive out the rivet stem.
Replace Huck rivet with:
– M8, grade 8 screw
– M8 nylon lock nut
– M8 washer between each fastener and 09
frame.
INSERTS FOR M6 BO LT SHOWN

A. 9 ± 0.5 mm (.354 ± .02 in)
Frame Replacement
Blind threaded inserts are not installed on replace-
ment frames. Make sure to order enough inserts
Alternative Method when replacing frame. Refer to electronic parts
1. Measure outside diameter of rivet stem and se- catalog.
lect appropriate drill bit.
2. Drill the r i v e t s t e m — n o t t h e r i v e t h e a d using
a variable speed drill until rivet retainer is
freed.
N O T E : When possible, use an angle grinder to

grind rivet head or use an air hammer to cut the
rivet retainer.
373
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
374
TECHNICAL SPECIFICATIONS
10
375
Technical Specifications
Renegade
10 Technical Specifications
Renegade
Cooling System
Extended life pre-mixed coolant
or coolant specifically
Type
formulated for aluminum
Coolant engines
650 3.4 l (.9 gal(liq.,US))

Capacity
1000R 3.5 l (.92 gal(liq.,US))
Radiator cap opening pressure 110 kPa (16 lbf/in²)
Exhaust System
Spark arrestor approved by
Exhaust system USDA Forest Service
Catalyst on NRMM models (1)
(1) For NRMM models identification, refer to introduction section.
Electrical System
Type Maintenance free
Voltage 12 volts
Battery
Nominal rating 20 A•h
Power starter output 0.7 KW
High LED
Headlight
Low LED
Taillight 2 X 5/21 W
Main FL-1 16 gauge
Fusible links Cooling fan
FL-2 16 gauge
Accessories
Battery / Voltage regulator - 40 A
Fuse holder
DPS - 40 A
376
Renegade
Electrical System
Fan Relay RY1 -
Main Relay RY2 -

Relays Lights Relay RY3 -
Accessories RY5 -
Brake Relay RY6 -
Start Switch F1 10 A
Lights F2 30 A
Accessories 1 F3 20 A
Accessories 2 F4 20 A
Injectors
Ignition coils F5 10 A
Fuel Pump
Fuses Relays
DPS F6 10 A
Gauge
Brake lights F7 10 A
DESS Key,
F8 5A
ECM
2WD/4WD F9 10 A
DC Outlet F12 25 A
Fuel System
Electronic Fuel Injection (EFI), 46 10
650 mm throttle body, 1 injector per
cylinder
Fuel delivery Type
Electronic Fuel Injection (EFI), 54
1000R mm throttle body, 1 injector per
cylinder
Type Electrical (in fuel tank)

Fuel pump
Operating pressure 350 kPa (51 lbf/in²)
377
Renegade
Fuel System
Type Regular unleaded gasoline
Recommended 650 87 Pump Posted AKI (92 RON
octane rating or 95 E10 RON)
Type Premium unleaded gasoline
Fuel
Recommended 91 Pump Posted AKI (95 E10
octane rating 1000R RON)
Minimum octane 87 Pump Posted AKI (92 RON
rating or 95 E10 RON)
Fuel tank capacity 20.5 l (5.4 gal(liq.,US))
Fuel remaining when low fuel light turns ON ± 5 l (1.3 gal(liq.,US))
Drive System
Visco-lok † auto-locking front
Base
differential
Visco-lok† QE auto-locking front
Front drive X xc
differential
Visco-4Lok† auto-locking and
X mr
full lock front differential
Front drive ratio 3.6:1
Straight bevel gear / Shaft
Rear drive
driven final drive
Rear drive ratio 3.6:1
Base 500 ml (17 fl oz(US))
Capacity X xc
X mr 400 ml (14 fl oz(US))
Front differential oil
Recommended XPS 75W90 Synthetic gear oil
75W90 API GL-5 Synthetic
Alternate gear oil
Capacity 250 ml (8.45 fl oz(US))

Rear final drive oil
75W140 API GL-5 synthetic
Alternate gear oil
XPS CV joint grease or an
CV joint grease
equivalent
XPS Propeller shaft grease or

Propeller shaft grease for spline connections
an equivalent
378
Renegade
Steering
Total toe (vehicle on the ground) 0.5° t o e - i n
Camber angle (vehicle on the ground) 0°
Tie-rod maximum length unengaged threads 370 mm (14.57 in)
Front Suspension
Double suspension-arm with
Suspension type dive-control geometry and
external stabilizer bar
Base 23.3 cm (9.2 in)
Suspension travel X xc
X mr N/A
Qty 2
Base
HPG
X mr 650
Fox QS3† shocks with
X mr 1000R piggyback reservoir, quick
Shock absorber switch 3 positions
Type
Fox RC2 shock with piggyback
reservoir, dual speed
X xc compression damping
adjustment and rebound
adjustment.
Preload adjustment type Threaded
Rear Suspension
Torsional Trailing arm
10
Suspension type Independent (TTI) with
X mr N/A
Suspension travel All other 251.5 mm (9.9 in)
models
379
Renegade
Rear Suspension
Qty 2
Base
HPG
X mr 650
Fox QS3† shocks with
X mr 1000R piggyback reservoir, quick
Shock absorber switch 3 positions
Type
Fox RC2 shock with piggyback
reservoir, dual speed
X xc compression damping
adjustment.
Suspension Factory Settings

Base 650 49 mm (1.9 in)
X mr 650
Front X xc 42.6 mm (1.68 in)
X mr 1000R 63 mm (2.5 in)

Spring preload
Base 650 107 mm (4.2 in)
X mr 650
Rear X xc 106 mm (4.17 in)
X mr 1000R 85 mm (3.34 in)
Rebound 12 clicks CCW from full stop

High speed
2.25 turn CCW from full stop
Front compression
Slow speed
compression
Shock damping (X xc only)
High speed
Rear compression
Slow speed
compression
380
Renegade
Brakes
Qty 2
Front brake 214 mm cross drilled disc

Type brakes with hydraulic twin-
piston calipers
Qty 1
Rear brake 214 mm cross drilled disc

Type brake with hydraulic twin-
piston caliper
Brake fluid
Type DOT 4
Caliper piston diameter 2 x 26 mm
X mr Metallic
Brake pad material All other Organic
models
Minimum brake pad thickness 1 mm (.04 in)
Minimum brake disc thickness 4.0 mm (.157 in)

Maximum brake disc warpage 0.2 mm (.01 in)
Tires
Recommended tire inflation
Pressure pressure is found on the Tire
Label
Minimum tire thread depth 3 mm (.118 in)
71,1 x 20,3 x 30,5 cm (28 x 8 x
10
X mr 650 12 in.)
76,2 x 22,9 x 35,5 cm (30 x 9 x
Front X mr 1000R 14 in)
All other 205/80R12 (25 x 8 x 12 in)
models
Size
71,1 x 25,4 x 30,5 cm (28 x 10
X mr 650 x 12 in.)
76,2 x 22,9 x 35,5 cm (30 x 9 x
Rear X mr 1000R 14 in)
All other 280/60R12 (25 x 11 x 12 in)
models
381
Renegade
Wheels
Base Cast aluminium
Type X mr
Aluminium with beadlocks
X xc
X mr 1000R 35,5 x 16,5 cm (14 x 6.5 in)
Front All other 30,5 x 15,2 cm (12 x 6 in)
models
Rim size
X mr 1000R 35,5 x 16,5 cm (14 x 6.5 in)
Rear All other 30,5 x 19,1 (12 x 7.5 in)
models
Wheel nut torque 80 ± 5 Nm (59 ± 4 lbf-ft)
Dimensions
Base 218.4 cm (86 in)
Overall length X xc
X mr 224 cm (83 in)
Base 121.9 cm (48 in)
Overall width X xc
X mr 127 cm (50 in)
Base 124 cm (49 in)
Overall height X xc
X mr 131 cm (56 in)
Wheelbase 129.5 cm (51 in)

Base 102 cm (40.2 in)
Front X xc
X mr 103.5 cm (40.7 in)
Wheel track
Base 97.5 cm (38.4 in)
Rear X xc
X mr 100.6 cm (39.61 in)
Base 26.7 cm (10.5 in)
X xc
Ground clearance X mr 650 30.5 cm (12 in)
X mr 1000R 31.8 cm (12.5 in)
382
Renegade
Weight And Loading Capacity
Base 650 340 kg (750 lb)
X xc 361 kg (795 lb)

Dry weight
X mr 650 395 kg (870 lb)
X mr 1000R 440 kg (971 lb)

Rear cargo area capacity 16 kg (35 lb)
Total vehicle load allowed (including driver, passenger, all other
141 kg (310 lb)
loads and added accessories)
Towing capacity 590 kg (1,300 lb)
Tongue capacity 13 kg (30 lb)

Rear load (including rear cargo area and tongue load if applicable) 23 kg (50 lb)
10
383
Renegade - T Category
Cooling System
Extended life pre-mixed
coolant or coolant specifically
Type
formulated for aluminum
Coolant
engines
Capacity 3.5 l (.92 gal(liq.,US))
Radiator cap opening pressure 110 kPa (16 lbf/in²)
Exhaust System
Spark arrestor approved by
Exhaust system USDA Forest Service
Catalyst on NRMM models (1)
(1) For NRMM models identification, refer to Introduction section.
Electrical System
Type Maintenance free
Voltage 12 volts
Battery
Nominal rating 18 A•h
Power starter output 0.7 KW
High LED
Headlight
Low LED
Taillight 2 X 5/21 W
Front LED
Turn signal lights
Rear 4 x 10 W
Front LED
Position lights
Rear 2x5W
Licence plate light 1 x 10 W
Main
FL-1 16 gauge
Cooling fan
Fusible links
Lights 16 gauge
FL-2
Accessories
Battery/voltage regulator - 40 A
Fuse holders DPS - 40 A
ABS - 40 A
384
Electrical System
Cooling fan relay RY1 -
Main relay RY2 -
Relays Lights relay RY3 -
Accessories relay RY5 -
Brake relay RY6 -
Ignition switch
Gauge F1 10 A
Lights F2 30 A
Accessory 1 F3 20 A
Accessory 2 F4 20 A
Fuel pump
Injectors
F5 10 A
Ignition coils
EVAP
Fuses Gauge
DPS
Speed limiter F6 10 A
Relays
Tail Lights
Brake lights F7 10 A
D.E.S.S.
F8 10 A
ECM
4WD actuator F9 10 A
Cooling fan (resetable) F12 25 A
10
Fuel System
Electronic Fuel Injection (EFI),
Fuel delivery 46 mm throttle body, 1 injector
per cylinder
Type Electrical (in fuel tank)
Fuel pump
Operating pressure 350 kPa (51 lbf/in²)
Type Regular unleaded gasoline
Fuel Recommended octane
rating 91 RON or 95 E10 RON
Fuel tank capacity 20.5 l (5.4 gal(liq.,US))

Fuel remaining when low fuel light turns ON ± 5 l (1.3 gal(liq.,US))
385
Drive System
Visco ABS, Open differential
Front drive with BTC (Brake Traction
Control)
Front drive ratio 3.6:1
Spiral bevel gear / Shaft
Rear drive
driven final drive
Rear drive ratio 3.6:1
Capacity 500 ml (17 fl oz(US))

Front differential oil
Alternate gear oil
XPS 75W140 Synthetic gear
Recommended
Rear final drive oil oil
Alternate gear oil
XPS CV joint grease or an
CV joint grease
equivalent
XPS Propeller shaft grease or
Propeller shaft grease for spline connections
an equivalent
Steering
Total toe (vehicle on the ground) 0.5° toe-in
Camber angle (vehicle on the ground) 0°
Tie-rod maximum length unengaged threads 370 mm (14.57 in)
Front Suspension
Double suspension-arm with
Suspension type dive-control geometry and
Suspension travel 233.7 mm (9.2 in)
Qty 2
Base HPG
Shock absorber Fox RC2 shock with

Type piggyback reservoir, dual
X xc speed compression damping
adjustment.
386
Front Suspension
Rear Suspension
Torsional Trailing arm
Suspension type Independent (TTI) with
Suspension travel 251.5 mm (9.9 in)
Qty 2
Base HPG
Shock absorber Fox RC2 shock with

Type piggyback reservoir, dual
X xc speed compression damping
adjustment.
Suspension Factory Settings
Base 49 mm (1.9 in)

Front
X xc 42.5 mm (1.67 in)
Spring preload
Base 107 mm (4.2 in)
Rear
X xc 59 mm (2.32 in)

High speed
Front
Compres
sion
2.25 turn CCW from full stop 10
Slow speed
Compres 2.25 turn CCW from full stop
sion
Shock damping ( X xc only)
High speed
Rear sion
Slow speed
sion
387
Brakes
Type Hydraulic disc brakes with ABS
Qty 2
Front brake 214 mm cross drilled discs with
Type
twin-piston floating calipers
Qty 1
Rear brake 214 mm cross drilled disc with
Type
twin-piston floating caliper
Brake fluid
Type DOT 4
Caliper piston diameter 2 x 26 mm
Brake pad material Organic
Minimum brake pad thickness 1 mm (.04 in)
Minimum brake disc thickness 4.0 mm (.157 in)

Maximum brake disc warpage 0.2 mm (.01 in)
Tires
Recommended tire inflation
Pressure pressure is found on the Tire
Label
Minimum tire thread depth 3 mm (.118 in)
Front 205/80R12 (25 x 8 R 12 in)

Size
Rear 280/60R12 (25 x 11 R 12 in)
Wheels
Base Cast aluminium
Type
X xc Aluminium with beadlocks
Front 30,5 x 15,2 cm (12 x 6 in)
Rim size
Rear 30,5 x 19,1 cm (12 x 7.5 in)
Front 41.2 mm (1.6 in)

Wheel offset
Rear 51 mm (2 in)
Wheel nut torque 80 ± 5 Nm (59 ± 4 lbf-ft)
Dimensions
Overall length 218.4 cm (86 in)
Overall width 121.9 cm (48 in)
388
Dimensions
Overall height 124 cm (49 in)
Wheelbase 129.5 cm (51 in)
Front 102 cm (40.2 in)

Wheel track
Rear 97.5 cm (38.4 in)
Ground clearance 26.7 cm (10.5 in)
Weight And Loading Capacity
650 375 kg (825 lb)

Dry weight
1000 375 kg (825 lb)
Rear cargo area capacity 23 kg (50 lb)
Rear storage compartment loading capacity No rear storage compartment

available
Total vehicle load allowed (including driver, passenger, all other
141 kg (310 lb)
loads and added accessories)
Trailer without brakes 395 kg (871 lb)

Towing capacity
Trailer with brakes 660 kg (1,455 lb)
Tongue capacity 75 kg (165 lb)
Noise and Vibration

650 79 dB (A)
Exterior sound level (dB Stationary
(A)) 1000 80 dB (A)
According to Annex II 650 84 dB (A)
(EU) 2018/985 Moving
1000 85 dB (A)
10
Driver perceived sound level (dB (A)) 650 76 dB (A)
According to Annex XIII (EU) 1322/2014 1000 76 dB (A)
Seat vibration 650 0.51 m/s2
According to Annex XIV (EU) 1322/2014 1000 0.89 m/s2
389
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
390
WIRING DIAGRAM
11
391
Wiring Diagram
Wiring Diagram Information
11 Wiring Diagram
Connector Code
Wiring Diagram The wire connects to the indicated connector.
Information Connector Pin
General The wire is the indicated pin in the connector.
Wiring Diagram Location
NOTE: Could be identified by either a number
Wiring diagrams are found in the Wiring Diagram or by a letter depending on the type of connector
Booklet. used.
Wiring Diagram Codes Following a Circuit
The wiring diagrams use the following codes. To follow a circuit, search the in section of the wir-
ing diagram shown in the wiring diagram index.
1 (-C-3) YL/BU-22 5
N O T E : The arrow indicates the direction of the
YL/BK-16
power in the circuit.
F11 R5
C6
D6
In this example, the power comes f r o m section

30A
30 86 (-C-3).
87 85
(-C-3) YL/BU-22
C7
3
OR/BK-22 (-B-5) 1
OR/BK-22
JT-OR/BK
3 HIC1_F
OR/BK-22
C In following example, the power goes t o the sec-
2 tion (-B-5).
4
1.
2.
Wiring diagram index
Connector code OR/BK-22 (-B-5)
3. Connector pin
4. Splice
5. Color and size
Wiring Diagram Index Wire Colors and Sizes

The wiring diagram is separated by rows (letters)
and columns (numbers).
1. Wire color
2. Wire gauge (AWG)
The first color of a wire is the main color, second

color is the stripe.
Example: YE/BK is a YELLOW wire with a BLACK
stripe.
WIRING DIAGRAM INDEX
392
Wiring Diagram
COLOR CODE N O T E : Ensure all terminals are properly crimped

on wires and connector housings are properly fas-
OR tened. When replacing any electric or electronic
BG — BEIGE OG —
ANGE part(s), always check electrical connections. Make
sure that they are clean, corrosion-free, tight and
BK — BLACK RD — RED make good contact. The voltage and current might
BU — BLUE VT — VIOLET be too weak to go through dirty or corroded con-
nector pins or terminals.
BN — BROWN WH — WHITE
If a fault is intermittent and cannot be found
YEL through static continuity checks, it may indicate:
GN — GREEN YE —
LOW
– A loose connection
GY — GRAY PK — PINK – A bad splice in a harness
– A pin that is unlocked in a connector and barely
LT prefix means a "light" color. E.g: LT GN =
making contact
Light green.
– An intermittent electronic component within a
module.
Splices in Wiring Harness
Splices in wiring harness are indicated on the wir- Do the following:
ing diagram as follows. – Try moving the harness and connectors to sim-
ulate vehicle vibration as you carry out your
1 2 checks with the multimeter.
– Try spraying water to the harness, connectors
JT - RD/BU or sensors to simulate riding under the rain or
high humidity as you carry out your checks with
the multimeter.
1. JT: Splice indication I M P O R T A N T : In an electrical circuit, the bat-
2. Spliced wire color tery usually provides power to a switch, which then
Troubleshooting supplies the electric component when the switch
contacts are closed (low power circuits). Therefore
Diagnostic Tips the switch opens and closes the positive side of
I M P O R T A N T : When trying to solve an electri- the circuit. In circuits controlled by the ECM and
cal problem, check the following: other modules, the battery supplies the electric
– The ignition switch is turned ON. component, and the ECM/module acts as the
– The engine RUN/STOP switch is in RUN switch which completes the circuit to ground. A re-
position. lay acts as a remote switching device for higher
– The battery condition as well as its cables and power components or for supplying multiple cir-
connections. cuits. Take this into account when troubleshooting
– The system fuse condition of the related circuit the electrical system. 11
using an ohmmeter.
– Ensure a positive electrical connection of the Pay attention to ground wires. They could become
fuse to the fuse holder contacts. loose or corroded which causes them to act as an
– Examine related circuit harness and additional load in a circuit, dropping voltage and
connections. reducing current to components. Some compo-
nents may be grounded through their outer casing
Install a battery charger before any tests that in- and mounting hardware. This should also be
volve prolonged "key ON". If system voltage is too considered.
low, some accessories will be shut off and test re- Simplifying Electrical System Tests
sults can be altered.
For complex systems where there are electronic
Pay particular attention to electrical connectors modules, sensors, actuators, relays etc., it is often
and ensure that pins are not out of their housings, beneficial for diagnosing problems to divide up the
loose, or damaged. The troubleshooting proce- system into some basic smaller subsystems, to
dures may not cover problems resulting from one help narrow down where the problem lies.
of these causes.
393
Wiring Diagram
Use BUDS2 to check for fault codes, refer to Com-

munication Tools and also Diagnostic and Fault
Codes subsections. Follow S e r v i c e A c t i o n s listed
in BUDS2.
Common
Guideline
Subsystem
Power – Battery – Check if a group of

And – Fuses components or systems
Grounds – Relays stopped working or if
– Con nothing works (lights,
nec gauge, etc.).
tions – Start from the power
source (battery) and
move outwards towards
the modules, checking
for voltage at each
connection.
– Check grounds and
battery (+) using a
voltmeter.
– Disconnect and test
wiring.
Inputs – Sen – View measurements in

and sors BUDS2
Outputs – Gauge – Activate all possible
s items and monitor
– Actua response.
tors – Disconnect and test
– Motors wiring.
Commu – Be – View measurements in

nication tween BUDS2
Mod – Disconnect and test
ules wiring.
and
with
BUDS2
For ALL wiring tests, you need to check for:
Possible Problem Common cause
– Open circuit – Loose terminals, broken

– Shorts to ground wires.
(battery -) – Wires rubbed through,
– Shorts to battery water in connectors.
(+) – Corroded wires and
– Shorts to other terminals.
circuits
– Higher resistance
than desired
394
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
395
www.brp.com
SKI-DOO® SEA-DOO® CAN-AM®
LYNX® EVINRUDE® ROTAX®

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Vehicle Service Manual

2023 Renegade Series

CALIFORNIA PROPOSITION 65 WARNING

™®Trademarks of BRP or its affiliates.

TESTING A FUSE LINK ......................................................................................................... 136

VISCO-LOK SYSTEM DESCRIPTION ...................................................................................... 212

PITMAN ARM (WITH DPS)..................................................................................................... 284

Page:215, 229, 242

Page:213, 227, 240, 253

Page:214, 227, 241, 253

Steering alignment tool

Page:218, 245 Page:270

Page:35, 119, 131

Brake Caliper Synthetic Grease XPS Synthetic suspension

Cleaner and degreaser PRO C1

Clutch and pulley flange cleaner

Loctite 271 (red)

Loctite 406 (glue)

Loctite 648 (green)

Loctite 767 (anti-seize lubricant)

Lubricant and anti-corrosive

XPS ATV wash

XPS Brakes and Parts cleaner

XPS Fuel stabilizer

XPS Synthetic grease

recommend that you do not attempt to perform the

We have provided you with some of the most im-

1. Engine Identification Number (EIN)

VIN Decal Description

TYPICAL — VEHICLE SERIAL NUMBER DECAL UNDER SEAT

NOTE: Any tampering with the engine or its

Engine Emissions When servicing any vehicle; adjustments must be

Manual Information This manual uses technical terms which may be

A number of procedures throughout the book re- Manual Layout

Whenever possible, always apply torque on the nut.

FASTENER FASTENER GRADE/TORQUE

1.5 – 2 N∙m (13 – 18 2.5 – 3 N∙m (22 – 27 3.5 - 4 N∙m (31 - 35

Threadlocker Application for Uncovered Holes

Self-Locking Fastener Procedure

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

Use a metal brush or a tap to properly clean a

Loctite® Threadlocker Application

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

N O T E : Retaining compound is always forced out

Standard Thread Repair

N O T E : Normally used on worn-out housings to N O T E : DO NOT apply release agent on stud.

Gasket Compound Application

1. Proper strength Loctite

1. Remove old gasket and other contaminants

N O T E : If the cover is bolted to blind holes, apply

EPA Regulation - Canadian and USA Vehicles

Severe Dusty Conditions

Operation in trail riding conditions

Maintenance Schedule (except 6x6)

Regular Maintenance Overview

Severe Duty and Mud/Water Maintenance Overview

DEEP MUD / WATER A+ A B

DEEP MUD / WATER A+ A B

Periodic Maintenance Procedures