SAFETY NOTICE

SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair 2008/2009 Outlander™ 400 EFI
Series ATVs as describe in the model list in the INTRODUCTION.
This edition was primarily published to be used by mechanical technicians who are already familiar with
all service procedures relating to BRP products. Mechanical technicians should attend training courses
given by B.R.P.T.I.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This shop manual uses technical terms which may be slightly different from the ones used in the PARTS
CATALOG.
It is understood that this manual may be translated into another language. In the event of any discrepan-
cy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser-
vice and Warranty Bulletins may be published to update the content of this manual. Make sure to read
and understand these. It does not include dealer modifications, whether authorized or not by BRP, after
manufacturing the product.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of BRP parts is most strongly recommended when considering replacement of any component.
Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those for which it was designed.

 WARNING
Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair
procedures.

This manual emphasizes particular information denoted by the wording and symbols:

 WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including pos-
sibility of death.

CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo-
nents.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents.
We strongly recommend that any services be carried out and/or verified by a highly skilled professional
mechanic. It is understood that certain modifications may render use of the vehicle illegal under existing
federal, provincial and state regulations.

VIII vmr2008-113
INTRODUCTION

Vehicle Serial Number Replacement or repair of any emission related

The Vehicle Identification Number (V.I.N.) is component must be executed in a manner that
scribed on vehicle description decal. See above. maintains emission levels within the prescribed
It is also engraved on frame near vehicle descrip- certification standards.
tion decal. 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, such as altitude adjustments for exam-
vmr2007-011-001_c ple.
1. Vehicle serial number
Owner Responsibility
The owner/operator is required to have engine
Engine Serial Number maintenance performed to maintain emission
levels within prescribed certification standards.
The owner/operator is not to, and should not al-
low anyone to modify the engine in any manner
that would alter the horsepower or allow emis-
sions levels to exceed their predetermined factory
specifications.

EPA Emission Regulations

Some ATVs manufactured by BRP are certified
to the EPA as conforming to the requirements
of the regulations for the control of air pollution
from new ATV engines. This certification is con-
tingent on certain adjustments being set to factory
standards. For this reason, the factory procedure
for servicing the product must be strictly followed
vmo2008-019-010_a and, whenever practicable, returned to the origi-
1. Engine serial number nal intent of the design.
The responsibilities listed above are general and
in no way a complete listing of the rules and regu-
ENGINE EMISSIONS lations pertaining to the EPA requirements on ex-
INFORMATION haust emissions for ATVs products. For more de-
tailed information on this subject, you may contact
Manufacturer's Responsibility the following locations:
Manufacturers of engines must determine the ex- FOR ALL COURIER SERVICES:
haust emission levels for each engine horsepower U.S. Environmental Protection Agency
family and certify these engines with the United Office of Transportation and Air Quality
States of America ENVIRONMENTAL PROTEC- 1310 L Street NW
TION AGENCY (EPA). An emissions control infor- Washington D.C. 20005
mation label, showing emission levels and engine REGULAR US POSTAL MAIL:
specifications, must be placed on each vehicle at 1200 Pennsylvania Ave. NW
the time of manufacture. Mail Code 6403J
Washington D.C. 20460
Dealer Responsibility INTERNET: http://www.epa.gov/otaq/
When performing service on ATVs that carry an
E-MAIL: otaqpublicweb@epa.gov
emissions control information label, adjustments
must be kept within published factory specifica-
tions.

X vmr2008-113
 INTRODUCTION

TIGHTENING TORQUE In order to avoid a poor assembling, tighten

screws, bolts or nuts in accordance with the
Tighten fasteners to torque mentioned in explod- following procedure:
ed views and/or text, When they are not specified,
refer to following table. Manually screw all screws, bolts and/or nuts.
Apply the half of the recommended torque value.
 WARNING CAUTION: Be sure to use proper tightening
Torque wrench tightening specifications torque for the proper strength grade.
must strictly be adhered to. NOTE: When possible, always apply torque on the
Locking devices (e.g.: locking tabs, elastic nut.
stop nuts, self-locking fasteners, cotter pins,
etc.) must be replaced with new ones. Torque at the recommended torque value.
NOTE: Always torque screws, bolts and/or nuts in
a crisscross sequence.
4.8 8.8 9.8 10.9 12.9
Property
class and
head 4.8 8.8 9.8 10.9 12.9
markings
4.8 8.8 9.8 10.9 12.9 12.9

5 8 10 12
Property
class and

12
10
nut
5

markings
A00A8BS

FASTENER FASTENER GRADE/TORQUE

SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
1.5 – 2 N•m 2.5 – 3 N•m 3.5 – 4 N•m 4 – 5 N•m
M4
(13 – 18 lbf•in) (22 – 27 lbf•in) (31 – 35 lbf•in) (35 – 44 lbf•in)
3 – 3.5 N•m 4.5 – 5.5 N•m 7 – 8.5 N•m 8 – 10 N•m
M5
(27 – 31 lbf•in) (40 – 47 lbf•in) (62 – 75 lbf•in) (71 – 89 lbf•in)
6.5 – 8.5 N•m 8 – 12 N•m 10.5 – 15 N•m
M6 16 N•m (142 lbf•in)
(58 – 75 lbf•in) (71 – 106 lbf•in) (93 – 133 lbf•in)
M8 15 N•m (133 lbf•in) 25 N•m (18 lbf•ft) 32 N•m (23 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 (53 lbf•ft)
M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105 N•m (77 lbf•ft) 128 N•m (94 lbf•ft)
M14 85 N•m (63 lbf•ft) 135 N•m (100 lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft)

vmr2008-113 XI
INTRODUCTION

SELF-LOCKING FASTENERS Apply a few drops of threadlocker at proposed

PROCEDURE tightened nut engagement area.
Position nut and tighten as required.
Blind Holes

A00A6LA
2
TYPICAL — SELF-LOCKING FASTENER

The following describes the most common appli-

cation procedures when working with self-locking
fasteners.
Use a metal brush or a tap to clean the hole prop-
erly then use a solvent, let act during 30 minutes
lmr2007-040-004_a
and wipe off. The solvent utilization is to ensure
the adhesive works properly. 1. On threads
2. On threads and at the bottom of hole

LOCTITE® APPLICATION Clean threads (bolt and hole) with solvent.

PROCEDURE Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30 sec-
The following describes the most common ap-
onds.
plication procedures when working with Loctite
products. Choose proper strength Loctite threadlocker.
NOTE: Always use proper strength Loctite prod- Apply several drops along the threaded hole and
uct as recommended in this shop manual. at the bottom of the hole.
Apply several drops on bolt threads.
Threadlocker
Tighten as required.
Uncovered Holes (bolts and nuts)
Stud in Blind Holes

1
1 3

2
lmr2007-040-005_a

A00A3LA 1. On threads
2. On threads and in the hole
1. Apply here 3. Onto nut threads
2. Do not apply
Clean threads (stud and hole) with solvent.
Clean threads (bolt and nut) with solvent.
Apply Loctite Primer N (P/N 293 800 041) on
Apply Loctite Primer N (P/N 293 800 041) on threads and allow to dry.
threads and allow to dry.
Put 2 or 3 drops of proper strength Loctite
Choose proper strength Loctite threadlocker. threadlocker on female threads and in hole.
Fit bolt in the hole.

XII vmr2008-113
 INTRODUCTION

NOTE: To avoid a hydro lock situation, do not apply Adjusting Screw

too much Loctite.
Apply several drops of proper strength Loctite on 2
1
stud threads.
Install stud.
Install cover, etc.
Apply drops of proper strength Loctite on uncov-
ered threads.
Tighten nuts as required.
Pre-Assembled Parts
A00A3PA

1. Apply here
2. Plunger
1
Adjust screw to proper setting.
Apply drops of proper strength Loctite thread-
locker on screw/body contact surfaces.
Avoid touching metal with tip of flask.
NOTE: If it is difficult to readjust, heat screw with
a soldering iron (232°C (450°F)).

Stripped Thread Repair

2
A00A3OA
5
1. Apply here
1
2. Do not apply 6
Clean bolts and nuts with solvent. 8
2
Assemble components.
Tighten nuts.
Apply drops of proper strength Loctite on 3
bolt/nut contact surfaces.
Avoid touching metal with tip of flask.
A00A3QA 4 7
NOTE: For preventive maintenance on exist-
ing equipment, retighten nuts and apply proper 1. Release agent
2. Stripped threads
strength Loctite on bolt/nut contact surfaces. 3. Form-A-Thread
4. Tapes
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:
a. Apply release agent on mating surfaces.
b. Put waxed paper or similar film on the sur-
faces.
– Twist bolt when inserting it to improve thread
conformation.
NOTE: NOT intended for engine stud repairs.
vmr2008-113 XIII
INTRODUCTION

Repair of Small Holes/Fine Threads If holes are sunken, apply proper strength Loc-
Option 1: Enlarge damaged hole, then follow tite on bolt threads.
STANDARD THREAD REPAIR procedure. Tighten as usual.
Option 2: Apply FORM-A-THREAD on the screw
and insert in damaged hole. Mounting on Shaft
Permanent Stud Installation (light duty) Mounting with a Press
– Use a stud or thread on desired length.
– DO NOT apply release agent on stud.
– Do a STANDARD THREAD REPAIR.
– Allow to cure for 30 minutes.
1
– Assemble.

Gasket Compound 2

1 2 3
A00A3UA

1. Bearing
2. Proper strength Loctite
3. Shaft

Clean shaft external part and element internal

part.
1 Apply a strip of proper strength Loctite on shaft
circumference at insert or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
DO NOT use antiseize Loctite or any similar
product.
No curing period is required.
1 3
lmr2007-040-006_a Mounting in Tandem
1. Proper strength Loctite Apply retaining compound on internal element
2. Loctite Primer N (P/N 293 800 041) and Loctite 518
(P/N 293 800 038) on both sides of gasket bore.
3. Loctite Primer N only
Continue to assemble as shown above.
Remove old gasket and other contaminants
with Loctite Chisel (gasket remover (P/N 413 Case-In Components
708 500). Use a mechanical mean if necessary. Metallic Gaskets
NOTE: Avoid grinding.
Clean both mating surfaces with solvent.
Spray Loctite Primer N on both mating surfaces
and on both sides of gasket. Allow to dry 1 or 2
minutes.
Apply Loctite 518 (P/N 293 800 038) on both
sides of gasket, using a clean applicator.
Place gasket on mating surfaces and assemble
immediately.
A00A3VA 1
NOTE: If the cover is bolted to blind holes (above),
apply proper strength Loctite in the hole and on 1. Proper strength Loctite
threads. Tighten.
Clean inner housing diameter and outer gasket
diameter.
XIV vmr2008-113
 INTRODUCTION

Spray housing and gasket with Loctite Primer N

(P/N 293 800 041).
Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
strength and gap are required.
Install according to standard procedure.
Wipe off surplus.
Allow it to cure for 30 minutes.
NOTE: Normally used on worn-out housings to
prevent leaking or sliding.
It is generally not necessary to remove gasket
compound applied on outer gasket diameter.

MANUAL INFORMATION
The manual is divided into many major sections as
you can see in the main table of contents at the
beginning of the manual.
Each section is divided in various subsections, and
again, each subsection has one or more division.
Illustrations and photos show the typical construc-
tion of the different assemblies and, in all cases,
may not reproduce the full detail or exact shape of
the parts shown. However, they represent parts
which have the same or a similar function.
CAUTION: Most components of those vehicles
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or
vice-versa. Mismatched or incorrect fasteners
could cause damage to the vehicle or possible
personal injury.
As many of the procedures in this manual are inter-
related, we suggest, that before undertaking any
task, you read and thoroughly understand the en-
tire section or subsection in which the procedure
is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before commenc-
ing any procedure, be sure that you have on hand
all the tools required, or approved equivalents.
The use of RIGHT and LEFT indications in the text,
always refers to driving position (when sitting on
vehicle).

vmr2008-113 XV
INTRODUCTION

TYPICAL PAGE

Section 06 ENGINE Page heading

Subsection 01 (MAGNETO) indicates section
and subsection.

Subsection title MAGNETO

Indicates applicable Models
models.

Loctite 243 Drop represents a

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

Bold face number

1 is used to identify
a part referred to
the text.
NEW indicates that the
part must be replaced NEW
with a new one.

5 N•m
(44 lbf•in)

Illustration number
for publishing process. XXX0000

Document number for 55 Page number

publishing process.
mmr2008-001

Typical_iso_2008_en

XVI vmr2008-113
 INTRODUCTION

TYPICAL PAGE

Section 03 ENGINE
Subsection 09 (MAGNETO SYSTEM)
Tittle in bold
indicates category
of information to be GENERAL
carried out. NOTE: The following procedures can be done
without removing the engine.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Reference to a Clean threads before applying a threadlocker. Re-
specific section fer to the SELF-LOCKING FASTENERS and LOC-
or subsection. TITE APPLICATION sections at the beginning of
this manual for complete procedure. “TYPICAL”
WARNING indicates a general
Torque wrench tightening specifications
view which may
must be strictly adhered to. not represent exact
Locking devices (e.g.: locking tabs, elastic 1 details.
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones. TYPICAL
1. Starting pulley

PROCEDURES NOTE: To remove starting pulley bolts, hold mag- Call-outs pertaining
Indicates component neto flywheel with a socket as shown. to above illustration.
procedures apply to. MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean magneto flywheel using only
Indicates specific a clean cloth. Illustration always
procedure to be Magneto Flywheel Removal follows text to which
carried out. Remove muffler, refer to the EXHAUST SYSTEM it applies.
section.
Remove acoustic panel.
Remove rewind starter. mmr2007-016-002

Remove starting pulley no. 2. TYPICAL Italic bold face type-

Models
Models
setting indicates a
Remove the connecting flange retaining the
procedure applicable
rewind starter to the engine housing. to a specific
model(s).

mmr2008-001 57

Bold face number following part

name refers to exploded view
at beginning of subsection.

typical_txt_2008_en

vmr2008-113 XVII
 Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)

MAINTENANCE CHART
MAINTENANCE CHART
The schedule should be adjusted according to operating conditions and use. The initial maintenance is
very important and must not be neglected.
NOTE: The chart gives an equivalence between number of hours and months/year. Perform the mainte-
nance operation to whatever time comes first.
IMPORTANT: ATV rental operations or intensive use of ATV, will require greater frequency of inspection
and maintenance.

INITIAL INSPECTION 10 H OR 30 DAYS OR 300 km (185 mi)

A: ADJUST
C: CLEAN 25 H OR 750 km (470 mi)
I: INSPECT 50 H OR 1500 km (930 mi)
L: LUBRICATE 100 H OR 1 YEAR OR 3000 km (1865 mi)
R: REPLACE
200 H OR 2 YEARS OR 6000 km (3730 mi)
PART/TASK REFER TO
ENGINE
Engine oil and filter R R LUBRICATION SYSTEM
Valves I, A I, A CYLINDER HEAD/CYLINDER
Engine seals I I ENGINE
Engine mounting fasteners I I ENGINE REMOVAL/INSTALLATION
Air filter C (1) R AIR INTAKE SYSTEM
Exhaust system I I
EXHAUST SYSTEM
Spark arrester C
Coolant I I (2) R
Radiator cap/cooling system pressure test I I
COOLING SYSTEM
I, C I, C
Radiator (1) (1)

Rewind starter rope I REWIND STARTER

ENGINE MANAGEMENT SYSTEM
EMS sensors I I
ENGINE MANAGEMENT
EMS fault codes I I
FUEL SYSTEM
Throttle body I I,L ELECTRONIC FUEL INJECTION
I, A, I, A,
Throttle cable STEERING SYSTEM
L L
Fuel lines, connections and fuel tank
I I
pressure test
FUEL TANK AND FUEL PUMP
In-line fuel filter (2008 models only) R
Fuel pump pressure test I

vmr2008-114 1
Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)

INITIAL INSPECTION 10 H OR 30 DAYS OR 300 km (185 mi)

A: ADJUST
C: CLEAN 25 H OR 750 km (470 mi)
I: INSPECT 50 H OR 1500 km (930 mi)
L: LUBRICATE 100 H OR 1 YEAR OR 3000 km (1865 mi)
R: REPLACE
200 H OR 2 YEARS OR 6000 km (3730 mi)
PART/TASK REFER TO
ELECTRICAL SYSTEM
Spark plug IGNITION SYSTEM
Battery connections I I CHARGING SYSTEM
ECM connectors
I ELECTRONIC FUEL INJECTION
(visual inspection without disconnecting)
Electrical connections and fastening
IGNITION SYSTEM, STARTING SYSTEM
(ignition system, starting system, fuel I I
and ELECTRONIC FUEL INJECTION
injectors etc.)
Ignition switch, engine start button and
I I IGNITION SYSTEM and STARTING SYSTEM
engine stop switch
Lighting system (HI/LO intensity, brake
I I LIGHTS, GAUGE AND ACCESSORIES
lamp, headlamp aiming, etc.)
CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
Drive belt I
Drive and driven pulleys I, C CONTINUOUSLY VARIABLE
One-way bearing inside CVT I, L TRANSMISSION (CVT)
CVT air inlet/outlet duct I I, C
DRIVE TRAIN
Front and rear differentials seals and
I I
vents
Front and rear differentials oil I I R FRONT DRIVE and REAR DRIVE
Drive shaft boots and protectors I I
Drive shaft joints I
Rear propeller shaft joints (1) I L I REAR DRIVE
4 x 4 coupling unit I I 4 X 4 COUPLING UNIT
WHEELS/TIRES
Wheel bearings I STEERING SYSTEM
Wheel nuts/studs I I WHEELS/TIRES
STEERING SYSTEM
Handlebar fastener I
Steering system mechanism (2)
I I
(column, bearing, etc.) STEERING SYSTEM
Tie rod ends I
Front wheel alignment I I, A

2 vmr2008-114
 Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)

INITIAL INSPECTION 10 H OR 30 DAYS OR 300 km (185 mi)

A: ADJUST
C: CLEAN 25 H OR 750 km (470 mi)
I: INSPECT 50 H OR 1500 km (930 mi)
L: LUBRICATE 100 H OR 1 YEAR OR 3000 km (1865 mi)
R: REPLACE
200 H OR 2 YEARS OR 6000 km (3730 mi)
PART/TASK REFER TO
SUSPENSION
Trailing arms I
REAR SUSPENSION
Trailing arm bearings I
FRONT SUSPENSION and
Shock absorbers I
REAR SUSPENSION
A-arms I, L
FRONT SUSPENSION
Ball joints I
BRAKES
Brake fluid I I R
Brake system (discs, hoses, etc.) I BRAKES
Brake pads I (1)

BODY/FRAME
Frame fastener I
BODY/FRAME
Frame I

(1) More often under severe use such as dusty area, sand, snow, wet or muddy conditions.
(2) Every 100 hours, check coolant strength.

vmr2008-114 3
 Section 01 MAINTENANCE
Subsection 02 (PRESEASON PREPARATION)

PRESEASON PREPARATION
Prior to use vehicle, proper vehicle preparation is
required after performing the storage procedure.
Any worn, broken or damaged parts found during
the storage procedure should have been replaced.
If not, proceed with the replacement.
Using the maintenance chart, performed items in
the column indicated: 100 h or 1 year or 3000 km
(1865 mi).

vmr2007-013-001_aen

1. Use this column

Furthermore, proceed with the following:

Vehicles Prepared as per Storage

Procedure
Remove rags from: CVT inlet and outlet hoses,
engine air intake and muffler.
Test drive vehicle to confirm proper operation.

Vehicles Not Prepared as per

Storage Procedure
Replace engine oil and filter.
Drain fuel tank and fill with fresh fuel.
Test drive vehicle to confirm proper operation.

vmr2008-115 5
 Section 01 MAINTENANCE
Subsection 03 (STORAGE PROCEDURE)

STORAGE PROCEDURE
SERVICE PRODUCTS
Description Part Number Page
BRP heavy duty cleaner........................................................ 293 110 001 ............................................. 8
XP-S Lube ............................................................................. 293 600 016 ............................................. 8
BRP fuel stabilizer................................................................. 413 408 600 ............................................. 7
Vinyl & Plastic Cleaner.......................................................... 413 711 200 ............................................. 8
storage oil ............................................................................. 413 711 600 ............................................. 7
storage oil (US) ..................................................................... 413 711 900 ............................................. 7

If the ATV is not used or is to be stored for an Stop the engine.

extended period of time, more than 4 months, be Change engine oil and filter. Refer to LUBRICA-
sure to perform the storage procedures described TION SYSTEM section.
below.
Remove spark plug and spray storage oil
(P/N 413 711 600) into cylinder.
FUEL SYSTEM
NOTE: For US citizens, use storage oil (US)
Fuel System Protection (P/N 413 711 900) only.
With the new fuel additives, it is critical to use the CAUTION: Do not inject storage oil into throttle
BRP fuel stabilizer (P/N 413 408 600) or an equiva- body bore to avoid blocking idle bypass valve.
lent to prevent fuel deterioration and fuel system Press start button, 1 or 2 seconds maximum, to
gumming. Follow the manufacturer's instructions lubricate cylinder.
for proper use.
Reinstall the spark plug.
CAUTION: Fuel stabilizer should be added
prior to engine lubrication to ensure fuel sys- COOLING SYSTEM
tem components protection against varnish
deposits.
Coolant Inspection
Pour fuel stabilizer in fuel tank. Fill up fuel tank.
Test coolant density using an antifreeze hydrome-
Do not drain fuel system. ter.
NOTE: Follow manufacturer's instructions for
ENGINE proper use.
Engine Oil and Filter Replacement A 50/50 mixture of antifreeze and distilled water
will provide the optimum cooling, corrosion pro-
Change engine oil and filter. Refer to LUBRICA- tection and antifreeze protection.
TION SYSTEM .
CAUTION: Do not use tap water, straight
Engine Internal Lubrication antifreeze or straight water in the system.
Tap water contains minerals and impurities
Engine internal parts must be lubricated to protect which build up in the system. Straight water
them from rust formation during the storage peri- will cause the system to freeze while straight
od. antifreeze will cause system temperature prob-
lems.
 WARNING
Change coolant if necessary. Refer to COOLING
This procedure must only be performed in a SYSTEM section.
well-ventilated area. Do not run engine dur-
ing storage period.
CVT TRANSMISSION
Proceed as follows: Pulley Inspection, Cleaning and
Start the engine and allow it to run at idle speed Protection
until the engine reaches its operating tempera- Remove drive belt from pulleys.
ture.
vmr2008-116 7
Section 01 MAINTENANCE
Subsection 03 (STORAGE PROCEDURE)

Inspect and clean pulleys then spray XP-S Lube

(P/N 293 600 016) on pulley faces.
Do not reinstall drive belt. Close CVT cover.

ELECTRICAL SYSTEM
Battery Removal and Storage
Remove the battery. Store it in dry and cool place
out of the sun, refer to BATTERY in CHARGING
SYSTEM section.
vmr2008-116-001_a

VEHICLE 1. Console

Vehicle Cleaning
To facilitate the inspection and ensure adequate
lubrication of components, it is recommended to
clean the entire vehicle.
Wash and dry the vehicle.
CAUTION: Never use a high pressure washer
to clean the vehicle. USE LOW PRESSURE ON-
LY (like a garden hose). The high pressure can
cause electrical or mechanical damages.
Remove any dirt or rust.
To clean the vinyl or plastic parts, use only flannel
vmr2008-116-002_a
clothes with Vinyl & Plastic Cleaner (P/N 413 711
200). 1. CVT inlet hose
2. Air intake inlet
CAUTION: It is necessary to use flannel cloths
on plastic parts to avoid damaging surfaces. The CVT outlet hose is located at the rear of en-
Never clean plastic parts with strong detergent, gine, against vertical frame beam. The removal of
degreasing agent, paint thinner, acetone, prod- the left side panel is necessary to reach the hose.
ucts containing chlorine, etc.
To clean the entire vehicle, including metallic parts
use BRP heavy duty cleaner (P/N 293 110 001).
Inspect the vehicle and repair any damage. Touch
up all metal spots where paint has been scratched
off. Spray all metal parts with XP-S Lube (P/N 293
600 016).

Vehicle Protection
To prevent the intrusion of small animals or oth-
er debris, block the following locations with clean
rags:
vmr2008-116-003_a
– CVT air inlet duct
1. CVT outlet hose
– CVT air outlet duct 2. CVT cover
– Air intake inlet
– Muffler. Protect the vehicle with a cover to prevent dust
accumulation during storage.
CAUTION: Do not forget, these rags must be
removed during preseason preparation before CAUTION: The vehicle has to be stored in a
starting the vehicle. cool and dry place and covered with an opaque
tarpaulin. This will prevent sun rays and grime
To reach the CVT air inlet duct and the air intake from affecting plastic components and vehicle
inlet, lift the console. Refer to BODY. finish.

8 vmr2008-116
 Section 01 MAINTENANCE
Subsection 04 (SPECIAL PROCEDURES)

SPECIAL PROCEDURES
SERVICE PRODUCTS
Description Part Number Page
XP-S Lube ............................................................................. 293 600 016 ....................................... 9–10

NOTE: These procedures give a guideline of Drain air filter housing then clean and dry air filter.
things to do if one of these abnormal situations Remove muffler and empty it. Let muffler dry
occur with the vehicle. then reinstall it on the vehicle.
Flush fuel tank and refill with new gas.
TURN OVER
Lubricate throttle body. Refer to FUEL SYSTEM.
When vehicle is turned over or stays tilted on the
Look for water in:
side, put the vehicle back on its wheels, then wait
3 to 5 minutes before starting the engine. – Brake system (replace brake fluid)
– Differentials (drain oil and check internal parts
Inspect air filter housing drain tube for oil accumu-
for rust or corrosion then refill).
lation, if any oil is found, clean air filter and air filter
housing. Refer to AIR INTAKE SYSTEM section. Lubricate all cables. Check if the cables operate
properly.
Check oil level and refill if necessary.
Spray all metal parts with XP-S Lube (P/N 293 600
Check engine coolant level and refill if necessary.
016).
Start engine and let it run at idle, around 1 minute,
Test ride to confirm all is working well (electrical
then stop engine. Check oil level immediately.
and mechanical components).
CAUTION: Stop engine immediately if the LOW
OIL message and check engine indicator light ATV Submerged for a Short Time
stay ON. (Less than One Hour)
If the engine oil level is good, check the following: Check if engine oil is contaminated (oil will be
– Oil filter for contamination. Replace oil filter and milky). If so, perform the following instructions.
oil. Drain engine oil.
If the problem is still not resolved, check the fol- Drain air filter housing then clean and dry air filter.
lowing:
– Oil pressure switch for damages. Replace it if Look for water in fuel tank, in doubt, flush fuel
necessary. tank and refill with new gas.
– Oil strainer cleanliness and damages. Clean or Drain the CVT housing. Refer to CONTINUOUS-
replace oil strainer. LY VARIABLE TRANSMISSION (CVT).
– Oil pressure regulator valve stays open in the Remove the CVT cover then clean and check all
crankcase due to contamination (metallic parti- parts of CVT.
cles). Clean or replace the valve. Lubricate all cables. Check if the cables operate
– Valve piston stuck in the oil pump housing. Re- properly.
pair valve piston. Remove spark plug then crank engine slowly
– Oil pump cleanliness and operation. Clean or several times.
replace oil pump if necessary.
Add a small quantity of engine oil in cylinder
(approximately 2 teaspoonfuls). Do not reinstall
ATV IMMERSION spark plug at this moment.
ATV Submerged for a Long Time Refill engine at the proper level with the recom-
(Over One Hour) mended oil. Crank engine several times.
Disassemble engine and transmission to clean the Check condition of spark plug. If spark plug ap-
internal parts and check if there is no rust or cor- pears good reinstall it, if not install a new one.
rosion on any internal parts. Refer to the specific
ENGINE section.
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Section 01 MAINTENANCE
Subsection 04 (SPECIAL PROCEDURES)

Start the engine and allow it to run at idle speed

until the engine reaches its operating tempera-
ture.
Stop the engine.
Change engine oil and filter.
NOTE: Change oil as many times as necessary,
until there is no white appearance in engine oil.
Spray all metal parts with XP-S Lube (P/N 293 600
016).
Test drive to confirm all is working well (electrical
and mechanical components).

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 Section 02 TROUBLESHOOTING
Subsection 01 (TECHNICAL GUIDELINES)

TECHNICAL GUIDELINES
The following charts are provided to help in diagnosing the probable source of troubles. It should be used
as a guideline.

ENGINE
Cooling System
Symptom: HIGH ENGINE OPERATING TEMPERATURE
1. Check mud/dust in radiator fins.
- Radiator fin obstructed, hard air cooling. Clean radiator fins.
2. Check coolant level.
- Coolant less than recommended level. Refill.
3. Check radiator cap.
- Defective radiator cap relief valve. Replace.
4. Check vent holes in coolant expansion tank cap.
- Inner cap vent hole of coolant expansion tank is clogged. Replace.
- Cap vent hole of coolant expansion tank is clogged. Replace.
5. Check cooling fan fuse and relay.
- Faulty fan switch and/or faulty fuse. Replace defective part(s).
6. Check cooling fan and connection.
- Fan motor faulty. Replace.
- Wire harness is brittle or hard (no connection). Replace.
7. Check radiator condition for leakage.
- Radiator swelled, cracked or deformed. Replace radiator.
8. Check condition of hoses and clamps fixation.
- Hoses are brittle and/or hard. Replace.
- Hose clamps are loose. Retighten clamps.
9. Check for air bubbles in cooling system.
- Air in cooling system. Refill and bleed cooling system (refer to COOLING SYSTEM).
10. Check engine temperature sensor for electrical/mechanical failure.
- Engine is not overheating. Temperature sensor defective. Replace.
11. Check thermostat.
- Thermostat defective. Replace.
12. Check coolant bleeding screw on thermostat housing.
- Screw is loosed/missing and/or gasket ring is missing/broken. Retighten/add screw and replace
gasket ring.
13. Check gasket(s) of water pump cover.
- Leakage in water pump cover area. Retighten screws and/or replace gasket.
14. Check leak indicator hole (water pump housing area MAG side) if coolant leaks.
- Coolant leaking from leak indicator hole means a damaged rotary seal inside magneto cover.
Replace both rotary seal and oil seal (refer to COOLING SYSTEM and MAGNETO/STARTER).
15. Check condition of water pump impeller.
- Impeller wings broken and/or impeller thread is damaged. Replace.

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Subsection 01 (TECHNICAL GUIDELINES)

Symptom: HIGH ENGINE OPERATING TEMPERATURE (cont’d)

16. Check cylinder head and/or cylinder base gasket.
- Worn out gasket(s) is (are) causing water leakage. Replace gasket(s) and refill with coolant and
oil (refer to COOLING SYSTEM and LUBRICATION SYSTEM ).
17. Check intermediate gear(s) behind magneto cover.
- Worn out and/or broken gear(s) is (are) causing less coolant supply. Replace worn out and/or
broken gear(s) (refer to LUBRICATION SYSTEM and MAGNETO/STARTER).
18. Check if water pump shaft is seized.
- Water pump shaft does not turn. Replace defective part(s).

Lubrication System
Symptom: LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION
1. Check oil level and look for leakage on crankcase and/or defective seals.
- Crankcase is leaking due to damage. Rebuild engine with new crankcase and gasket parts. Use
recommended oil (refer to TECHNICAL SPECIFICATIONS).
- Crankcase is leaking due to loose screws. Retighten screws with recommended torque.
- Sealing rings, O-rings and/or gaskets are brittle and/or hard or damaged. Replace damaged parts.
- Piston rings worn out (blue-colored engine exhaust emission). Replace piston rings (refer to
CYLINDER HEAD/CYLINDER).
- Piston rings are broken (low compression and blue-colored engine exhaust emission). Replace
piston rings (refer to CYLINDER HEAD/CYLINDER).
- Valve stem seal damaged and/or sealing lip is hard and/or brittle. Replace all valve stem seals.
2. Check oil drain plug underneath engine.
- Plug is loosen and/or gasket ring is missing. Retighten the plug and/or place gasket ring.
3. Check leak indicator hole for oil leaks (crankcase MAG, beside water pump housing area).
- Oil leaking from leak indicator hole means a damaged oil seal of water pump shaft inside mag-
neto cover. Replace both rotary seal and oil seal (refer to COOLING SYSTEM and MAGNE-
TO/STARTER).
4. Check oil filter for contamination.
- Oil filter clogged. Replace oil filter and oil at the same time. Use recommended oil (refer to
TECHNICAL SPECIFICATIONS).
5. Check oil pressure switch operation.
- Oil pressure switch damaged. Replace oil pressure switch.
6. Check oil strainer underneath engine.
- Screw(s) is (are) loosed and/or gasket is damaged, brittle or hard. Retighten screw and/or replace
gasket.
- Oil strainer is clogged due to contamination. Clean or replace strainer and diagnose causes. Re-
place possible damaged parts. Use recommended oil (refer to TECHNICAL SPECIFICATIONS).
7. Check oil orifice(s) on the oil pump suction side.
- Oil orifice(s) is (are) clogged. Clean from contamination. Replace oil and oil filter if necessary
(refer to MAINTENANCE or LUBRICATION SYSTEM ).
8. Check oil pressure regulator valve (spring) operation.
- Valve spring damaged (valve always open). Replace spring.
- Valve piston in oil pump housing stays open due to contamination (metallic particles). Clean
and/or repair valve piston and oil pump housing.

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Subsection 01 (TECHNICAL GUIDELINES)

Symptom: LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION (cont’d)

9. Check oil pump operation.
- Oil pump rotor is out of wear limit. Replace oil pump shaft (refer to LUBRICATION SYSTEM).
- Oil pump seized due to oil leakage and/or air inclusion. Replace oil pump (refer to LUBRICATION
SYSTEM).
- Gears driving oil pump are broken or damaged. Replace gears.
- Incorrect oil being used. Use recommended oil (refer to TECHNICAL SPECIFICATIONS).
10. Check plain bearings in crankcase for severe wear.
- Plain bearings out of specification (increased clearance). Replace all plain bearings at the same
time (refer to CRANKCASE/CRANKSHAFT).

Symptom: OIL CONTAMINATION (WHITE APPEARANCE)

1. Check leak indicator hole (crankcase MAG, beside water pump housing area) if water and
oil leaks.
- Leakage of oil/water mixture from leak indicator hole means damaged oil seal and rotary seal
of water pump shaft inside magneto cover. Replace both, rotary seal and oil seal and refill with
recommended oil and/or coolant (refer to COOLING SYSTEM and MAGNETO/STARTER).
2. Check cylinder head and/or cylinder base gasket.
- Gasket damaged or leaking. Retighten cylinder head with recommended torque and/or replace
gasket.
3. Check tightening torque of cylinder head screws.
- Screws not properly tightened. Retighten screws to recommended torque and replace oil.
4. Check oil for particles (may indicate possible damages inside the engine).
- Oil contamination due to metal or plastic particles. Replace possibly damaged parts including oil
and oil filter. Use recommended oil (refer to TECHNICAL SPECIFICATIONS).

Cylinder and Head

Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATION AT IDLE SPEED
1. Check valve adjustment.
- Intake and/or exhaust valves not adjusted correctly. Adjust valves.
2. Check operation of decompressor located on camshaft.
- Decompressor shaft sticks and/or torsion spring is damaged. Replace spring and/or decompres-
sor mechanism.
- Loose camshaft gear. Retighten camshaft gear (refer to CYLINDER HEAD/CYLINDER).
3. Check chain tensioner operation.
- Faulty chain tensioner. Replace spring and/or mechanism.

Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATION WHILE OPERATING

1. Check items of UNUSUAL ENGINE NOISE AND/OR VIBRATION AT IDLE SPEED.
2. Check noise coming from cylinder head area.
- Chain guide worn out. Replace chain guide.
- Stretched chain and/or worn out sprocket. Replace chain and sprocket at the same time.
- Sprocket screw got loose. Retighten screw with recommended torque.
- Rocker arm(s) is (are) worn out (valve adjustment). Replace rocker arm(s) and/or shaft(s) and
readjust valve clearance.
- Thrust washer(s) on rocker arm shaft is (are) missing. Fit thrust washer(s) (refer to CYLINDER
HEAD/CYLINDER).

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Section 02 TROUBLESHOOTING
Subsection 01 (TECHNICAL GUIDELINES)

Crankshaft and Balancer Shaft

Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATIONS
1. Check if mark on balancer shaft is aligned with crankshaft position mark.
- Mark on balancer shaft and crankshaft are not aligned. Readjust position of balancer shaft and
crankshaft (refer to CRANKCASE/CRANKSHAFT).
2. Check for possible plain bearing failure.
- Connecting rod big end clearance is out of specification. Replace damaged and/or worn out
part(s).
- Oil pressure is out of specified values. Replace damaged parts (refer to LUBRICATION SYS-
TEM).
- Connecting rod small end bearing is damaged and/or out of specification. Replace damaged
and/or worn out part(s).
- Crankshaft plain bearing MAG/PTO side is damaged and/or out of specification. Replace crank-
shaft and plain bearing MAG/PTO at the same time (refer to CRANKCASE/CRANKSHAFT).
3. Check ball bearing(s) on balancer shaft end(s).
- Ball bearing(s) do(es) not move freely. Replace bearing(s).

Gearbox
Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATIONS
1. Check oil level in engine.
- Oil leakage from engine. Replace damaged gasket(s) and/or oil seal(s), torque screws and refill
with recommended oil up to specified level (refer to TECHNICAL SPECIFICATIONS).
2. Check magnetic drain plug.
- Magnetic drain plug shows particles. Check engine for internal damage.
3. Check bearings in the gearbox for free movement.
- Bearing(s) do(es) not move freely. Replace bearing(s).
4. Check for knocking noise.
- Tooth of gears are damaged and/or worn. Replace respective gears.

Symptom: GEAR INDICATION FAILS

1. Check wire harness connector pins (gear indicator) and/or multifunction gauge.
- Connector pins are corroded and/or damaged. Clean connector and/or replace wire harness if
damaged.
- Multifunction gauge failed and/or damaged. Repair and/or replace damaged part(s).
2. Check gearbox position switch(es) condition on PTO side (behind CVT driven pulley).
- Gearbox position switch(es) pin(s) is (are) worn and/or damaged. Replace gearbox position
switch(es).
- Contact(s) is (are) corroded and/or contact screw for wire harness got loose. Clean contact sur-
face and retighten contact screw(s) with recommended torque.
- Wire harness has broken cables. Replace wire harness.

Symptom: GEAR(S) IS (ARE) HARD TO SHIFT

1. Check engine idle speed.
- Check throttle cable and its adjustment.
- Check idle air control valve and connectors.

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Subsection 01 (TECHNICAL GUIDELINES)

Symptom: GEAR(S) IS (ARE) HARD TO SHIFT (cont’d)

2. Check transmission lever and connecting rod.
- Ball joint and/or ball joint nut is (are) loose. Retighten or replace the ball joint. Check shifter
adjustment.
3. Check spring on shifter plate.
- Broken spring. Replace the spring.
4. Check for any mud intrusions.
- CVT parts dirty. Clean all CVT parts.
5. Check CVT one way clutch on drive pulley.
- CVT one way clutch was not lubricated correctly. Lubricate CVT one way clutch (refer to CON-
TINUOUSLY VARIABLE TRANSMISSION (CVT)).
- CVT one way clutch is worn out or damaged. Replace defective part(s) (refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT)).
6. Check shift shaft spline and/or shift forks for wear and/or damages.
- Shift shaft is worn out and/or shows damaged splines. Replace shift shaft.
- Shift drum track(s) and/or splines is (are) worn out or damaged. Replace shift drum and damaged
part(s).
- Shift fork(s) is (are) worn out and/or engagement pins are damaged. Replace shift fork(s).
- Shift fork(s) is (are) worn out and/or fork(s) is (are) damaged. Replace shift fork(s).
- Shift gear(s) is (are) worn out. Replace shift gear(s).
- Gearbox position switch(es) pin(s) is (are) worn out (no roundings on top of pin). Replace gearbox
position switch(es).

Rewind Starter
Symptom: REWIND STARTER ROPE DOES NOT REWIND
1. Check rewind spring.
- Broken spring. Replace spring (refer to REWIND STARTER).

Symptom: REWIND STARTER PAWL DOES NOT ENGAGE

1. Check stop spring.
- Broken stop spring. Replace.
2. Check pawl and pawl lock.
- Pawl and pawl lock are stuck together because of heat. Replace.
3. Check pawl and rope sheaves.
- Pawl and rope sheaves are stuck together because of heat. Replace.

CVT TRANSMISSION
Symptom: THE ATV ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED
1. Check drive belt condition.
- Belt is too narrow (drive belt engagement is higher in drive pulley). Replace belt if width is less
than specified (refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT) and/or TECHNICAL
SPECIFICATIONS).

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Section 02 TROUBLESHOOTING
Subsection 01 (TECHNICAL GUIDELINES)

Symptom: THE ATV ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED (cont’d)

2. Check roller(s) on governor cup and/or lever condition on drive pulley sliding sheave.
- Roller(s) is (are) worn and/or damaged (refer to CONTINUOUSLY VARIABLE TRANSMISSION
(CVT)). Replace governor cup assembly.
- Lever(s) on drive pulley sliding sheave is (are) worn and/or damaged (refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT)). Replace all levers at the same time (lever kit).
3. Check drive pulley sliding sheave for free axial movement.
- Sliding sheave is stuck (refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT)). Replace
damaged part(s).
4. Check condition of drive/driven pulley spring.
- Drive pulley spring tension is too smooth and/or damaged (refer to CONTINUOUSLY VARIABLE
TRANSMISSION (CVT)). Replace spring.
- Driven pulley spring tension is too stiff (refer to CONTINUOUSLY VARIABLE TRANSMISSION
(CVT)). Replace spring.
5. Check condition of fixed and sliding sheaves (drive and driven pulley).
- Check surface of fixed and sliding sheaves (drive and driven pulley) for grooves or other damages;
refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT)).
6. Check if cam of driven pulley is worn.
- Replace if out of specifications; (refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT)).

Symptom: ENGINE MAXIMUM RPM IS TOO HIGH AND TOP SPEED IS NOT REACHED
1. Check drive/driven pulley area for contamination and/or water intrusion.
- CVT area is contaminated with water, dirt or oil. Clean CVT system and replace damaged part(s).
2. Check items 1 to 4 of THE ATV ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED.

Symptom: DRIVE PULLEY NOISE AT IDLE SPEED

1. Check slider shoes (drive pulley).
- Worn slider shoes (increased clearance between governor cup and drive pulley sliding sheave).
Replace all slider shoes at the same time (slider shoes kit).
2. Check driven pulley sliding mechanism (between driven pulley outer and inner sheave).
- Mechanism is stuck and/or damaged. Replace driven pulley assembly.
3. Check roller(s) and/or levers for wear (located on sliding sheave of drive pulley).
- Roller(s) on governor cup is (are) worn out and/or damaged (refer to CONTINUOUSLY VARIABLE
TRANSMISSION (CVT)). Replace governor cup assembly.
- Lever(s) on drive pulley sliding sheave is (are) worn out and/or damaged (refer to CONTINUOUS-
LY VARIABLE TRANSMISSION (CVT)). Replace all levers at the same time (lever kit).
4. Check drive pulley screw torque.
- Loose screw. Retighten screw with recommended torque.
5. Check one-way clutch condition on drive pulley sliding sheave.
- Bearing(s) do(es) not move freely. Replace damaged part(s) and lubricate inside of one-way
clutch (refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT)).
- Spring sleeve(s) inside one-way clutch is (are) worn out. Replace both sleeves and springs and
lubricate inside of one-way clutch (refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT)).
- Spring(s) inside one-way clutch is (are) worn out. Replace both pins and springs and lubricate
inside of one-way clutch (refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT)).

Symptom: DRIVE PULLEY NOISE WHEN ACCELERATING/DECELERATING

1. Check items 1 to 5 of DRIVE PULLEY NOISE AT IDLE SPEED.

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Symptom: DRIVE PULLEY NOISE WHEN ACCELERATING/DECELERATING (cont’d)

2. Check if belt runs in dry conditions.
- Drive pulley area is wet/contaminated due to water/dirt intrusion. Clean driven pulley area and/or
drain water out of CVT cover.
3. Check drive/driven pulley screw torque.
- Loose screw on drive and/or driven pulley. Retighten screw with recommended torque.
4. Check cam and driven pulley fixed sheave for wear.
- Cam and/or drive pulley fixed sheave out of wear limit and/or damaged. Replace damaged part(s).
5. Check torque gear in driven pulley sliding sheave for wear.
- Torque gear out of wear limit and/or damaged. Replace torque gear (refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT)).
6. Check for foreign particles in CVT area (stones, dirt, etc.).
- Small particles damaged belt and/or pulley surface(s). Clean system and replace damaged parts
(refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT)).

Symptom: VIBRATIONS ORIGINATING FROM DRIVE PULLEY

1. Check torque of drive pulley screw.
- Moving sliding sheave. Retighten screw.
2. Check fixed sheave bushings.
- Excessive gap between bushings and fixed sheave shaft, thus restraining sliding sheave move-
ments. Replace fixed sheave assembly.
3. Check starter ring gear condition.
- Starter ring gear loosened. Retighten ring gear and/or mount it in original position (balanced
system).
4. Check if slider shoes are present and/or placed in correct position.
- Slider shoe(s) is (are) missing and/or damaged. Replace all slider shoes at the same time (slider
shoes kit).

Symptom: VIBRATIONS ORIGINATING FROM DRIVEN PULLEY

1. Check fixed and sliding sheave bushings on driven pulley.
- Excessive gap between bushings and CVT shaft, thus restraining sliding sheave movements.
Replace fixed and/or sliding sheave of driven pulley, polish CVT shaft area with fine emery cloth
and wipe clean with a cloth.

Symptom: PULLEYS DO NOT DOWNSHIFT OR UPSHIFT PROPERLY

1. Check drive pulley bushings (cleanliness, wear, etc.).
- Bushings stick to fixed sheave pulley shaft. Clean or replace.
- Spring seat sticks to sliding sheave pulley bushing. Clean system and/or replace sliding sheave
pulley.
- One-way clutch does not operate properly. Clean system and/or replace damaged part(s).
2. Check driven pulley spring tension.
- Driven pulley spring tension is too weak and/or broken. Replace.
- Driven pulley cam is worn or damaged. Replace.

Symptom: BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE

1. Check if CVT air intake and/or outlet is clogged.
- CVT area heats up due to contamination. Clean air intake and/or outlet from contamination.
- Fins of drive pulley fixed sheave (underneath ring gear) are clogged. Clean from contamination.

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Subsection 01 (TECHNICAL GUIDELINES)

Symptom: BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE (cont’d)

2. Check if pulley sheaves are clean.
- Oil on pulley surfaces. Clean pulley sheaves and replace belt.
- Water intrusion in CVT area. Find root cause and repair. Drain water and replace belt.

Symptom: BELT WORN EXCESSIVELY ON TOP WIDTH

1. Check drive belt width.
- Considerable wear. Replace belt if narrower than specified (refer to CONTINUOUSLY VARIABLE
TRANSMISSION (CVT) or TECHNICAL SPECIFICATIONS).
2. Check drive belt identification number.
- Improper belt angle (wrong type of belt). Replace belt with an appropriate drive belt.
3. Check for localized belt wear caused by belt slippage.
- Localized wear. Replace belt.

Symptom: BELT DISINTEGRATION

1. Check if drive belt lifetime is exceeded.
- Clean CVT system and rebuild with a new drive belt.
2. Check drive belt identification number.
- Excessive belt speed. Using unspecified type of belt. Replace belt with proper type of belt (refer
to TECHNICAL SPECIFICATIONS).
3. Check if pulley sheaves are clean.
- Oil on pulley surfaces. Clean pulley surfaces with fine emery cloth and wipe clean using Pulley
Flange Cleaner (P/N 413 711 809) and a cloth.
- Drive/driven pulley sheaves are damaged by stones inside CVT area. Clean pulley surfaces with
fine emery cloth, wipe clean with a cloth or replace drive/driven pulley sheaves and belt.

Symptom: FLEX CRACKS BETWEEN COGS

1. Check drive belt condition.
- Considerable use, belt wearing out. Replace.
- Brittle belt condition through aging. Replace belt.

ELECTRICAL SYSTEM
Ignition System
Symptom: NO SPARK OR POOR SPARK
1. Check spark plug cap contact and/or cable.
- Spark plug cap loose. Replug cap.
- Spark plug cable melted and/or damaged. Replace spark plug cable.
2. Check spark plug condition and/or gap.
- Fouled spark plug or wrong spark plug gap. Readjust gap and clean spark plug or replace.
3. Check ignition coil.
- Check ignition coil input voltage and continuity of the appropriate circuit of the wiring harness.
Repair the connectors or replace the wiring harness between ECM connector and the ignition
coil, refer to IGNITION SYSTEM.
- Perform ignition coil resistance test. Replace ignition coil. Refer to IGNITION SYSTEM.
4. Check crankshaft position sensor.
- Test sensor operation. Replace if faulty. Refer to ELECTRONIC FUEL INJECTION.
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 Section 02 TROUBLESHOOTING
Subsection 01 (TECHNICAL GUIDELINES)

Starting System
Symptom: STARTER DOES NOT TURN
1. Check that multifunction gauge and taillight turn on when ignition switch is turned on and
engine stop switch is set to RUN.
- Check main fuse and ECM fuse. Replace if faulty.
- Repair or replace faulty switch(es) or repair wiring harness.
2. Transmission not set to Park or Neutral.
- Set transmission to PARK or NEUTRAL.
3. Poor contact of battery terminal(s) or ground cable connections.
- Clean and tighten terminal(s).
4. Weak or faulty battery.
- Recharge or replace battery.
5. Poor contact or open circuit of start switch or starting solenoid.
- Check and replace defective part.
6. Gear selection indicator switch(es) is (are) defective.
- Check switch(es) and wiring connection. Refer to CRANKCASE/CRANKSHAFT.
7. Diode (D4) failure.
- Check diode condition of starter solenoid circuit. Refer to STARTING SYSTEM.
8. Starter, starter drive or starter bushings defective or worn out.
- Check or replace the faulty component. Refer to CRANKCASE/CRANKSHAFT and STARTING
SYSTEM.
9. Engine mechanical problem (ensure that other electric components are good).
- Check and replace defective part.

Symptom: STARTER TURNS BUT DOES NOT CRANK THE ENGINE

1. Check gear condition on electric starter.
- Worn and/or damaged starter gear. Replace electric starter and/or starter drive.
2. Check condition of starter pinion gear.
- Worn and/or damaged starter pinion and/or ring gear. Replace starter drive and/or drive pulley
fixed sheave.
3. Check splines on starter drive.
- Poor movement of pinion gear on splines. Clean and/or replace starter drive.

Symptom: STARTER KEEPS RUNNING

1. Check splines on starter drive.
- Poor movement of pinion gear on splines. Clean and/or replace starter drive.

CHARGING SYSTEM
Symptom: BATTERY NOT CHARGING OR CHARGING VOLTAGE INADEQUATE
1. Check battery.
- Battery is discharged. Recharge battery.
- Battery does not remain charged. Check battery and charging system. Refer to CHARGING
SYSTEM.

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Section 02 TROUBLESHOOTING
Subsection 01 (TECHNICAL GUIDELINES)

Symptom: BATTERY NOT CHARGING OR CHARGING VOLTAGE INADEQUATE (cont’d)

2. Check voltage regulator/rectifier.
- Refer to CHARGING SYSTEM.
3. Check wiring harness for cracks or other damages.
- Harness shows electrical failure and/or other damages. Replace/repair wiring harness.
4. Check magneto for damage and/or electrical failure.
- Radial position of rotor wrong due to a broken Woodruff key. Replace Woodruff key.
- Connector on magneto is damaged and/or has electrical failure. Repair and clean contacts of
connector.
- Coating on stator winding is damaged. Replace stator.
- Resistance value is out of specification (refer to CHARGING SYSTEM). Replace stator.
- Weak magneto magnets. Replace magneto.

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Subsection 02 (DIAGNOSTIC FLOW CHART)

DIAGNOSTIC FLOW CHART

FUEL SYSTEM
Fuel pump does not run Turn ignition key ON and set engine Fuel pump runs
for 5 sec. then stops
stop switch to RUN

- Check fuses and relays.

- Check ignition switch and
engine stop switch. Install fuel pressure gauge
- Check fuel pump operation. on fuel pressure line
- Repair or replace if necessary.

Turn ignition key ON and set engine Replace fuel

stop switch to RUN pump module

Fuel pump runs

Repair or Fuel pressure less Fuel pressure is Fuel pressure more

replace than 350 kPa (51 PSI) 350 kPa (51 PSI) than 350 kPa 51 PSI)

Fails Check fuel line/

rail for leaks
OK
Fails Crank or Start engine
Perform fuel pump test

OK

Fast No Fuel pressure less Fuel pressure more Fuel pressure is

pressure drop than 350 kPa (51 PSI) than 350 kPa (51 PSI) 350 kPa (51 PSI)
Yes
OK Check
Verify fuel
pump check fuel line/ Repair or
valve rail for leaks Fails FUEL SYSTEM OK
replace

OK
Fails
Fails

OK
Check fuel Perform fuel Replace fuel
injectors pump test pump module Retest
Fails
OK

vmr2008-023-100_aen

vmr2008-119 21
 Section 03 ENGINE
Subsection 01 (ENGINE REMOVAL/INSTALLATION)

ENGINE REMOVAL/INSTALLATION
SERVICE TOOLS
Description Part Number Page
lifting tool.............................................................................. 529 035 619 ........................................... 28
engine lifting tool .................................................................. 529 035 898 ........................................... 28

SERVICE PRODUCTS
Description Part Number Page
Loctite 243 (blue).................................................................. 293 800 060 ........................................... 29

vmr2008-120 23
Section 03 ENGINE
Subsection 01 (ENGINE REMOVAL/INSTALLATION)

4 N•m
(35 lbf•in)

48 N•m
(35 lbf•ft)
Loctite
243

7 N•m
(62 lbf•in)

7 N•m
(62 lbf•in)

61 N•m
(45 lbf•ft)
61 N•m
(45 lbf•ft)

25 N•m
(18 lbf•ft)

vmr2008-120-001_a

24 vmr2008-120
 Section 03 ENGINE
Subsection 01 (ENGINE REMOVAL/INSTALLATION)

GENERAL
 WARNING
To avoid potential burns, let engine and ex-
haust system cool down before performing
any servicing.

During assembly/installation, use the torque val-

ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE vmr2008-120-002_a
APPLICATION at the beginning of this manual for
1. Engine cover
complete procedure.

 WARNING Drain engine oil. Refer to LUBRICATION SYSTEM

section for procedure.
Torque wrench tightening specifications
Drain cooling system. Refer to COOLING SYS-
must be strictly adhered to.
TEM section.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pin, Remove the rear propeller screw.
etc.) must be replaced with new ones.

Hoses or cables removed or disconnected must

be installed and routed at the same place.
CAUTION: Locking ties removed during a pro-
cedure must be replaced and installed at the
same location.

PROCEDURES
ENGINE
Engine Removal vmr2008-120-003_a

Place the vehicle on a workstation that will have 1. Rear propeller shaft screw
access to an engine-lifting hoist. 2. Rear propeller shaft

Place the transmission lever on “P” position. Unplug the vehicle speed sensor (VSS), oil pres-
Disconnect BLACK (-) cable from battery, then sure sensor (OPS) and the indicator switches con-
RED (+) cable. nectors.
Using procedures described in BODY section, re-
move the following parts:
– Seat(s)
– LH and RH side panels
– LH and RH footrests.
Remove the air filter housing. Refer to AIR IN-
TAKE SILENCER section.
Remove the engine cover.

vmr2008-120-004_a

1. OPS connector
2. VSS connector
3. Indicator switches connector

vmr2008-120 25
Section 03 ENGINE
Subsection 01 (ENGINE REMOVAL/INSTALLATION)

Detach link rod from shifting plate.

vmr2008-120-008_a

1. Coolant hose
2. Throttle body

vmr2008-120-005_a Unplug the cooling temperature sensor (CTS).

1. Link rod Unplug the crankshaft position sensor (CPS) con-
2. Shifting plate
nector.
Disconnect coolant hose from water pump cover.

vmr2008-120-009_a

1. CTS connector
2. CPS connector
vmr2008-120-006_a

1. Coolant hose Unplug the magneto connector.

2. Water pump cover

Unscrew the engine ground cable from the en-

gine.
Remove the starter cable from the starter.

vmr2008-120-010_a

1. Magneto connector
2. Ignition coil

Remove screws securing the coupling unit to en-

vmr2008-120-007_a
gine.
1. Engine ground cable
2. RED starter cable

Disconnect coolant hose from cylinder head.

26 vmr2008-120
 Section 03 ENGINE
Subsection 01 (ENGINE REMOVAL/INSTALLATION)

vmr2008-120-012_a
vmr2008-120-014_a
1. Coupling unit screws
1. Caliper screws
Unscrew exhaust pipe nuts.
Remove differential bolts.

vmr2008-120-013_a

vmr2008-120-016_a
1. Exhaust pipe nuts
1. Differential bolts
Apply parking brake and remove the four (4)
screws retaining the brake disc to LH drive shaft. Remove exhaust pipe. Refer to EXHAUST SYS-
TEM section.
Remove the upper engine support.

vmr2008-120-015_a

1. Brake disc screws

vmr2008-120-017_a

Release parking brake and remove screws secur- 1. Engine support bolts
ing the front LH caliper.
Remove the spark plug cable.

vmr2008-120 27
Section 03 ENGINE
Subsection 01 (ENGINE REMOVAL/INSTALLATION)

vmr2008-120-018_a

1. Spark plug cable

Remove the intake adaptor from cylinder head. V07C1DA

TYPICAL

Install the lifting tool (P/N 529 035 619) to tilt en-
gine.

vmr2008-120-019_a

1. Intake adaptor screws

2. Throttle body

Temporarily, attach throttle body, all cables, wires

and hoses on the frame.
Detach the CVT air inlet duct.
V07C17A 1
TYPICAL
1. Lifting tool

On both sides, remove bolts securing the front

engine support to frame.

vmr2008-120-020_a

1. CVT air inlet duct

2. CVT cover

Install the engine lifting tool (P/N 529 035 898) in

lifting location. vmr2008-120-021_a

1. Front LH engine support

2. Engine support bolts

Remove the rear engine mounting bolt.

28 vmr2008-120
 Section 03 ENGINE
Subsection 01 (ENGINE REMOVAL/INSTALLATION)

ENGINE MOUNT
NOTE: Use the same procedure for the front and
rear engine mounts.

Engine Mount Removal

Insert a punch in hole of engine mount bushing
and push the other bushing out of the housing.

vmr2008-120-022_a

1. Rear engine mounting bolt

Lift engine approximately 25.4 to 38 mm (1 to

1-1/2 in).
Move engine and front differential forward to dis-
connect the rear propeller shaft from engine.
V07C1FA

Lift engine a little more to clear rear mounting

TYPICAL
bracket from frame.
Turn the rear of engine toward left side to disen- Use punch to remove the other bushing.
gage the front propeller shaft from the coupling
unit.
Take the engine out of the frame.

Engine Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Lift engine and move it into the frame (cylinder
head first).
Insert the front engine output shaft end into the
coupling unit. V07C1GA

Move the rear side of engine into the frame and TYPICAL
install the rear propeller shaft.
Lower engine into place.
Engine Mount Installation
Install front engine support bolts. Do not torque
The installation is the reverse of the removal pro-
yet.
cedure.
Install rear engine mounting bolt.
When installing the upper engine support, apply
Loctite 243 (blue) (P/N 293 800 060) on threads of
lower bolts M10.
Tighten all bolts.
Install all other removed parts.
Fill engine with recommended engine oil and
coolant. Refer to LUBRICATION SYSTEM and
COOLING SYSTEM sections.
Start vehicle and check for leaks.
Stop engine and check if coolant and oil levels are
correct.
Test drive vehicle to confirm proper operation.
vmr2008-120 29
 Section 03 ENGINE
Subsection 02 (AIR INTAKE SYSTEM)

AIR INTAKE SYSTEM

SERVICE PRODUCTS
Description Part Number Page
air filter cleaning solution...................................................... 219 700 341 ........................................... 32

Throttle body
1.2 N•m
(9 lbf•in)

Crankcase

vmr2008-121-001_a

vmr2008-121 31
Section 03 ENGINE
Subsection 02 (AIR INTAKE SYSTEM)

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

 WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic vmr2008-121-005_a

stop nuts, self-locking fasteners, etc.) must

be installed or replaced with new ones where
specified. If the efficiency of a locking device
is impaired, it must be renewed.

PROCEDURES
AIR FILTER
Air Filter Removal
CAUTION: Never remove or modify any com-
ponent in the air filter housing. The engine
is calibrated to operate specifically with these
components. Otherwise, engine performance vmr2008-121-006_a

degradation or damage can occur.

If liquid or deposits are found, clean the foam pre-
Remove seat and RH side panel. Refer to BODY. filter. Replace filter element if damaged.
Release clamps and remove air filter housing cov- CAUTION: Do not start engine if liquid or de-
er. posit are found. If there is oil in the air filter
housing, check engine oil level. Oil level may
be too high.

Air Filter Cleaning

Foam Prefilter
Pour air filter cleaning solution (P/N 219 700 341)
or an equivalent into a bucket. Put the foam filter
in to soak.
While filter soaks, clean inside of air filter housing.
Rinse foam prefilter with warm water and let it dry
completely.
Air Filter
vmr2008-121-002_a Blow low pressure compressed air on filter ele-
Loosen clamp and remove air filter. ment to clean it.

Air Filter Installation

Properly reinstall removed parts in the reverse or-
der of their removal.

32 vmr2008-121
 Section 03 ENGINE
Subsection 02 (AIR INTAKE SYSTEM)

AIR FILTER HOUSING Remove air filter housing cover.

Detach inlet tube.
Air Filter Housing Draining
Remove retaining screws of air filter housing.
Periodically inspect air filter housing drain tube for
liquid or deposits. Cut locking tie.

vmr2008-121-003_a
vmr2008-121-008_a

NOTE: If vehicle is used in muddy area, inspect On LH side of vehicle, do the following:
more frequently than specified in maintenance
chart. Remove the LH side panel.
If liquid or deposits are found, squeeze and re- Detach throttle body.
move the drain tube clamp. Pull drain tube out and Detach crankcase vent hose.
empty it. Remove retaining screws of air filter housing.

vmr2008-121-009_a
vmr2008-121-004_a

CAUTION: Do not start engine if liquid or de- Pull out air filter housing.
posit are found in the drain tube. If there is oil
in the air filter housing, check engine oil level. Air Filter Housing Installation
Oil level may be too high. For installation, reverse the removal procedure.
Inspect air filter. CAUTION: Pay attention to fuel hoses and fit-
tings on fuel tank.
Air Filter Housing Removal
Remove seat and console. Refer to BODY.
On RH side of vehicle, perform the following:
Remove the RH side panel.
vmr2008-121 33
 Section 03 ENGINE
Subsection 03 (EXHAUST SYSTEM)

EXHAUST SYSTEM
Outlander 400 EFI 3.5 N•m
Outlander 400 EFI XT 3.5 N•m (31 lbf•in)
(31 lbf•in)

NEW

13 N•m
25 N•m (115 lbf•in)
(18 lbf•ft)
NEW
10 N•m 6 N•m
(89 lbf•in) (53 lbf•in)

3.5 N•m
(31 lbf•in)
3.5 N•m
(31 lbf•in)

6 N•m NEW
(53 lbf•in)

10 N•m
(89 lbf•in)

13 N•m
25 N•m (115 lbf•in)
(18 lbf•ft) NEW
6 N•m
(53 lbf•in)

Outlander MAX 400 EFI

Outlander MAX 400 EFI XT
vmr2008-122-001_a

vmr2008-122 35
Section 03 ENGINE
Subsection 03 (EXHAUST SYSTEM)

GENERAL
 WARNING
To avoid potential burns, never touch exhaust
system components immediately after the
engine has been run because these compo-
nents are very hot. Let engine and exhaust
system cool down before performing any
servicing.

During assembly/installation, use the torque val- vmr2008-122-002_a

ues and service products as in the exploded MAX SERIES ONLY

views. 1. Storage tray

Clean threads before applying a threadlocker. Re- Remove seat support with the heat shield.
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

 WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pin,
etc.) must be replaced with new ones.

Always inspect exhaust system parts for the fol-

lowing defects or damages:
vmr2008-122-003_a
– Cracks
1. Seat support screws
– Tearing
– Bending On MAX Series, remove the rear heat shield.
– Dents
– Corrosion
– Leaks
– Any other damage or defect which could affect
system performance.
Replace if required.

PROCEDURES
MUFFLER
vmr2008-122-004_a

Muffler Removal MAX SERIES ONLY

1. Heat shield screws
Refer to BODY section to remove the following
components: Unscrew muffler clamp at exhaust pipe.
– Seat(s)
– LH side panel.
On MAX Series, remove the storage tray.

36 vmr2008-122
 Section 03 ENGINE
Subsection 03 (EXHAUST SYSTEM)

Install muffler bolt. Use the following illustration

to position parts properly.

vmr2008-122-005_a

1. Exhaust pipe
2. Muffler clamp
3. Muffler

While supporting muffler, unscrew muffler bolts. vmr2008-122-008_a

1. Spacer (MAX Series only)

2. Flat washer M8
3. Muffler
4. Large washer
5. Muffler bolt

Torque muffler clamp to 25 N•m (18 lbf•ft).

EXHAUST PIPE
Exhaust Pipe Removal
Remove the MUFFLER, see procedure above in
vmr2008-122-006_a
this section.
1. Muffler bolts
Remove the RH inner fender. Refer to BODY sec-
Carefully remove muffler from exhaust pipe. tion.
Discard old muffler gasket. Unscrew exhaust pipe nuts.

Muffler Installation
Install a NEW muffler gasket.

vmr2008-122-009_a

1. Exhaust pipe
2. Exhaust pipe nuts

Push the exhaust pipe forward then remove it.

vmr2008-122-007_a
Remove the exhaust gasket from engine exhaust
1. Muffler gasket port.
2. Exhaust pipe
Exhaust Pipe Inspection
Insert muffler clamp over exhaust pipe.
Check exhaust pipe for:
Insert muffler on exhaust pipe.
– Cracks
NOTE: Make sure exhaust pipe joint is positioned – Bending
correctly to prevent leakage.
– Other damages.
Replace as required.
vmr2008-122 37
Section 03 ENGINE
Subsection 03 (EXHAUST SYSTEM)

Exhaust Pipe Installation

Install a NEW exhaust gasket on exhaust pipe end
(cylinder head side).
Secure exhaust pipe on cylinder head with ex-
haust nuts. Do not tighten yet.
Install muffler.
Align all parts then tighten nuts, clamp and bolts.

38 vmr2008-122
 Section 03 ENGINE
Subsection 04 (REWIND STARTER)

REWIND STARTER
SERVICE PRODUCTS
Description Part Number Page
Loctite 243 (blue).................................................................. 293 800 060 ..................................... 43–44
Molykote PG 54.................................................................... 420 899 763 ........................................... 41

6
Loctite
243
5
3

4
7
15
8 N•m 2
(71 lbf•in)
8
Molykote Pg 54 9
10
11
12
Molykote Pg 54 14
13

Molykote Pg 54
6.5 N•m
(58 lbf•in)

Loctite 243
25 N•m
(18 lbf•ft)

R400motr218U

vmr2008-123 39
Section 03 ENGINE
Subsection 04 (REWIND STARTER)

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

 WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, etc.) must R400motr219A 1
be installed or replaced with new ones where 1. Rope
specified. If the efficiency of a locking device
is impaired, it must be renewed. Untie knot holding rewind starter grip and remove
grip.

PROCEDURES
REWIND STARTER
Rewind Starter Removal
Remove engine cover.

R400motr220A 2 1
1. Starter housing
2. Rewind starter grip

Finally untie the other knot and slowly release rope

into starter housing to release spring tension.
CAUTION: Hold rope sheave to slow down the
spring tension effect while releasing the rope
into starter housing.

vmr2008-123-100_a

Remove rewind starter mounting bolts no. 15 and 1

pull rewind starter.
To release tension from torsion spring no. 2:
First pull grip no. 6 and tie a knot more than 20 cm
(8 in) below it.

R400motr221A 2
1. Direction to release spring tension
2. Rope sheave

40 vmr2008-123
 Section 03 ENGINE
Subsection 04 (REWIND STARTER)

Rewind Starter Disassembly At assembly, position spring no. 2 outer end into
spring guide notch. Use appropriate ring to push
 WARNING spring into starter housing as illustrated.
Spring tension has to be released prior to
withdraw the rewind starter sheave.  WARNING
Since the spring is tightly wound inside the
To remove rope no. 5 from rewind starter mech- guide it may fly out when rewind is handled.
anism: Always handle with care.
First remove flat washer no. 11 and screw no. 12,
locking spring no. 10, locking spring washer no. 9,
pawl lock no. 8 and pawl no. 7.
NOTE: Use two flat screwdrivers to withdraw
locking spring washer no. 9.
Remove sheave no. 3 from starter housing no. 1. A
Disengage key no. 4 and pull out rope no. 5.

 WARNING
Torsion spring is tightly wound inside the
guide. Handle with care and always wear
safety goggles and hand gloves.

R400motr223A 1 2 3
TYPICAL
1. Outer end into guide notch
2. Apply Molykote PG 54 inside spring guide
3. Ring for spring installation
A. 82 + .2 mm (3.23 + .008 in)

NOTE: Due to dust accumulation, rewind starter

must be periodically cleaned, inspected and relu-
bricated.
R400motr222A
NOTICE It is of the utmost importance that
the rewind starter spring(s) be lubricated peri-
TYPICAL — GENTLY TAP ON KEY odically using specific lubricants. Otherwise,
rewind starter component life will be short-
 WARNING ened and/or rewind starter will not operate
Never remove spring out of starter housing properly under very cold temperatures.
except if spring is damaged. Torsion spring Lubricate spring assembly with Molykote PG 54
is spring loaded, so handle with care and al- (P/N 420 899 763) and position into starter housing
ways wear safety goggles and hand gloves. as illustrated.

Rewind Starter Assembly

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

 WARNING
Always install new spring into starter hous-
ing. Torsion spring is spring loaded, so
handle with care during installation. Always
wear safety goggles and hand gloves.

vmr2008-123 41
Section 03 ENGINE
Subsection 04 (REWIND STARTER)

Install locking spring no. 10.

R400motr224A 1
TYPICAL
1. Apply Molykote PG 54 in spring area
R400motr227A 1 3 4 2
NOTICE The use of standard multipurpose TYPICAL
1. Locking spring
grease could result in rewind starter malfunc- 2. Pawl
tion. 3. Pawl lock
4. Locking spring washer
To install a new rope no. 5, insert rope into sheave
orifice and lock it with the key no. 4 as illustrated. Install washer no. 11 and torque screw no. 12.
1 2

R400motr229A 1 2
R400motr225A
1. Washer
2. Screw
TYPICAL
1. Punch
2. Key Rotate rope sheave clockwise until rope end is
A. Maximum 14 mm (.55 in)
B. Rope overstand 20 to 25 mm (.787 to .984 in)
accessible through starter housing orifice.
Pull rope out of the starter housing and temporarily
To Adjust Rope Tension: hold it.
Wind rope on sheave and place rope sheave into NOTE: It is recommended to use a hose clamp to
starter housing making sure that the sheave hub fix rope in place. A knot can get too tight.
notch engages in the rewind spring hook.

 WARNING
To prevent spring from flying out of the
guide, it is mandatory to secure rope sheave
in place. Always handle with care and use
safety goggles and hand gloves.

Position pawl no. 7, pawl lock no. 8 and locking

spring washer no. 9.
42 vmr2008-123
 Section 03 ENGINE
Subsection 04 (REWIND STARTER)

Rewind Starter Installation

For installation, reverse the removal procedure.
Pay attention to the following details.
Prior to reinstalling rewind starter on engine, clean
threads from Loctite deposits.
NOTE: Before torquing mounting bolts no. 15,
apply Loctite 243 (blue) (P/N 293 800 060) on
1 threads.

R400motr226A 2
TYPICAL
1. Turn clockwise
2. Position to fix rope in place

Thread starter rope no. 5 through rope guide when

applicable.
Prior to installing starter grip on new rope, it is first
necessary to fuse the rope end with a lit match.

R400motr228A

TYPICAL
1. Fuse end of starter rope

Pass rope through starter grip, tie a knot in the

rope end.

R400motr230A

TYPICAL

Insert rope end down and pull the starter grip over
the knot.

vmr2008-123 43
Section 03 ENGINE
Subsection 04 (REWIND STARTER)

STARTING PULLEY
Starting Pulley Removal
Remove rewind starter.
Remove screw no. 13 and starting pulley no. 14
from crankshaft MAG side.

Starting Pulley Installation

For installation, reverse the removal procedure.
Pay attention to the following details.
CAUTION: Take care to have the starting pulley
well mounted on crankshaft end.
Apply Loctite 243 (blue) (P/N 293 800 060)
on threads and torque the screw to 25 N•m
(18 lbf•ft).

44 vmr2008-123
 Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

LUBRICATION SYSTEM
SERVICE TOOLS
Description Part Number Page
adapter hose......................................................................... 529 035 652 ........................................... 50
pressure gauge..................................................................... 529 035 709 ........................................... 50

SERVICE PRODUCTS
Description Part Number Page
XP-S 5W30 4-stroke oil......................................................... 219 700 706 ........................................... 47
XP-S 5W40 synthetic oil ....................................................... 293 600 039 ........................................... 47
Loctite 243 (blue).................................................................. 293 800 060 ........................................... 51

vmr2008-124 45
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

Engine oil

2
NEW

10 N•m
(89 lbf•in)
13
NEW
Engine oil 12 N•m 5
Engine oil (106 lbf•in) Loctite
Engine 243
10 N•m oil
(89 lbf•in) 7

9
6
30 N•m 4 NEW
(22 lbf•ft) 3 10 12
8

M18 x 1.5
11

Engine oil

10 N•m
(89 lbf•in)

vmr2008-124-001_a

46 vmr2008-124
 Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

GENERAL Engine Oil Viscosity Chart

During assembly/installation, use the torque val-
ues and service products as in the exploded SAE 0W30
views. SAE 5W30 (XP-S 5W30 Mineral Oil)
Clean threads before applying a threadlocker. Re-
SAE 10W30
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for SAE 5W40 (XP-S 5W40 Synthetic Oil)
complete procedure.
SAE 10W40 (XP-S 10W40 Mineral Oil)
 WARNING SAE 15W40
Torque wrench tightening specifications
must be strictly adhered to. SAE 20W50
Locking devices (e.g.: locking tabs, elastic TEMPERATURE RANGE
stop nuts, self-locking fasteners, cotter pin, 50°C (122°F)
etc.) must be installed or replaced with new 40°C (104°F)
ones where specified. If the efficiency of 30°C (86°F)
a locking device is impaired, it must be re- 20°C (68°F)
newed. 10°C (50°F)
0°C (32°F)
- 10°C (14°F)
MAINTENANCE - 20°C (- 4°F)
- 30°C (- 22°F)
ENGINE OIL
Oil Level Verification
Recommended Oil
CAUTION: Check level frequently and refill
Use 4-stroke SAE 5W30 engine oil that meets or if necessary. Do not overfill. Operating the
exceeds the requirements for API service classifi- engine/transmission with an improper level
cation SM, SL or SJ. Always check the API service may severely damage engine/transmission.
label certification on the oil container it must con- Wipe off any spillage.
tain at least one of the above standards.
The XP-S 5W30 4-stroke oil (P/N 219 700 706) is
recommended.
For improved overall performance and all season
application, use XP-S 5W40 synthetic oil (P/N 293
600 039).

V07C24A

RH SIDE OF ENGINE
1. Dipstick

With vehicle on a level surface and engine cold,

not running, check the oil level as follows:
1. Unscrew dipstick no. 1 then remove it and
wipe clean.
2. Reinstall dipstick, screw in it completely.

vmr2008-124 47
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

3. Remove and check oil level. It should be near

or equal to the upper mark.

vmr2008-124-101_a

vmr2008-124-100_a
1. Dipstick
2. O-ring
1. Full
2. Add Unscrew drain plug no. 3.
3. Operating range

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

the dipstick tube to avoid spillage.
Add a small amount of recommended oil and
recheck oil level.
Repeat the above procedures until oil level reach-
es the dipstick's upper mark. Do not overfill.
Properly tighten dipstick.

Engine Oil Replacement

Prior to change the oil, ensure vehicle is on a level
surface.
Oil and oil filter no. 2 must be replaced at the same
time. Oil change and oil filter replacement should
vmr2008-124-102_a
be done with a warm engine.
SEEN FROM RH SIDE, UNDERNEATH VEHICLE
 WARNING
Allow oil to drain completely from crankcase.
The engine oil can be very hot. Wait until en-
gine oil is warm. Clean the magnetic drain plug from metal shav-
ings and residue. Presence of debris gives an in-
dication of failure inside the engine.
Place a drain pan under the engine drain plug area.
Install a new gasket ring no. 4 on drain plug.
Clean the drain plug area.
Remove dipstick. CAUTION: Never use the gasket ring a second
time. Always replace by a new one.
CAUTION: Pay attention not to lose the O-ring Torque drain plug to 30 N•m (22 lbf•ft).
on dipstick.
Replace the oil filter.
Refill engine with recommended engine oil. Oil
change capacity with filter is 3 L (3.17 qt).
After filling, check the oil level with the dipstick.
Refer to OIL LEVEL CHECK above.
NOTE: Run engine to ensure oil filter and drain
plug areas are not leaking.

48 vmr2008-124
 Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

Dispose oil and filter as per your local environmen-

tal regulations.

OIL FILTER
Oil Filter Removal
Remove:
– Engine cover

R400motr112A 2 1
1. Inlet bore from the oil pump to the oil filter
2. Outlet bore to the engine oil providing system

Oil Filter Installation

The installation is the opposite of the removal pro-
cedure. Pay attention to the following details.
vmr2008-123-100_a
Apply oil on rubber seal of oil filter to ensure proper
installation.
– Oil filter screws Install O-ring on oil filter cover.
– Oil filter cover with O-ring
– Oil filter.

R400motr113A
R400motr111A 4 3 2 1
1. O-ring in place
1. Oil filter screws
2. Oil filter cover
3. O-ring
4. Oil filter
INSPECTION
Oil Filter Inspection ENGINE OIL PRESSURE TEST
Check oil filter cover O-ring, change it if necessary. NOTE: The engine oil pressure test should be
Check and clean the oil filter inlet and outlet area done with a warm engine and the recommended
for dirt and other contaminations. oil.
Remove the oil pressure switch no. 5.

vmr2008-124 49
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

vmr2008-124-103_A
vmr2008-124-105_a

Install the pressure gauge (P/N 529 035 709) and

Start engine and measure oil pressure as per fol-
the adapter hose (P/N 529 035 652) to the switch
lowing table.
hole.
The engine oil pressure should be within the fol-
lowing values.

PRESSION/
1300 RPM 6000 RPM
RPM
Minimal 70 kPa (10 PSI) 350 kPa (51 PSI)
529 035 709
Nominal 350 kPa (51 PSI) 500 kPa (73 PSI)
Maximal 550 kPa (80 PSI) 700 kPa (102 PSI)

If the engine oil pressure is out of specifications,

check the points described in TECHNICAL GUIDE-
LINES (TROUBLESHOOTING) section.

PROCEDURES
529 035 652 OIL PRESSURE SWITCH

vmr2008-124-103_a

50 vmr2008-124
 Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

Oil Pressure Switch Activation OPS CIRCUIT MEASUREMENT

Oil pressure switch is normally closed and it opens RESISTANCE
when engine runs and pressure reaches 30 and OPS PIN ECM PIN
@ 20°C (68°F)
60 kPa (4.4 and 8.7 PSI). So, when engine runs,
switch is open and if pressure goes to low, the 1 E2 Close to 0
switches closes.
To check the function of the oil pressure switch,
an oil pressure test has to be performed. Refer to
ENGINE OIL PRESSURE.
If the engine oil pressure is good, check the resis-
tance of the oil pressure switch while engine is off
and while engine is running.

Oil Pressure Switch Resistance Test

Disconnect the connector from the oil pressure
switch.
Use a multimeter and select to check the resis-
tance as shown.

OPS ENGINE NOT ENGINE

CONNECTOR RUNNING RUNNING vmr2008-124-104_b

PIN RESISTANCE
Oil Pressure Switch Removal
Infinitely
Unplug and unscrew the oil pressure switch no. 5.
Close to 0 high when
Engine
1 (normally pressure reaches
ground
closed switch) 30 - 60 kPa
(4.4 - 8.7 PSI)

vmr2008-124-103_A

Oil Pressure Switch Installation

Apply Loctite 243 (blue) (P/N 293 800 060) and
vmr2008-124-104_a torque switch to 12 N•m (106 lbf•in).
If resistance values are incorrect, replace the oil Plug switch connector.
pressure switch.
If the values are correct, check the continuity of OIL STRAINER
the wiring harness.
Oil Strainer Removal
Disconnect the ECM connector and check conti-
Engine must be lifted or removed to access the
nuity of circuit between switch and ECM.
oil strainer. Refer to the ENGINE REMOVAL/IN-
STALLATION.

vmr2008-124 51
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

Drain engine oil, refer to OIL CHANGE in this sec- Inspect O-ring on the oil collector and rubber ring
tion. on the oil strainer cover.
Remove screws retaining oil strainer cover. If O-ring and/or rubber ring is (are) brittle, cracked
or hard, replace the defective part(s).
2
Clean both contact surfaces of oil strainer cover.
Check and clean the oil inlet and outlet area for dirt
and other contaminations.

R400motr114A 2 1
1. Oil strainer cover
2. 5 screws
R400motr116A 2 1 3
Remove oil collector with O-ring and oil strainer.
1. Oil inlet to the oil pump
2. Oil return from the oil pressure regulator system
1 2 3. Oil return from the engine oil circulation

Oil Strainer Installation

For installation, reverse the removal procedure.
Torque oil strainer cover screws as per following
sequence.

4
R400motr115A
3
1. Oil collector with O-ring
2. Oil strainer
2

Oil Strainer Cleaning and Inspection

Clean oil strainer with a part cleaner then use an
R400motr114B
air gun to dry it.

 WARNING
Reinstall engine in vehicle. Refill engine at the
proper level with the recommended oil.
Always wear eye protector. Chemicals can Start engine and let idle for a few minutes. Ensure
cause a rash break out in and an injury to your oil filter and magnetic drain plug areas are not leak-
eyes. ing.

52 vmr2008-124
 Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

Stop engine. Wait a while to allow oil to flow Oil Pressure Regulator Inspection
down to crankcase then check oil level. Refill as Inspect valve piston for scoring or other damages.
necessary.
Check compression spring for free length.
ENGINE OIL PRESSURE COMPRESSION SPRING FREE LENGTH
REGULATOR
NEW NOMINAL 64 mm (2.519 in)
The oil pressure regulator is located in the oil pump
SERVICE LIMIT 62 mm (2.441 in)
housing (engine MAG side, behind magneto cov-
er).
Replace both parts if important wear or damage
are present.
Clean bore and threads in the oil pump housing
from metal shavings and other contaminations.

Oil Pressure Regulator Installation

For installation, reverse the removal procedure.

OIL PUMP
The oil pump is located on the engine MAG side
(refer to ENGINE OIL PRESSURE REGULATOR).

Oil Pump Removal

Remove:
1 2 – Engine from vehicle (refer to ENGINE RE-
vmr2006-054-003_a
MOVAL/INSTALLATION)
1. Oil pressure regulator plug – Water pump cover (refer to COOLING SYSTEM )
2. Oil pump housing
– Magneto cover (refer to MAGNETO/STARTER).
NOTE: The oil pressure regulator system works NOTE: The following steps to remove the drive
when the oil pressure exceeds 500 kPa (73 PSI). gear no. 6 and the intermediate gear no. 7 are not
necessary to replace only the oil pump.
Oil Pressure Regulator Removal
Remove retaining ring no. 8 then drive gear no. 6
Remove: and needle pin no. 9.
– Engine from vehicle (refer to ENGINE RE-
MOVAL/INSTALLATION) CAUTION: Never use the retaining ring a sec-
ond time. Always replace by a new one.
– Water pump cover (refer to COOLING SYSTEM)
NOTE: Drive gear is snapped on a needle pin. This
– Magneto cover (refer to MAGNETO/STARTER)
needle pin passes through the balancing shaft.
– Oil pressure regulator plug, compression spring
and valve piston. Remove pin and intermediate gear.

 WARNING
Oil pressure regulator plug on oil pump hous-
ing is spring loaded.

R400motr117A 3 2 1
1. Valve piston
2. Compression spring
3. Oil pressure regulator plug

vmr2008-124 53
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

1 2

1
vmr2006-054-004

1. Dowel pins

R400motr118A
Remove oil pump gear no. 11.
1. Intermediate gear
2. Pin
NOTE: Oil pump gear is snapped on needle pin.
This needle pin passes through the oil pump shaft.
Remove oil pump cover screws and oil pump cov- Use screwdrivers to remove this gear.
er.
4 2 3
1

R400motr119A 1
1. 4 oil pump cover screws R400motr122A
2. Oil from the pump to the oil filter in the magneto cover
3. Oil pump cover
1. Flat screwdrivers
4. Oil seal to crankcase MAG side

NOTE: To remove oil pump system, lift the dowel 2

pins no. 10 a bit. The oil pump housing with oil 3
pump shaft assembly will be easier to remove.
CAUTION: Pay attention not to drop the dowel 2
pins inside the engine.

4
1

1
R400motr123A

1. Oil pump gear

2. Dowel pins
R400motr120A
3. Suction side of the oil pump
4. Outlet from the engine oil pressure regulator valve
1. Oil pump system

Remove needle pin no. 12, oil pump shaft assem-

bly and oil pump housing.
54 vmr2008-124
 Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

1
R400motr126A

1. Pittings on the teeth

1 Using a feeler gauge, measure the clearance be-

R400motr125A tween inner and outer rotor.
1. Oil pump shaft assembly
2. Oil pump housing

C
1

R400motr127A

1. Outer rotor
2. Inner rotor

vmr2008-124-002_a
OUTER AND INNER ROTOR CLEARANCE
1. Bore for dowel pin support SERVICE LIMIT
2. Oil return from the oil pressure regulator system
3. Oil inlet to the oil pump (leads to strainer on engine bottom) A
B 0.25 mm (.009 in)
Oil Pump Inspection C
Inspect oil pump shaft assembly, housing and cov-
er for marks or other damages. If clearance between inner and outer rotor ex-
ceeds the tolerance, replace oil pump shaft
Replace O-ring no. 13 if brittle or hard. This O-ring
assembly. Ensure to also check oil pump housing
is located on the oil pump housing.
and cover. If damaged, replace the complete oil
Check inner rotor for corroded pin holes or other pump assembly.
damages. If so, replace oil pump shaft assembly.
If clearance between outer rotor and its bore in
Check the inside of oil pump housing and its cover oil pump exceeds the tolerance, replace the com-
for scoring or other damages. If so, change the plete oil pump assembly.
complete oil pump assembly.
Using a dial indicator, measure side wear as
shown.

vmr2008-124 55
Section 03 ENGINE
Subsection 05 (LUBRICATION SYSTEM)

1 4

2 2
3

R400motr119B

NOTE: After tightening the oil pump housing

screws check for smooth operation of the oil
1
R400motr128B
pump assembly.
1. Oil pump housing surface
Install the O-ring no. 13 on oil pump cover.
2. Dial indicator After engine is completely reassembled, start en-
gine and make sure oil pressure is within specifi-
cations (refer to ENGINE OIL PRESSURE TEST at
the beginning of this section).

1
R400motr128B

1. Oil pump outer rotor surface

2. Dial indicator

Difference between pump housing and outer rotor

should not exceed 0.1 mm (.004 in). If so, replace
the complete oil pump assembly.
NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure de-
creases.

Oil Pump Installation

For installation, reverse the removal procedure.
CAUTION: Never apply any sealing compound
on split surfaces of oil pump.
Tightening oil pump housing screws as per follow-
ing sequence.

56 vmr2008-124
 Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

COOLING SYSTEM
SERVICE TOOLS
Description Part Number Page
small hose pincher................................................................ 295 000 076 ........................................... 64
pressure/vacuum pump........................................................ 529 021 800 ........................................... 64
large hose pincher ................................................................ 529 032 500 ........................................... 62
oil seal pusher....................................................................... 529 035 757 ........................................... 75
water pump ceramic seal installer........................................ 529 035 766 ........................................... 75
Fluke 115 multimeter ........................................................... 529 035 868 ........................................... 69
test cap................................................................................. 529 035 991 ........................................... 64
ECM adapter tool.................................................................. 529 036 085 ........................................... 70

SERVICE PRODUCTS
Description Part Number Page
BRP premixed coolant .......................................................... 219 700 362 ........................................... 62
Super Lube grease ............................................................... 293 550 030 ........................................... 75
Loctite 243............................................................................ 293 800 060 ........................................... 65

vmr2008-125 57
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

RADIATOR (2008)

Some 2008
Models

7 N•m
(62 lbf•in)
5.5 N•m
(49 lbf•in)

7 N•m
(62 lbf•in)

vmr2008-125-001_a

58 vmr2008-125
 Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

RADIATOR (2009)

5.5 N•m
(49 lbf•in)

7 N•m
(62 lbf•in)

vmr2008-125-011_a

vmr2008-125 59
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

WATER PUMP

10 N•m 1
(89 lbf•in)
Right hand thread
2.5 N•m
2 (22 lbf•in)

Engine oil
Super Lube grease

5
3

vmr2007-024-001_b

60 vmr2008-125
 Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

THERMOSTAT

5 N•m
(44 lbf•in)
6 N•m
(53 lbf•in)

Loctite 243

16 N•m
(142 lbf•in)

vmr2008-125-002_a

vmr2008-125 61
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

GENERAL Draining the Cooling System

 WARNING  WARNING
Never start engine without coolant. Engine Never drain or refill cooling system when en-
parts and ceramic seal on water pump shaft gine is hot.
can be damaged.
Remove the service compartment cover.
During assembly/installation, use the torque val- Remove radiator cap.
ues and service products as in the exploded
views. Remove RH engine cover.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

 WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, etc.) must
be installed or replaced with new ones where
specified. If the efficiency of a locking device
is impaired, it must be renewed.
vmo2008-019-025_a

1. RH engine cover

MAINTENANCE Partially unscrew cooling system drain plug locat-

ed below coolant pump housing.
ENGINE COOLANT
 WARNING
To avoid potential burns, do not remove the
radiator cap or loosen the cooling system
drain plug if the engine is hot.

Recommended Coolant
Use BRP premixed coolant (P/N 219 700 362) or a 1
blend of 50% antifreeze with 50% water. R400motr231A

To prevent antifreeze deterioration, always use 1. Cooling system drain plug

the same brand. Never mix different brands
unless cooling system is completely flushed and When cooling system is drained completely, re-
refilled. move drain plug completely and install a new gas-
CAUTION: To prevent rust formation or freez- ket ring.
ing conditions, always replenish the system Reinstall drain plug and torque it to 10 N•m
with an ethylene glycol antifreeze containing (89 lbf•in).
corrosion inhibitors specifically recommended
for aluminum engines such as the BRP pre- Refilling and Bleeding the Cooling
mixed coolant. System
Do not use tap water, straight antifreeze or Remove the RH side body panel.
straight water in the system. Tap water contains
minerals and impurities which build up in the sys- Pinch the radiator coolant return hose between ra-
tem. During cold weather, straight water causes diator and thermostat housing with a large hose
the system to freeze while straight antifreeze pincher (P/N 529 032 500) as per following illus-
thickens and does not have the same efficiency. tration.
62 vmr2008-125
 Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

V07C0AA 1
1. Hose pincher
R400motr237A

Remove cooling system bleeder screw from top TYPICAL

of thermostat housing. 1. Gasket ring
2. Bleeder screw

Remove hose pincher from radiator coolant return

hose.
Top up radiator coolant and install radiator cap.
Refill coolant tank up to the MIN. level mark and
install the coolant tank cap.

vmr2008-125-003_a

1. Bleeder screw
2. Thermostat housing
3. Coolant temperature sensor

With vehicle on a flat and level surface, and the

engine cold, refill the radiator.
When coolant starts to escape from the ther-
mostat housing bleeder port, install the bleeder
screw with its gasket ring and torque to 5 N•m vmo2008-019-013_a

(44 lbf•in). TYPICAL

1. Coolant tank
2. MAX. fill level mark
3. MIN. fill level mark

Run engine until thermostat opens then stop en-

gine.
When engine has completely cooled down,
recheck coolant level in radiator and coolant tank,
top up if necessary. The level in the coolant tank
should be between MIN. and MAX. marks.
NOTE: Coolant concentration (freezing point)
should be checked with an appropriate tester,
or replaced as specified in the MAINTENANCE
CHART section.

vmr2008-125 63
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

INSPECTION
COOLING SYSTEM LEAK TEST
 WARNING
To avoid potential burns, do not remove the
radiator cap or loosen the cooling system
drain plug if the engine is hot.

Remove the service compartment cover.

Remove the radiator cap.
Install test cap (P/N 529 035 991) on radiator.

529 035 991 V07C0NA 1

TYPICAL
1. Special radiator cap

Check all hoses, radiator and engine cylinder/base

for coolant leaks or air bubbles.
Install a small hose pincher (P/N 295 000 076) on
the overflow hose. Inspection
Check general condition of hoses and clamps.
Check the leak indicator hole on the coolant pump
for oil or coolant.

V07C0MA 1 2
TYPICAL
1. Hose pincher
2. Radiator overflow hose
R400motr132A 1
Using pressure/vacuum pump (P/N 529 021 800), 1. Leak indicator hole
pressurize system to 103 kPa (15 PSI).
NOTE: Flowing coolant indicates a damaged or
worn rotary seal. Oil indicates a defective oil seal,
located behind the rotary seal. If either seal is
leaking, the water pump has be removed and both
seals must be replaced. Refer to WATER PUMP
SHAFT AND SEALS in this section.

64 vmr2008-125
 Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

PROCEDURES
THERMOSTAT
The thermostat is a single action type, located on
the RH rear side of the cylinder head.

Thermostat Removal
Remove the RH side body panel.
Install a hose pincher on both radiator hoses.

vmr2008-125-005_a

1. Thermostat with gasket

Thermostat Test
To test thermostat, suspend it submerged in a pot
of water and heat the water until the thermostat
opens. Measure the water temperature.
NOTE: The thermostat should open when the wa-
ter temperature reaches 65°C (149°F).

Thermostat Installation
vmr2008-125-006_a
For installation, reverse the removal procedure,
1. Hose pinchers pay attention to the following details.
2. Coolant return hose from thermostat
3. Radiator coolant outlet hose Check gasket to see if it is brittle, hard or dam-
aged. If so, replace gasket.
Remove thermostat housing screws and pull ther-
mostat housing off cylinder head. Apply Loctite 243 (P/N 293 800 060) to the ther-
mostat housing mounting screws.
Torque mounting screws to 6 N•m (53 lbf•in).
Check coolant level in radiator and coolant tank.
Top up if necessary.
Bleed the cooling system. Refer to ENGINE
COOLANT in this section.

RADIATOR CAP
Using a pressure cap tester, test to see at what
pressure the radiator cap opens. If cap pressure
valve does not open at or near 110 kPa (16 PSI),
install a new cap (do not exceed this pressure).
NOTE: If cap opens at a low pressure, cooling sys-
vmr2008-125-004_a
tem efficiency will be reduced.
1. Thermostat housing
2. Screws CAUTION: An over pressure condition in the
cooling system can cause coolant leaks and
Remove thermostat and gasket from cylinder component damage.
head.
NOTE: Note location of gasket for installation. RADIATOR
Radiator Inspection
Check radiating fins for clogging or damage.

vmr2008-125 65
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

Remove insects, mud or other obstructions with

compressed air or low pressure water.

Radiator Removal
Drain cooling system, refer to ENGINE COOLANT
in this section.
Remove front fascia and both inner fenders, refer
to BODY.
Remove radiator coolant outlet and return hoses.

vmr2008-125-013_a

TYPICAL
1. Radiator overflow hose
2. Spring clamp

Disconnect radiator fan connector located just be-

hind the coolant tank.
1

V07C0PA

1. Radiator coolant return hose

vmr2008-125-007_a

TYPICAL — VIEW THROUGH LH FRONT WHEEL WELL

1. Radiator cooling fan connector

Disconnect the vent tube from the cooling radiator

fan motor.

V07C0QA 1
TYPICAL
1. Radiator coolant outlet hose
vmr2008-125-012_a

Remove overflow hose at radiator filler neck. 1. Radiator fan vent tube
2. Disconnect tube from fan motor

66 vmr2008-125
 Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

Remove radiator mounting screws. Coolant Tank Removal

Remove the LH inner fender panel, refer to BODY
section.
Remove the coolant tank support bolt.

V07C0SA
V07C0RA 1
TYPICAL — COOLANT TANK
1. Radiator mounting screws
Remove the service compartment cover to access
Remove radiator from vehicle. top of coolant tank.
Radiator Installation On applicable models, pull the coolant tank
vent/overflow hose to the top of the vehicle.
For installation, reverse the removal procedure.
Pay attention to the following details.
Install rubber bushings between bottom of radia-
tor and radiator support.
Torque all mounting screws as specified in explod-
ed view.
Fill radiator with coolant. Refer to ENGINE
COOLANT procedure in this section.
Check for any coolant leakage from radiator and
hoses.

COOLANT TANK vbs2008-014 006_b

TYPICAL
The coolant expands as its temperature rises (up 1. Coolant tank cap
2. Vent/overflow hose
to 100 - 110°C (212 - 230°F)) causing pressure rise
in the system. If the system working pressure Remove the coolant tank support screw and lower
limit is reached 110 kPa (16 PSI), the pressure re- coolant tank sufficiently to access hoses connect-
lief valve in the radiator cap is lifted from its seat ed to tank.
and allows coolant to flow through a hose into the
coolant tank. Disconnect the radiator overflow hose from the
coolant tank.
NOTE: On some 2008 models and on all 2009
models, a vent/overflow hose in the coolant tank Remove the support and lower the coolant tank.
cap allows excess pressure and coolant to escape. NOTE: On applicable models, be careful not to
When the system cools and the pressure decreas- snag the coolant tank vent hose to avoid breaking
es (generally after engine shutdown), the internal the cap or hose fitting as you lower the tank.
system pressure may become lower than atmo- Empty coolant tank.
spheric pressure. Coolant will then flow from the
tank into the radiator to maintain it at a full state.
vmr2008-125 67
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

Coolant Tank Installation Remove the cooling fan fuse and test it to be sure
Installation is the reverse of the removal proce- that it is good.
dure. Remove the cooling fan relay.
Torque tank mounting screw as specified in ex-
ploded view.
Position the vent tube of the coolant tank in the al-
lowable range as shown in the following pictures.
NOTE: This is important to avoid any interference
with the service compartment cover.

vmr2008-139-004_n

1. Cooling fan fuse

2. Cooling fan relay

Install an insulated jumper wire between contacts

vbs2008-014 006_c 1D and 3E of the fuse box.
SHORT ROUTING

vmr2008-125-010_a

JUMPER WIRE 1D TO 3E

As you install the cooling fan fuse, the fan should

vbs2009-009-002_a
turn on.
LONG ROUTING

CAUTION: Ensure the open end of the

vent/overflow tube is routed down and away
from moving parts, electrical components, or
any component that may be adversely affected
by overflowing coolant.

RADIATOR COOLING FAN

Radiator Cooling Fan Test
NOTE: It is not required to turn the ignition key
to ON for this test. vmr2008-125-008_a

Remove the service compartment cover. 1. Reinstall cooling fan fuse

Remove the fuse box cover.

68 vmr2008-125
 Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

If the fan functioned normally with a jumper in-

stalled in place of the relay, remove the cooling
fan fuse and the jumper wire.
Carry out the following test:
– Fan relay input voltage
– Fan relay continuity
– Fan relay control circuit continuity.
If the fan does not function with a jumper installed
in place of the relay, remove the cooling fan fuse
and the jumper wire.
Carry out the following test:
– Fan input voltage vmr2008-139-004_a

– Fan ground circuit continuity FUSE BOX PIN-OUT

– Fan power circuit continuity test.
If battery voltage is measured, carry out a fan relay
Fan Relay Input Voltage Test test.
Remove cooling fan relay. If battery voltage is not measured, test the fan/ac-
cessories fuse in the rear fuse holde, and the wire
continuity from said fuse to the fan relay.

vmr2008-139-004_n

vmr2008-139-015_a
1. Cooling fan fuse
2. Cooling fan relay REAR FUSE HOLDER (PF2)
1. Main fuse 30 A (F8)
Set the Fluke 115 multimeter (P/N 529 035 868) 2. Spare fuse 30 A
3. Fan/accessories fuse 30 A (F9)
to Vdc and test fan relay input voltage as per fol-
lowing table. Repair or replace fuse or wiring as required.

FAN RELAY INPUT VOLTAGE TEST Fan Relay Test

TEST PROBES READING To test the radiator cooling fan relay, refer to the
LIGHTS/GAUGE/ACCESSORIES section. Use the
Contact 1D
(fuse box)
accessories relay test procedure.
Chassis Battery
ground voltage Replace relay as required.
Contact 3D
(fuse box)
Fan Relay Control Circuit Test
Disconnect ECM connector.

vmr2008-125 69
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

vmr2008-125-008_b

FAN RELAY CONTROL CIRCUIT TEST

vmr2008-139-008_a
If continuity was not measured, repair or replace
1. Press to release connector lock
2. Push to rotate connector lock upwards wiring/connector as required.
If cooling fan relay, relay input voltage and relay
Install ECM connector onto the ECM adapter tool control circuit continuity tested good, the problem
(P/N 529 036 085). is related to the ECM. Refer to the ELECTRONIC
FUEL INJECTION section for ECM testing.

Fan Input Voltage Test

Ensure cooling fan relay and fuse are installed.
Disconnect the radiator cooling fan connector.
Set multimeter to Vdc.
Test for battery voltage at the radiator cooling fan
connector BROWN/WHITE wire.

vmr2008-139-016_a

1. ECM connector
2. Adapter tool

Set multimeter to setting.

Test for continuity of the relay control circuit OR-
ANGE/WHITE wire as per following table.

FAN RELAY CONTROL CIRCUIT TEST

RESISTANCE
TEST PROBES
@ 20°C (68°F)
vmr2008-125-009_a
Contact 1E Pin B3
Close to 0 FAN INPUT VOLTAGE TEST (BROWN/WHITE WIRE)
(fuse box) (ECM adapter)
If battery voltage is measured, test fan ground cir-
cuit continuity.
If battery voltage was not measured, test fan pow-
er circuit continuity.

Fan Ground Circuit Continuity Test

Set multimeter to setting.
Test for continuity of the fan ground wire (BLACK
wire) to chassis ground.

70 vmr2008-125
 Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

vmr2008-125-009_b vmr2008-125-007_a

FAN GROUND CIRCUIT CONTINUITY TEST (BKACK WIRE) 1. Radiator cooling fan connector

If continuity was not measured, repair or replace On 2009 models, remove the cooling fan vent
wiring/connector as required. tube.
If fan input voltage and ground circuit continuity
measured good, replace the radiator cooling fan.

Fan Power Circuit Continuity Test

Remove fan relay.
Remove fan fuse.
Test for continuity of the fan power circuit wiring
as per following table.

FAN POWER CIRCUIT CONTINUITY TEST

FUSE BOX FAN RESISTANCE
CONTACTS CONNECTOR @ 20°C (68°F)
3E 9C —
Close to 0 vmr2008-125-012_a

8C — Pin B (BR/WH) TYPICAL

1. Radiator fan vent tube
2. Disconnect tube from fan motor
Repair or replace wiring/connectors as required.
Remove the 4 fan mounting screws, refer to the
Radiator Cooling Fan Removal
exploded views. Note the position of the mount-
Remove both inner fender panels. Refer to the ing bracket for the inner fender panel installation.
BODY section.
Disconnect radiator cooling fan connector.

vmr2008-125 71
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

vmr2008-125-003_b

vmr2008-125-012_b 1. Coolant temperature sensor

2. Valve cover
TYPICAL — LEFT SIDE ILLUSTRATED, RIGHT SIDE SIMILAR 3. Thermostat housing
1. Radiator mounting screws
2. Mounting bracket for inner fender panel
Refer to ELECTRONIC FUEL INJECTION section
Remove the fan from the vehicle. for testing and replacement procedures of the
coolant temperature sensor (CTS).
CAUTION: Be careful not to damage radiator
cooling fins and coolant passages when re-
moving fan from vehicle. WATER PUMP COVER
NOTE: The water pump cover is located on the
Radiator Cooling Fan Installation engine MAG side (RH).
For the installation, reverse the removal proce-
dure. Water Pump Cover Removal
Install the mounting brackets for the inner fender Drain cooling system, refer to ENGINE COOLANT
panels on the lower radiator mounting screws as in this section.
noted during the removal procedure. Remove radiator outlet hose from water pump
Torque fan mounting screws as per exploded housing.
view. Remove screws retaining water pump cover.
Ensure to reconnect the fan vent tube on 2009
models.

COOLANT TEMPERATURE
SENSOR (CTS)
The coolant temperature sensor is located next to
the thermostat housing on the RH rear side of the
cylinder head.
2

R400motr137A 1
WATER PUMP COVER REMOVAL
1. Mounting screws, cooling system drain plug with sealing washer
2. Mounting screw

Pull on water pump cover to remove it.

72 vmr2008-125
 Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

Water Pump Cover Inspection Unscrew impeller from water pump shaft.
Check if gasket is brittle, hard or damaged. 1
Replace as required.

R400motr140A

1. Impeller

NOTE: Water pump shaft and impeller have right-

hand threads. Remove by turning counterclock-
R400motr138A
wise and install by turning clockwise.
WATER PUMP COVER
1. Gasket Water Pump Impeller Inspection
Check impeller for cracks or other damages. Re-
Water Pump Cover Installation place impeller if damaged.
The installation is the opposite of the removal pro- Water Pump Impeller Installation
cedure.
The installation is the opposite of the removal pro-
CAUTION: To prevent leaking, make sure the cedure.
gasket is properly inserted in the pump cover
groove when you reinstall the water pump cov- NOTE: Be careful not to damage the impeller
er. blades during installation.
Tightening sequence for screws on water pump Torque impeller as specified in exploded view.
cover is as per following illustration (criss-cross).
Apply torque specified in exploded view. WATER PUMP SHAFT AND SEALS
Water Pump Shaft and Seal Removal
Remove water pump cover no. 1.
Remove impeller no. 2.
3
1 Remove magneto cover, refer to the MAGNE-
2 TO/STARTER section.
Remove retaining ring (circlip) from the water
pump gear using the appropriate pliers. Discard
the retaining ring.
4
R400motr231B

WATER PUMP IMPELLER

Water Pump Impeller Removal
Remove water pump cover as per previous proce-
dure.

vmr2008-125 73
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

1 2

R400motr144A 1
1. Water pump shaft with rotary seal

R400motr141B
Extract oil seal no. 3 from inside magneto cover
using an appropriate pusher.
1. Retaining ring (circlip)
2. Water pump gear

Remove water pump gear, needle pin and thrust

washer.
1

R400motr145A 1 2
2 1. Oil seal behind the rotary seal
3 2. Rotary seal bore
R400motr142B
CAUTION: Be careful not to damage the surface
1. Water pump gear of the rotary seal bore in magneto cover.
2. Needle pin
3. Thrust washer

Using a soft hammer, tap on the end of the water

pump shaft from inside the magneto cover to push
the shaft and rotary seal out of the magneto cover.
CAUTION: Always replace rotary seal and wa-
ter pump shaft no. 5 together. Also install a
new oil seal no. 3 at the same time.

R400motr146A 1
1. Special area for oil seal removal

74 vmr2008-125
 Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

Water Pump Shaft and Gear Inspection

Inspect water pump gear no. 4 for wear, cracks
or broken teeth. Also inspect the gear snap (lock-
ing) mechanism to the needle pin. Replace if dam-
aged.
Inspect shaft and rotary seal for wear or damages.
NOTE: Water pump shaft must rotate freely with-
in the rotary seal no. 5. Otherwise, replace the
assembly.

Water Pump Shaft and Seal Installation 529035766

For installation, reverse the removal procedure.

However, pay attention to the following. NOTE: Never use oil or grease in the press fit
area of the oil seal and rotary seal bores.
CAUTION: When replacing water pump shaft,
always replace retaining ring (circlip), oil seal, Apply Super Lube grease (P/N 293 550 030) to the
water pump shaft and rotary seal with new oil seal no. 3 after it is installed in the magneto
parts. cover.
Install the water pump shaft oil seal no. 3 using oil Apply a light coat of engine oil on the water pump
seal pusher (P/N 529 035 757). shaft no. 5.
Press the water pump shaft assembly into the
magneto cover using the outside area of the ro-
tary seal.

vmr2006-040-015_a

1. Handle
2. Pusher

1 3

R400motr150A 1
1. Surface used to press water pump shaft assembly in place

CAUTION: Never use a hammer for rotary seal

installation. To avoid damaging the ceramic
component, seal must be installed using a
press.

R400motr147A 2
1. Oil seal for water pump shaft
2. Oil seal pusher
3. Handle for insertion jig

Use water pump ceramic seal installer (P/N 529

035 766) to install the water pump shaft assembly.

vmr2008-125 75
Section 03 ENGINE
Subsection 06 (COOLING SYSTEM)

R400motr148A 1
TYPICAL
1. Water pump shaft with rotary seal
2. Water pump ceramic seal installer

Always use torque values specified in the explod-

ed view.
Torque water pump cover screws as per sequence
specified in following illustration.

3
1 2

4
R400motr231B

76 vmr2008-125
 Section 03 ENGINE
Subsection 07 (MAGNETO/STARTER)

MAGNETO/STARTER
SERVICE TOOLS
Description Part Number Page
crankshaft protector ............................................................. 420 876 557 ........................................... 86
handle ................................................................................... 420 877 650 ........................................... 82
magneto puller...................................................................... 529 035 748 ........................................... 86
oil seal installer ..................................................................... 529 035 759 ........................................... 82
Fluke 111 multimeter ........................................................... 529 035 868 ............................... 82–84, 87
oil seal protector ................................................................... 529 035 935 ..................................... 80, 82

SERVICE PRODUCTS
Description Part Number Page
dielectric grease ................................................................... 293 550 004 ........................................... 89
Super Lube grease ............................................................... 293 550 030 ........................................... 89
Loctite 5910.......................................................................... 293 800 081 ........................................... 80
Loctite chisel (gasket remover) ............................................ 413 708 500 ........................................... 80
pulley flange cleaner............................................................. 413 711 809 ........................................... 86

vmr2008-126 77
Section 03 ENGINE
Subsection 07 (MAGNETO/STARTER)

Super Lube grease

10 N•m
(89 lbf•in)

10 N•m Super Lube

(89 lbf•in) grease
25 N•m
(18 lbf•ft)
25 N•m
10 N•m Loctite (18 lbf•ft)
(89 lbf•in) 5910
Super
Lube
grease Loctite 243
Super Lube
grease
NEW

10 N•m
(89 lbf•in)

25 N•m
(18 lbf•ft) 10 N•m
(89 lbf•in) Loctite 243

180 N•m
(133 lbf•ft)

Loctite 5910
10 N•m
(89 lbf•in)

vmr2008-126-001_a

78 vmr2008-126
 Section 03 ENGINE
Subsection 07 (MAGNETO/STARTER)

GENERAL
The engine removal is necessary to work on mag-
neto components except for the CPS (Crankshaft
Position Sensor), vehicle speed sensor and oil
seal.
Always perform the electric tests before removing
or installing whatever component.
During assembly/installation, use the torque val- 1 2
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
V07C0JA

 WARNING 1. Loosen only these screws if output shaft is not removed

2. Remove these screws
Torque wrench tightening specifications
must strictly be adhered to.
Remove magneto cover screws.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pin, Remove magneto cover.
etc.) must be installed or replaced with new NOTE: Lift the magneto cover from the provided
ones where specified. If the efficiency of area using two flat screwdrivers prying equally at
a locking device is impaired, it must be re- the same time.
newed.

PROCEDURES
MAGNETO COVER
Magneto Cover Removal
Remove engine from vehicle.
Remove 4WD coupling unit.
Lock crankshaft at TDC (refer to
CRANKCASE/CRANKSHAFT).
Disconnect magneto, CPS and vehicle speed sen-
sor connectors. R400motr03A 1
Remove: 1. Special area for removal of magneto cover
– Rewind starter (refer to REWIND STARTER)
– Water pump cover (refer to COOLING SYSTEM)
– Starter
– Screws holding output shaft bearing flange in
place.
NOTE: Remove the screws on magneto cover
side and loosen only the screws on the crankcase
side if the output shaft is not removed. Remove
all screws and bearing flange if output shaft is re-
moved.

vmr2008-126 79
Section 03 ENGINE
Subsection 07 (MAGNETO/STARTER)

NOTE: It is recommended to apply this specific

sealant as described here to get an uniform appli-
cation without lumps. If you do not use the roller
method, you may use your finger to uniformly dis-
tribute the sealant (using a finger will not affect
1 the adhesion).

R400motr04A

1. Special area for removal of magneto cover

Magneto Cover Inspection and

Cleaning
Check magneto cover for cracks or other dam-
ages. Replace if necessary. F12R17A

NOTE: Clean all metal component in a non-ferrous Apply Loctite 5910 all around the magneto cover
metal cleaner. Use Loctite chisel (gasket re- mating surface except the areas described below.
mover) (P/N 413 708 500), or suitable equivalent.
To remove remaining Loctite 5910 on the contact NOTE: Do not apply in excess as it will spread out
surface, use a copper brush. inside cover.
CAUTION: Apply the product only in the shown
 WARNING areas.
Wear safety glasses and work in a well
ventilated area when working with strong
chemical products. Also wear suitable
non-absorbent gloves to protect your hands.

Magneto Cover Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
Use the silicone-based Loctite 5910 (P/N 293 800
081) on mating surfaces.
IMPORTANT: When beginning the application of
the sealant, the assembly and the first torquing vmr2008-126-002_a
should be done within 10 minutes. It is suggested
1. Mating surface on the magneto cover
to have all you need on hand to save time. 2. No need to apply Loctite 5910
Use a plexyglass plate and apply some sealant on
it. Use a soft rubber roller (50 - 75 mm (2 - 3 in)) Install the oil seal protector (P/N 529 035 935) on
as per supplier (available in arts products suppliers crankshaft end to avoid damaging the oil seal dur-
for print making) and roll the sealant to get a thin ing installation of the magneto cover.
uniform coat on the plate (spread as necessary).
When ready, apply the sealant on magneto mating
surfaces.

529035935

80 vmr2008-126
 Section 03 ENGINE
Subsection 07 (MAGNETO/STARTER)

Install the magneto cover.

vmr2008-126-004_a

1. Gasket ring

Tightening sequence for screws on magneto cov-

vmr2008-126-003_a
er is as per following illustration.
1. Oil seal protector
2. Oil seal on magneto cover
3. Crankshaft MAG side

Refer to the following illustration for proper instal-

lation of screws.
CAUTION: Never use the gasket ring a second
time. Always install a new one.
3 2 1

vmr2008-126-004_b

Let the sealant dry before starting engine. Refer

to the manufacturer's label for the sealant curing
time.

OIL SEAL
Remove rewind starter (refer to REWIND
STARTER) to access oil seal.
R400motr02A

1. Gasket ring
Oil Seal Inspection
2. Screw M6 Check the oil seal on the magneto cover. If brittle,
3. CPS (Crankshaft Position Sensor)
hard or damaged, replace it.

Oil Seal Removal

NOTE: The oil seal can be removed with the mag-
neto cover in place.
Pry out oil seal with a small screwdriver.
CAUTION: Be careful not to damage the oil seal
bore of the magneto cover and/or the crank-
shaft when using a screwdriver.

Oil Seal Installation

NOTE: Never use oil in the press fit area of oil seal.

vmr2008-126 81
Section 03 ENGINE
Subsection 07 (MAGNETO/STARTER)

Install the oil seal protector (P/N 529 035 935) on

crankshaft end to avoid damaging oil seal during
installation. 2

529035935

With Magneto Cover Removed

Using the oil seal installer (P/N 529 035 759) and
the handle (P/N 420 877 650), install the oil seal in
its location.
R400motr09A 3
1. Oil seal
2. Oil seal protector
3. Tube

STATOR
vmr2008-126-010_a

1. Oil seal installer Stator Continuity Test

2. Handle
Test at Voltage Regulator/Rectifier
Input Connector
3
Remove the starter solenoid cover.
Disconnect the voltage regulator input connector
(three YELLOW wires).
2
1

R400motr10A

1. Oil seal
2. Oil seal installer (P/N 529 035 759)
3. Handle (P/N 420 877 650) vmr2008-138-005_a

1. Disconnect the voltage regulator input connector (three

Reinstall other removed parts in the reverse order. YELLOW wires)
Install magneto cover, refer to MAGNETO COVER
above. Set Fluke 111 multimeter (P/N 529 035 868) to .
Connect multimeter between each pair of YEL-
Without Magneto Cover Removed
LOW wires.
Using a suitable tube, with the proper diameter,
install the oil seal as per following illustration.

82 vmr2008-126
 Section 03 ENGINE
Subsection 07 (MAGNETO/STARTER)

vmr2008-138-005_b vmr2008-138-007_a

STATOR CONTINUITY TEST STATOR CONNECTOR PIN-OUT

Read resistance as per following table. NOTE: Pin 2 is not used.

If resistance readings are as specified, repair or re-
YELLOW WIRES RESISTANCE @ place connector or wiring between the front stator
(EACH PAIR) 20°C (69°F) connector and the voltage regulator input connec-
1 and 2 tor.
1 and 3 0.1 - 1 If resistance readings are not as specified, the sta-
tor or the wiring is shorted to ground and requires
2 and 3 to be repaired or replaced.
If any reading is out of specification, repeat test at Stator Insulation Test
stator connector.
Test at Voltage Regulator/Rectifier
Test at Stator Connector Input Connector
To access the stator connector, remove the RH To access connector, refer to STATOR CONTINU-
inner fender panel, refer to BODY section. ITY TEST.
Set Fluke 111 multimeter (P/N 529 035 868) to .
Connect multimeter between any YELLOW wire
and engine ground.

vmr2008-138-006_a

STATOR CONNECTOR, INNER FENDER PANEL REMOVED

Disconnect the stator connector and repeat stator

continuity test. Resistance readings should be as vmr2008-138-005_c
per previous table. STATOR INSULATION TEST

Read resistance.

RESISTANCE @
TEST PROBES
20°C (69°F)
Any YELLOW wire and
Infinity (open circuit)
engine ground

vmr2008-126 83
Section 03 ENGINE
Subsection 07 (MAGNETO/STARTER)

If there is a resistance or continuity, repeat test at

stator connector.
Test at Stator Connector
To access the stator connector, remove the RH
inner fender panel, refer to BODY section.

vmr2008-138-005_a

1. Disconnect the voltage regulator input connector

Set Fluke 111 multimeter (P/N 529 035 868) to Vac

scale.
Start engine.
vmr2008-138-006_a
Connect multimeter between each pair of YEL-
STATOR CONNECTOR, INNER FENDER PANEL REMOVED LOW wires.
Disconnect the stator connector and repeat stator
insulation test as per previous table.

vmr2008-138-005_d

STATOR OUTPUT VOLTAGE TEST

vmr2008-138-007_a
Read voltage.
STATOR CONNECTOR PIN-OUT
TEST ENGINE
NOTE: Pin 2 is not used. TERMINAL VOLTAGE
SPEED
If resistance readings are as specified, repair or re- 1 and 2
place connector or wiring between the front stator 50 Vac
connector and the voltage regulator input connec- 4000 RPM 1 and 3
minimum
tor. 2 and 3
If resistance readings are not as specified, the sta-
tor or the wiring is shorted to ground and needs to If voltage is lower than specification, repeat test
be repaired or replaced. at front stator connector.
Reinstall removed connectors and panels. Test at Stator Connector
To access the stator connector, remove the RH
Stator Output Voltage Test inner fender panel, refer to BODY section.
Test at Voltage Regulator/Rectifier
Input Connector
Disconnect the voltage regulator input connector.

84 vmr2008-126
 Section 03 ENGINE
Subsection 07 (MAGNETO/STARTER)

vmr2008-138-006_a

STATOR CONNECTOR, RH INNER FENDER PANEL REMOVED

vmr2008-126-006_a

Disconnect the stator connector and repeat stator 1. Stator

2. Stator screws
output voltage test as per previous table. 3. Holding strip
4. Holding strip screw

Stator Inspection
Check stator condition. If damaged replace it.

Stator Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
CAUTION: When installing the stator take care
that the cable is in place (guide for the wire).
There is only one position for the stator (notch in
vmr2008-138-007_a the magneto cover).
STATOR CONNECTOR PIN-OUT

NOTE: Pin 2 is not used.

If voltage readings are as specified, repair or re-
place connector or wiring between front stator
connector and the voltage regulator input connec-
tor.
If voltage readings are not as specified, repair or
replace wiring, connector or stator.
Install removed connectors and panels.

Stator Removal
Remove:
– Magneto cover
vmr2008-126-007_a
– Stator screws
1. Thread for cable holding strip
– Holding strip screw 2. Notch for stator
3. Crank position sensor
– Stator.

ROTOR
Rotor Removal
Lock crankshaft. Refer to CRANKCASE/CRANK-
SHAFT.

vmr2008-126 85
Section 03 ENGINE
Subsection 07 (MAGNETO/STARTER)

Remove: Measure trigger wheel teeth diameter at different

– Magneto cover locations. Maximum allowed diameter is 134 mm
– Nut retaining rotor (5.28 in). Otherwise, check for bent teeth.
– Serrated washer.

vmr2008-014-011_a

1. Rotor
2. Trigger wheel
3. Maximum 134 mm (5.28 in)

vmr2008-126-008_a
Check woodruff key and keyway on the crankshaft
1. Nut and the serrated washer for wear or damages.
2. Serrated washer
3. Rotor Replace as necessary.

Install the magneto puller (P/N 529 035 748) and Rotor Installation
the crankshaft protector (P/N 420 876 557) then For installation, reverse the removal procedure.
remove rotor. However, pay attention to the following.
NOTE: Use grease to place protector on crank- Clean crankshaft taper with pulley flange cleaner
shaft end prior to screw on the magneto puller. (P/N 413 711 809).

CRANKSHAFT POSITION
SENSOR (CPS)
CPS Inspection
Check the CPS condition and replace it if neces-
sary.
vmr2006-041-008
To test the CPS refer to ELECTRONIC FUEL IN-
JECTION.

CPS Removal
Remove side panels. Refer to BODY.
Unplug CPS connector.

420876557

Rotor Inspection
Check inner side of rotor for scratches or other
damage.
Check keyway of the rotor for wear or damages.
Check if trigger wheel teeth are bent or otherwise
damaged.

86 vmr2008-126
 Section 03 ENGINE
Subsection 07 (MAGNETO/STARTER)

vmr2008-139-004_c

vmr2008-136-026_A
FUSE F3
Remove conduit clips and corrugated tube from
sensor and stator cables. NOTE: Check engine will be displayed in multi-
function gauge, starter will crank engine but with
Unscrew the CPS screw and pull CPS to remove an initial delay of approximately 4 seconds.
it.
Remove RH side panel, refer to BODY section.
Pull back red rubber boot from starter terminal.

vmr2008-126-012_a
vmr2008-139-009_a
1. Conduit clip
2. Corrugated tube PULL BACK RED RUBBER BOOT
3. Crankshaft position sensor
4. Screw
Set Fluke 111 multimeter (P/N 529 035 868) to
Vdc.
CPS Installation Press the start button and measure for battery
For installation, reverse the removal procedure. voltage between the starter terminal and chassis
ground as the starter is cranking.
STARTER NOTE: Battery voltage will drop and fluctuate with
starter cranking load.
Starter Voltage Test
Remove front storage cover. STARTER VOLTAGE TEST

Remove fuse box cover. BLACK

RED PROBE MEASUREMENT
PROBE
Remove fuse F3 to prevent engine from starting.
Starter Chassis Battery voltage
terminal ground (fluctuating)

vmr2008-126 87
Section 03 ENGINE
Subsection 07 (MAGNETO/STARTER)

Starter Removal
Make sure the ignition switch is in the OFF posi-
tion.
Disconnect the BLACK (-) battery cable from the
battery.

vmr2008-139-009_b

STARTER VOLTAGE TEST

If you do not obtain close to battery voltage at the

starter terminal, carry out a continuity test of the
wire between the starter and the solenoid. vmr2008-138-004_b

If you obtained close to battery voltage at the

starter terminal and the starter does not rotate,
 WARNING
try a pull start to see if the engine is mechanically Always disconnect BLACK (-) battery cable
locked. first and reconnect last.
If engine rotates freely on a pull start, replace the Remove the RH side cover, refer to the BODY
starter. section.
Starter Cable Continuity Test Remove the radiator coolant hose support by re-
moving the two mounting screws.
Carry out a continuity test of the starter cable as
per following table.
NOTE: An abnormally high resistance may be at-
tributable to loose, dirty, or corroded connections.

STARTER CABLE CONTINUITY TEST

RED PROBE BLACK PROBE MEASUREMENT
Starter Solenoid starter Close to 0
terminal terminal (continuity)

vmr2008-139-011_a

1. Radiator coolant hose

2. Hose support
3. Remove support screws

Disconnect the RED (+) power cable from starter.

vmr2008-139-009_c

STARTER CABLE CONTINUITY TEST

Clean, repair, or replace wiring and connections

between starter and solenoid as required.

88 vmr2008-126
 Section 03 ENGINE
Subsection 07 (MAGNETO/STARTER)

vmr2008-139-014_a

Torque starter screws to 10 N•m (89 lbf•in).

Connect the RED (+) cable to the starter and
torque nut to 6 N•m (53 lbf•in).
vmr2008-139-009_d
Apply dielectric grease (P/N 293 550 004) on
Clean starter area. starter terminal and nut.
Remove the starter mounting screws.

vmr2008-139-009_e

vmr2008-139-012_a
1. Torque starter mounting screws
2. Apply dielectric grease
Pull starter out from gear box.
Connect the BLACK (-) battery cable.
Starter Installation
Installation is the reverse of the removal proce-
 WARNING
dure. However, pay particular attention to the fol- Always connect the RED (+) starter cable first,
lowing. then the BLACK (-) battery cable last. When-
ever connecting the RED (+) cable to the
Make sure that starter and engine mating surfaces starter motor, always make sure the BLACK
are free of debris. Serious problems may arise if (-) battery cable is disconnected to prevent
the starter is not properly aligned. electric shock.

Test starter operation.

vmr2008-139-013_a

Apply Super Lube grease (P/N 293 550 030) to the

starter O-ring seal.
vmr2008-126 89
 Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

CONTINUOUSLY VARIABLE
TRANSMISSION (CVT)
SERVICE TOOLS
Description Part Number Page
pulley holding tool................................................................. 529 006 400 ................................... 95, 104
drive pulley puller.................................................................. 529 035 746 ........................................... 96
driven pulley expander.......................................................... 529 035 747 ........................................... 94
pulley holding tool................................................................. 529 035 771 ......................................... 104

SERVICE PRODUCTS
Description Part Number Page
Isoflex grease Topas NB 52 .................................................. 293 550 021 ......................................... 102
Loctite 5910.......................................................................... 293 800 081 ........................................... 95
pulley flange cleaner............................................................. 413 711 809 ......................................... 106

vmr2008-127 91
Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Loctite 767
(antiseize lubricant)

15
12
13
8
13
Isoflex
topas NB52 16
Pulley 14
flange
cleaner
8
5 11
6 60 N•m
Isoflex
topas NB52 (44 lbf•ft)

5 N•m
(44 lbf•in)
7 100 N•m
(74 lbf•ft)
1 4
3
9
10
2

LH threads

7 N•m
(62 lbf•in)
vmr2008-127-001_a

92 vmr2008-127
 Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

GENERAL PROCEDURES
NOTE: For a better understanding, the following
illustrations are taken with engine out of vehicle. DRIVE BELT
To perform the following instructions, it is not nec-
essary to remove engine from vehicle. Drive Belt Removal
This CVT is lubrication free. Never lubricate any Remove:
components except drive pulley one-way clutch. – LH engine side panel
During assembly/installation, use the torque val- – LH footwell.
ues and service products as in the exploded Unscrew clamps retaining CVT cover hoses.
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

 WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pin,
etc.) must be installed or replaced with new
ones where specified. If the efficiency of
a locking device is impaired, it must be re- vmr2008-127-050_a

newed.
Remove retaining screws, CVT cover and its gas-
 WARNING ket.
Never touch CVT while engine is running.
Never drive vehicle when CVT cover is re-
moved.

 WARNING
Any drive pulley repairs must be performed
by an authorized Can-Am dealer. Subcompo-
nent installation and assembly tolerances re-
quire strict adherence to procedures detailed.

CAUTION: Never use any type of impact

wrench at drive pulley removal and installa-
tion.

 WARNING vmr2008-127-002_a

The clutch assembly is a precisely balanced 1. Retaining screws

2. CVT cover
unit. Never replace parts with used parts 3. Gasket
from another clutch assembly.
NOTE: Remove the center top screw last. This
CAUTION: These pulleys have metric threads. screw supports the cover during removal.
Do not use imperial thread puller. Always
tighten puller by hand to ensure that the drive
pulley has the same type of threads (metric vs
imperial) before tightening completely.

vmr2008-127 93
Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

vmr2008-127-002_b
R400motr157A
1. Remove last
1. Screw in of driven pulley expander
2. Removal direction for belt
Open driven pulley with the driven pulley expander
(P/N 529 035 747).
Drive Belt Inspection
Inspect belt for cracks, fraying or abnormal wear.
529 035 747
Replace if necessary.
Check drive belt width at cord level. Replace if it
is out of specification.
Screw tool in the threaded hole of driven pulley
and tighten to open the pulley. DRIVE BELT WIDTH
SERVICE LIMIT 30.00 mm (1.181 in)

R400motr158A 1
R400motr156A 2 1 1. Drive belt
1. Driven pulley expander A. Belt width
2. Fixed sheave of driven pulley

To remove belt, slip the belt over the top edge of Drive Belt Installation
sliding sheave, as shown. For installation, reverse the removal procedure.
Pay attention to following details.
The maximum drive belt life span is obtained
when the drive belt has the proper rotation direc-
tion. Install it so that the arrow printed on belt is
pointing towards the back of the vehicle.

94 vmr2008-127
 Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

DRIVE PULLEY

vmr2008-127-003_a

1. Arrow towards the back of the vehicle

2. Drive pulley (front) R400motr159A 2 1 3
3. Driven pulley (rear)
1. Belt
NOTE: To ease installation of CVT cover with gas- 2. Drive pulley
3. Driven pulley
ket, put in a few locations, a small amount of Loc-
tite 5910 (P/N 293 800 081) in the groove of CVT
cover. Place the gasket in the groove and remove Drive Pulley Removal
excessive Loctite. Install cover with gasket imme-
Remove drive belt.
diately.
To block drive pulley, two methods can be used.
Install the center top screw of cover in first.
First Method
Lock crankshaft. Refer to CRANKCASE/CRANK-
SHAFT section.
Second Method
Block drive pulley with the pulley holding tool
(P/N 529 006 400).
529 006 400

vmr2008-127-002_b

1. Install first

Install the other screws then torque them in a

crisscross sequence.

vmr2008-127 95
Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

R400motr161A 1 3 2
1. Pulley holding tool
R400motr162C 4 3 2 1
2. Drive pulley sliding sheave
1. Unscrew drive pulley screw
3. Area to place holding tool hook 2. Spring washer
3. Thrust washer
Removal Procedure Continuation when 4. Drive pulley sliding sheave
Drive Pulley is Blocked
Push the sliding sheave no. 1 of the drive pulley
Prior to removing the drive pulley, mark sliding
to release spring pressure then remove the screw
sheave and governor cup together to ensure cor-
completely.
rect reinstallation. There are 4 levers mounted out
of 6 possible positions.
 WARNING
1 2 Sliding sheave of drive pulley is spring load-
ed.

Slowly release sliding sheave.

Screw the drive pulley puller (P/N 529 035 746) in
fixed sheave to release sheave.
Withdraw fixed sheave.
529 035 746

R400motr164A

1. Mark on drive pulley sliding sheave

2. Mark on governor cup

Unscrew drive pulley screw clockwise.

CAUTION: Drive pulley screw has LH threads.
Remove screw, spring washer and thrust washer.

96 vmr2008-127
 Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

R400motr163A 2 1
1. Drive pulley puller
2. Fixed sheave R400motr171A 1
1. Slider shoe
Drive Pulley Disassembly
Put governor cup on a vise. Use protection plates
Governor Cup on the vise jaws to avoid marks and/or damages
Carefully lift governor cup no. 2 until slider shoes to the governor cup.
no. 3 come at their highest position into guides. Push out bearing sleeve with an appropriate punch
NOTE: The following procedure is not necessary in the opposite direction of the protruding arrow.
except if roller must be removed. Refer to IN- NOTE: Use a punch with a smaller diameter than
SPECTION before proceeding. the bearing sleeve.
NOTE: Whenever removing a governor cup that CAUTION: Do not clamp the governor cup in
has the 2 boxes marked (punch marks), replace it the vise to push out bearing sleeve. Governor
with a new one. cup will be damaged.

vmr2006-021-018

Remove slider shoes out of each bearing sleeve.

Use a flat screwdriver if necessary.
vmr2006-021-015_a

PUSHING OUT BEARING SLEEVE

1. Punch
2. Vise

CAUTION: Always replace all rollers at the

same time. Partially worn rollers may cause
damage to the CVT system.
Remove roller and thrust washers.

vmr2008-127 97
Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

vmr2008-127-004_a

1. Bearing sleeve
2. Roller
3. Thrust washers

Sliding Sheave
Unscrew lock nut and remove centrifugal lever piv- R400motr166A 2 3 1
ot bolt.
1. One-way clutch
Remove centrifugal lever and both thrust wash- 2. Fixed sheave
3. Spring sleeve area
ers. 4. Direction of removal

Hold both spring sleeves with fingers when pulling

out the one-way clutch.
Release springs after one-way clutch removal.
1 2

vmr2006-021-019_a

1. Lock nut
2. Centrifugal lever pivot bolt
3. Centrifugal lever
4. Thrust washers
R400motr167A 2 1
Fixed Sheave 1. Spring
2. Spring sleeves
 WARNING
Always wear safety glasses to remove spring
sleeves.
Drive Pulley Cleaning
Clean pulley faces and shaft with fine steel wool
Pull one-way clutch slowly until the half of spring and dry cloth.
sleeves are visible. Using a paper towel with cleaning solvent, clean
crankshaft tapered end and the taper inside of
the fixed sheave of the drive pulley, crankshaft
threads and threads of drive pulley screw no. 4.
CAUTION: To avoid damage, make sure cleaner
does not contact the crankshaft seal.

98 vmr2008-127
 Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Remove all hardened oil deposits that have baked Measure the roller diameter. If one roller is out of
on crankshaft and pulley tapered surfaces with specification, replace all rollers.
coarse or medium steel wool and/or sand paper
no. 600. ROLLER OUTER DIAMETER
CAUTION: Do not use any other type of abra- 13.70 to 13.90 mm
sive. NOMINAL
(.539 to .547 in)
Reclean mounting surfaces with paper towel and SERVICE LIMIT 13.20 mm (.519 in)
cleaning solvent.
ROLLER INNER DIAMETER
Wipe off the mounting surfaces with a clean, dry
paper towel. 8.05 to 8.15 mm
NOMINAL
(.317 to .321 in)
CAUTION: Mounting surfaces must be free of
any oil, cleaner or towel residue. SERVICE LIMIT 9.00 mm (.354 in)

Centrifugal Lever Pivot Bolt

Measure diameter of centrifugal lever pivot bolt,
replace if it is out of specification.
A

R400motr169A 1
1. Centrifugal lever pivot bolt
A. Measure diameter here

CENTRIFUGAL LEVER PIVOT BOLT DIAMETER

6.078 to 6.100 mm
NOMINAL
(.239 to .240 in)

R400motr168A 1 SERVICE LIMIT 6.00 mm (.236 in)

1. Taper of fixed sheave
Centrifugal Lever
Only use petrol base cleaner when cleaning bush- Check bushing diameter in the centrifugal lever
ings no. 5 and no. 6. no. 7 for wear. If a centrifugal lever must be re-
placed, replace all levers at the same time.
CAUTION: Do not use acetone to clean bush-
ing.
CENTRIFUGAL LEVER BORE DIAMETER
Drive Pulley Inspection 6.035 to 6.078 mm
NOMINAL
(.238 to .239 in)
Drive Pulley
SERVICE LIMIT 6.200 mm (.244 in)
Drive pulley should be inspected annually for wear
or damages.
Replace centrifugal lever, thrust washers, centrifu-
Governor Cup gal lever pivot bolts and lock nuts if the contact
Check governor cup no. 2 for cracks or other visi- surfaces show heavy visible wear.
ble damages. Replace if necessary.
Roller
Check each roller for roundness of external diam-
eter.
NOTE: Replace governor cup if the roller does not
move freely.

vmr2008-127 99
Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

vmr2006-021-019_b
A
1. Lock nut R400motr172A
2. Centrifugal lever pivot bolt
3. Centrifugal lever A. Centrifugal lever pivot bolt bore diameter
4. Thrust washers
5. Contact surface to the roller
CENTRIFUGAL LEVER PIVOT BORE DIAMETER
CAUTION: Whenever replacing centrifugal
6.113 to 6.171 mm
levers, always replace all levers at the same NOMINAL
(.241 to .243 in)
time. Otherwise, the drive pulley will be un-
balanced (because of lever differences). SERVICE LIMIT 6.300 mm (.248 in)
Slider Shoe
Measure bushing diameters of sliding sheave.
Check slider shoes for visible wear and replace if
damaged. Use a dial bore gauge to measure bushing diame-
ter. Measuring point must be at least 5 mm (1/4 in)
NOTE: If necessary, use a screwdriver to remove from bushing edge.
slider shoes.

R400motr173A 1
1. Bushing on fixed sheave side
R400motr171A 1 A. Bore diameter of bushing
1. Slider shoe
SLIDING SHEAVE LARGE BUSHING
Sliding Sheave 55.000 to 55.040 mm
NOMINAL
Check sliding sheave no. 1 for cracks and sliding (2.165 to 2.167 in)
contact surface for excessive wear. Replace slid- SERVICE LIMIT 55.200 mm (2.173 in)
ing sheave if necessary.
Measure centrifugal lever pivot bolt bores. Re-
place sliding sheave if bores are out of specifica-
tion or damaged.

100 vmr2008-127
 Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

A Check for any marks on fixed sheave plate. Re-

place if necessary.
Check ring gear teeth for excessive wear or other
damage. Replace fixed sheave if necessary.

 WARNING
Fixed sheave and ring gear are balanced to-
gether. Always replace both parts together
otherwise severe injury and/or damages may
occur.

Spring
Measure spring free length and squareness. If
spring is out of specification, replace by a new.

SPRING FREE LENGTH

R400motr174A 1
SERVICE LIMIT 75 mm (2.953 in)
1. Bushing on governor cup side
A. Bore diameter of bushing

SLIDING SHEAVE SMALL BUSHING

30.000 to 30.040 mm
NOMINAL
(1.181 to 1.261 in)
SERVICE LIMIT 30.200 mm (1.189 in)

Replace sliding sheave if bushings no. 5 and/or

no. 6 is (are) out of specification. Visually inspect
coatings.
Fixed Sheave
Check fixed sheave contact surface to the gover-
nor cup for scoring and other damages. If so, re-
place fixed sheave.
vmr2008-127-052_a

A. Free length

CLUTCH SPRING SQUARENESS

SERVICE LIMIT 4 mm (.157 in)

R400motr175A 1
1. Visually check here

vmr2008-127 101
Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

One-Way Clutch
Apply Isoflex grease Topas NB 52 (P/N 293 550
021) on spring sleeves no. 8 and their springs then
between one-way clutch bearings.
Sliding Sheave
Install centrifugal lever and both thrust washers.

vmr2008-127-053_a

A. Squareness

One-Way Clutch
Check bearings for excessive play and smooth op-
eration. Replace one-way clutch if necessary.
vmr2006-021-019_a

CAUTION: Be careful not to damage the inside 1. Lock nut

of one-way clutch during bearing removal. 2. Centrifugal lever pivot bolt
3. Centrifugal lever
4. Thrust washers

1
R400motr176A 2
1. One-way clutch
2. Bearings
3. Drive pulley sliding sheave side

Measure length of spring sleeveno. 8 and check if

edges on top of the spring sleeve are excessively CAUTION: Centrifugal lever must move easily
worn. If out of specifications, replace both spring after installation.
sleeves and springs at the same time. Governor Cup
SPRING SLEEVE LENGTH Rebuild governor cup with new bearing sleeves,
thrust washers, rollers and slider shoes.
SERVICE LIMIT 9 mm (.276 in)
Push in bearing sleeve with an appropriate punch
in the direction of the protruding arrow. Push until
Drive Pulley Assembly bearing sleeve aligns with the contact surface of
For assembly, reverse the disassembly procedure. the slider shoe.
Pay attention to following details. CAUTION: Final position of bearing sleeve has
to be flush with the contact surface of the slider
shoes (no protrusion).

102 vmr2008-127
 Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

vmr2006-021-017

CAUTION: Rollers must move easily after in-

stallation.
Insert slider shoes no. 3 into governor cup to prop-
vmr2006-021-029_a erly slide in guides.
1. Top edge of bearing sleeve Align governor cup with sliding sheave using the
2. Mating surface of slider shoes
3. Vise marks traced at disassembly.
1 2

vmr2008-127-051_a

1. Flush surfaces

Each time the bearing sleeves are replaced, punch R400motr164A

a mark in an empty telltale box. If each box is 1. Mark on drive pulley sliding sheave
already marked, replace governor cup with a new 2. Mark on governor cup
one.
CAUTION: Make a visible mark in the box, but Drive Pulley Installation
do not tap too hard. Severe damage tof the
governor cup may appear. For installation, reverse the removal procedure.
Pay attention to the following details.
CAUTION: Do not apply antiseize or any lubri-
cant on crankshaft and drive pulley tapers.
CAUTION: Never use any type of impact
wrench at drive pulley removal and installa-
tion.
Clean mounting surfaces as described in CLEAN-
ING above.
Install drive pulley on crankshaft extension.
vmr2008-127 103
Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

CAUTION: Ensure to place thrust washer no. 9 DRIVEN PULLEY

prior to install conical spring washer no. 10.
Install spring washer no. 10 with its concave side Driven Pulley Removal
towards drive pulley then install drive pulley screw Remove:
no. 4. – Drive belt (see DRIVE BELT above)
– Driven pulley.
3 2 1

vmr2008-127-054_a

1. Concave side here R400motr180A

 WARNING
1. Fixed sheave of driven pulley
2. Sliding sheave of driven pulley
3. Spring
Never substitute spring washer and/or screw
with jobber ones. Always use BRP genuine NOTE: Two methods can be carried out to remove
parts for this particular case. driven pulley.

Install the pulley holding tool (P/N 529 006 400) First Method
and torque screw counterclockwise to 100 N•m Block driven pulley fixed sheave with pulley hold-
(74 lbf•ft). ing tool (P/N 529 035 771) then unscrew the driven
pulley screw. Do not remove screw completely.
529 006 400
529 035 771

NOTE: Drive pulley screw has LH threads.

1 2
2 1

R400motr177A

1. Pulley holding tool R400motr178A

2. Drive pulley removal/installation area
1. Pulley holding tool
2. Driven pulley fixed sheave
104 vmr2008-127
 Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Second Method
Block driven pulley with pulley holding tool
(P/N 529 006 400) then unscrew the driven pulley
screw. Do not remove screw completely.
529 006 400

vmr2008-127-005_a

1. Driven pulley screw

2. Thrust washer
3. Driven pulley fixed sheave

Remove the driven pulley with the spring, cam and

the plate.

2
R400motr179A

1. Pulley holding tool

2. Driven pulley fixed sheave

Removal Procedure Continuation when

Driven Pulley is Blocked
Push the driven pulley and hold in this position
while removing screw and washer.
vmr2008-127-006_a

 WARNING 1. Fixed sheave of driven pulley

2. Sliding sheave of driven pulley
Driven pulley is spring loaded. Hold driven 3. Spring
clutch pulley tight and slowly remove the 4. Cam
5. Plate
driven pulley screw to release spring tension.

Driven Pulley Disassembly

Fixed Sheave
Remove retaining ring and lift torque gear.

vmr2008-127 105
Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

Clean the CVT crankcase area from contamination.

Using a paper towel with cleaning solvent to clean
main shaft end and the inside of the shaft no. 12.
CAUTION: To avoid damage, make sure cleaner
does not contact the countershaft seal.
1

vmr2006-021-035_a

1. Retaining ring
2. Torque gear
3. Fixed sheave of driven pulley

NOTE: The following procedure is not necessary

except if ball bearing no. 11 or shaft must be re-
moved. Refer to INSPECTION before proceeding. R400motr182A 2
Heat ball bearing area up to 100°C (212°F) before 1. Main shaft supports
2. Sealing lip of countershaft oil seal
removing ball bearing.
Use a soft hammer to push shaft with bearing out
of fixed sheave. Driven Pulley Inspection
1 2 Sliding Sheave
Check bushings no. 13 for cracks, scratch and
for free movement when assembled to sliding
sheave.
Using a dial bore gauge, measure bushing diam-
eters. Measuring point must be at least 5 mm
(1/4 in) from bushing edges.
These bushings are not replaceable. Replace slid-
ing sheave if bushings are out of specification. Vi-
sually inspect coatings.
1

R400motr181A

1. Soft hammer
2. Shaft

Remove shaft from ball bearing.

Driven Pulley Cleaning

To remove a dust deposit from cam or shaft, use
a dry cloth.
Clean pulley faces and shaft with fine steel wool
and dry cloth. R400motr183A

Use pulley flange cleaner (P/N 413 711 809) to 1. Bushing

clean driven pulley.
106 vmr2008-127
 Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

BUSHINGS BORE DIAMETER

30.060 to 30.100 mm
NOMINAL
(1.183 to 1.185 in) 2

SERVICE LIMIT 30.200 mm (1.189 in)

Fixed Sheave
Check ball bearing no. 11 for free play and smooth
operation. Replace if necessary.
1
Check shaft no. 12 for heavy wear or visible dam- A
age. Replace if necessary.
If the shaft is removed, measure bushing diameter
with a dial bore gauge. Measuring point must be
at least 5 mm (1/4 in) from bushing edge.
R400motr185A
This bushing is not replaceable. Replace fixed
sheave if bushing no. 14 is out of specification. 1. Contact surfaces for power train
Visually inspect coatings. 2. Caliper
A. Width to be measured due to wear on contact surface

BUSHING BORE DIAMETER WIDTH ON TOP SURFACE

30.060 to 30.100 mm SERVICE LIMIT 6.000 mm (.236 in)
NOMINAL
(1.183 to 1.185 in)
SERVICE LIMIT 30.200 mm (1.189 in) 1 3 2

Check torque gear for visible damage and wear

limit with a caliper.
A

R400motr186A

B 1. Caliper
2. Sliding sheave
3. Contact surface
R400motr184A A. Wear to be measured

A. Measurement inside WEAR ON CONTACT SURFACE

B. Measurement outside
SERVICE LIMIT 2.000 mm (.079 in)
WEAR ON TEETH BOTH SIDES
SERVICE LIMIT 7.500 mm (.295 in) Spring
Measure spring free length and squareness. If
Cam spring no. 33 is out of specification, replace by a
Check cam for visible damage and wear limit with new.
a caliper.
SPRING FREE LENGTH
SERVICE LIMIT 164 mm (6.457 in)

vmr2008-127 107
Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

vmr2008-127-055_a
R400motr187 1
A. Free length
1. Ball bearing
CLUTCH SPRING SQUARENESS
CAUTION: Do not use a hammer, use a press
SERVICE LIMIT 3.8 mm (.150 in) only.

1
2

vmr2008-127-056_a

R400motr188A
A. Squareness
1. Shaft
2. Fixed sheave
3. Press machine
Driven Pulley Assembly
For installation, reverse the removal procedure. Install torque gear then secure it with retaining
Pay attention to following details. ring.
Heat ball bearing area up to 100°C (212°F) before
ball bearing installation.
NOTE: Place new ball bearing in a freezer for 10
minutes before installation.
Install ball bearing with the writing on top and push
only on the outer ring.

108 vmr2008-127
 Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

R400motr189A 2 1
R400motr191A 2 1 3
1. Retaining ring
2. Torque gear 1. Sharp edge of cam retainer to engine side
2. Main shaft spline
3. Printed mark “ENGINE SIDE”

Driven Pulley Installation Install sliding sheave no. 15 into fixed sheave
For installation, reverse the removal procedure. no. 16.
Pay attention to the following details.
Place spring behind sliding sheave then align driv-
Place O-ring on main shaft splines and move it en pulley with cam.
with spacer in end position.
CAUTION: Chamfer on inside diameter of the 1 2
spacer must face engine side.
3
3 1 2

R400motr190A

1. O-ring
2. Distance sleeve R400motr192A

3. Chamfered area of distance sleeve

1. Cam
2. Spring
Install cam retainer on main shaft end the right 3. Driven pulley
way then install cam. 4. Location for pushing during screw installation

NOTE: Place cam retainer with printed mark “EN- Push the driven pulley by hand. Install the driven
GINE SIDE” towards the engine. pulley screw and its washer.

vmr2008-127 109
Section 03 ENGINE
Subsection 08 (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))

R400motr193A 1 2
1. Washer
2. Driven pulley screw

NOTE: Driven pulley end-play is 0 (zero).

Torque driven pulley screw.

110 vmr2008-127
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

CYLINDER HEAD/CYLINDER
SERVICE TOOLS
Description Part Number Page
dial gauge ............................................................................ 414 104 700 ......................................... 115
valve spring compressor cup................................................ 529 035 725 ......................................... 128
valve spring compressor clamp ............................................ 529 035 764 ......................................... 128
piston ring compressor tool.................................................. 529 035 919 ......................................... 133
piston circlip installer ............................................................ 529 035 921 ......................................... 136
valve guide remover ............................................................. 529 035 924 ......................................... 131
camshaft locking tool............................................................ 529 035 926 ................................. 120, 132
valve guide installer .............................................................. 529 036 140 ......................................... 131

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
leak down test kit ................................................................. 529 035 661 ......................................... 116
valve stem seal pliers ........................................................... Snap-on YA ......................................... 129
8230

SERVICE PRODUCTS
Description Part Number Page
Loctite 243 (blue).................................................................. 293 800 060 ................................. 118, 122
Loctite 767 (antiseize lubricant) ............................................ 293 800 070 ......................................... 131

vmr2008-128 111
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

CYLINDER HEAD

7 N•m
(62 lbf•in) 19
2 3 12 N•m
NEW 18 (106 lbf•in)
1 10 N•m
21 (89 lbf•in) 0.5 N•m
(5 lbf•in)
Loctite
30 243
Loctite 31
243 Engine 22
oil 29
33 NEW Engine
14 oil
11 10 N•m 27 34
12 (89 lbf•in)
30 N•m 13 Engine 10 N•m
(22 lbf•ft)15 Loctite oil (89 lbf•in) 25 N•m
Engine 243 Engine (18 lbf•ft)
oil 23 oil
17
16 20 N•m
19 22 NEW (15 lbf•ft)
18 Loctite 24
30 243
20
28 NEW
10 N•m 8
12 N•m (89 lbf•in)
(106 lbf•in) 31 29 34 NEW 10
Engine 33
oil Loctite
Loctite 767 NEW 243
(antiseize 8 N•m 9 Engine
lubricant) (71 lbf•in) oil
32 10 N•m
Engine 4 (89 lbf•in) 26
oil
6
0.1 N•m 60 N•m
5 (0.9 lbf•in) (44 lbf•ft)
See torquing
7 procedure
4.5 N•m inside
(40 lbf•in)

vmr2008-128-001_a

112 vmr2008-128
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

CYLINDER AND PISTON

8
Engine oil

4
Engine oil

6 20 N•m
(15 lbf•ft)
+ 60°
7
NEW

Engine oil

R400motr16T

vmr2008-128 113
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

GENERAL CAUTION: In case of piston rings and/or valve

replacement, always clean the whole engine
To work on cylinder head, cylinder and piston, the and change oil and oil filter.
engine removal is not necessary.
Always place the vehicle on level surface. MAINTENANCE
NOTE: For a better understanding, the many illus-
trations are taken with engine out of vehicle. VALVE ADJUSTMENT
When diagnosing an engine problem, always per- NOTE: Check and adjust valve clearance only
form a cylinder leak test. This will help pinpoint a when engine is cold.
problem.
Remove valve cover.
Always disconnect BLACK (-) cable from the bat-
tery, then RED (+) cable before working on the en- Lock crankshaft to TDC compression (refer to
gine. CRANKCASE/CRANKSHAFT section).
Using feeler gauge, check the valve clearance.
 WARNING
Always disconnect battery or starter cables VALVE CLEARANCE
exactly in the specified order, BLACK (-) cable 0.11 to 0.19 mm
first. EXHAUST
(.0043 to .0075 in)
0.06 to 0.14 mm
During assembly/installation, use the torque val- INTAKE
(.0024 to .0055 in)
ues and service products as in the exploded
views.
If the valve clearance is out of specification per-
Clean threads before applying a threadlocker. Re- form the valve clearance adjustment.
fer to SELF-LOCKING FASTENERS and LOCTITE
NOTE: Use mean value of exhaust/intake to en-
APPLICATION at the beginning of this manual for sure a proper valve adjustment.
complete procedure.
Hold the adjusting screw at the proper position
 WARNING and torque the locking nut.
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pin,
etc.) must be installed or replaced with new
ones where specified. If the efficiency of
a locking device is impaired, it must be re-
newed.

When disassembling parts that are duplicated in

the engine, (e.g.: valves), it is a strongly recom-
mended to note their position (PTO, MAG side)
and to keep them as a “group”. If you find a de-
fective component, it would be much easier to
find the cause of the failure among its group of
parts (e.g.: you found a worn valve guide. A bent
spring could be the cause and it will be easy to
know which one among the springs is the cause
vmr2007-036-004_a
to replace it if you grouped them at disassembly).
Besides, since used parts have matched together 1. Adjustment screw
2. Locking nut
during the engine operation, they will keep their 3. Feeler gauge
matched fit when you reassemble them together
within their “group”. Repeat the procedure for each valve.
Intake port/air filter contaminated (clogged) with Before installing valve cover, recheck all valve ad-
dirt, sand, etc. (leads to worn valves, piston rings justments.
and finally to leak of power).

114 vmr2008-128
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

INSPECTION Remove valve cover. Refer to CYLINDER

HEAD/CYLINDER.
LEAK TEST
Before performing the cylinder leak test, verify the
following:
– Clamp(s) tightness
– Radiator and hoses.
NOTE: For best accuracy, the leak test should be
done with the engine at normal operating temper-
ature.

 WARNING
Be careful not to burn yourself on hot engine
parts.

vmr2008_128-003_a

Preparation 1. Valve cover screws

2. Valve cover
Disconnect battery. 3. Valve cover gasket

 WARNING Turn crankshaft until piston is at TDC of compres-

sion stroke. To turn the crankshaft, there are two
Always respect this order for disassembly;
possible procedures.
disconnect BLACK (-) cable first.
First Procedure:
Remove radiator cap. – Turn the drive pulley.
 WARNING Second Procedure:
To prevent burning yourself, only remove the – Use rewind starter.
radiator cap by wearing the appropriate safe- Install a dial gauge (P/N 414 104 700) into spark
ty equipment. plug hole.
Turn the crankshaft and set the piston to TDC of
Refer to BODY and remove: compression stroke.
– LH side panel NOTE: The engine must be accurately set to TDC
– Engine cover of compression stroke. Otherwise the engine will
– Engine cover cap. continue to rotate when pressure builds up.
Remove spark plug.
2 1

vmr2007-003-001_a

TYPICAL
1. Dial gauge

NOTE: If a dial gauge is not available, use a screw-

R400motr104A
driver or another similarly suitable tool.
1. Spark plug cable CAUTION: Pay attention not to scratch or dam-
2. Spark plug
age piston/cylinder surface.
vmr2008-128 115
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

NOTE: At TDC of compression stroke, the marks 1

on the camshaft timing gear have to be parallel to
cylinder head edge as per following illustration.

V07C0KA 2
TYPICAL
1. Leak tester
2. Air supply hose
vmr2008-128-100_a

1. Marks on camshaft timing gear Set needle of measuring gauge to zero.

2. Cylinder head edge
3. Camshaft timing gear Install gauge adapter into previously cleaned spark
4. Timing gear tab
5. Decompressor shaft bore plug hole.
Supply combustion chamber with air pressure.
Leak Test Note the amount of leaking or percentage (de-
pending on tester).
Use the leak down test kit (P/N 529 035 661).
LEAKAGE
ENGINE CONDITION
PERCENTAGE
0% to 15% Excellent condition
16% to 25% Good condition
529 035 661
Fair condition; engine will run
26% to 40% and in some cases, performance
might be affected
Poor condition, diagnose and
41% and higher
repair engine
Connect air supply to the leak down test kit.
Diagnosis
Listen for air leaks.
– Air escaping on intake port/throttle body means
leaking intake valve(s).
– Air escaping on exhaust port means leaking ex-
haust valve(s).
– Air bubbles out of radiator means leaking cylin-
der head gasket.
– Air/oil escaping from crankcase means dam-
aged gasket and/or loosened screws.
– Air/coolant escaping from cylinder/head means
damaged gasket(s) and/or loosened screws.
– Air escaping into crankcase area means exces-
sively worn cylinder and/or broken piston rings.

116 vmr2008-128
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

NOTE: For all the checkpoints mentioned above Valve Cover Inspection
see the appropriate engine section to diagnose Check the gasket no. 1 on the valve cover no. 2
and repair the engine. if it is brittle, cracked or hard. If so, replace the
gasket.
Reassembly
Reverse the preparation procedure. Ensure to Valve Cover Installation
respect torque values and use of appropriate For installation, reverse the removal procedure.
products/lubricants. Refer to exploded views of
other sections of this manual. Torque the distance screws no. 3 in a criss-cross
sequence.
PROCEDURES
DECOMPRESSOR
VALVE COVER Decompressor Removal
Valve Cover Removal Remove:
Remove distance screws of valve cover. – Valve cover
– Camshaft timing gear screw
– Decompressor washer
– Centrifugal weight with torsion spring no. 11
and spacer no. 12
– Decompressor shaft no. 13.

vmr2008_128-004_a

1. Distance screws
2. Valve cover

Remove valve cover and gasket.

vmr2008-128-101_a

1. Camshaft timing gear screw

2. Decompressor washer
3. Centrifugal weight

Decompressor Inspection
Check decompressor shaft for service limit, re-
place if out of specifications.

vmr2008_128-005_a

1. Valve cover
2. Gasket

vmr2008-128 117
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

2 1 1
A
C

R400motr58A

1. Decompressor shaft
2. Groove for centrifugal weight
A. Measure here the bearing seat to cylinder head
B. Measure top end (contact to camshaft lobe exhaust)
C. 7 mm (.276 in)

DECOMPRESSOR SHAFT MEASUREMENT A

5.578 to 5.590 mm
NEW
(.219 to .220 in)
SERVICE LIMIT 5.450 mm (.215 in)
DECOMPRESSOR SHAFT MEASUREMENT B R400motr60A

5.300 to 5.350 mm 1. Position of torsion spring end

NEW
(.210 to .211 in)
SERVICE LIMIT 5.050 mm (.199 in) Engage the edge of centrifugal weight no. 14 into
the decompressor shaft groove then put the parts
Check torsion spring, edge and bearing bore of in place.
centrifugal weight for visible wear. If so, replace 2
them together.

R400motr59B 3
R400motr61A 1
1. Centrifugal weight
2. Edge of centrifugal weight 1. Decompressor shaft groove
3. Bearing bore 2. Centrifugal weight

Apply Loctite 243 (blue) (P/N 293 800 060) on

Decompressor Installation threads of camshaft timing gear screw no. 15.
The installation is the reverse of the removal pro- CAUTION: Take care before and after cover
cedure, but pay attention to the following details. installation that the centrifugal system moves
Position the end of torsion spring properly in the (slides) easily.
centrifugal weight location.

118 vmr2008-128
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

TIMING CHAIN TENSIONER 2

Tensioner Removal
 WARNING
Chain tensioner is spring loaded. Never per-
form this operation immediately after the en-
gine has been run because the exhaust sys-
tem can be very hot. Wait until exhaust sys-
tem is warm or cold.

Remove:
– Chain tensioner plug
– O-ring
– Spring R400motr56A 1
– Chain tensioner plunger. 1. Chain tensioner screw
2. Chain tensioner housing

Tensioner Inspection
Check chain tensioner plunger no. 4 for free
movement and/or scoring.
Check if possible chain guides for wear. Replace
as necessary.
Check if O-ring no. 5 is brittle, cracked or hard.
Replace as necessary.
Check condition of spring no. 6. Replace if broken
or worn.
Check the housing no. 9 for cracks or other dam-
ages. Replace it if necessary.
Check if O-ring no. 10 is brittle, cracked or hard.
Replace as necessary.
R400motr55A 4 3 2 1 Tensioner Installation
1. Chain tensioner plug For installation, reverse the removal procedure.
2. O-ring
3. Spring However, pay attention to the following.
4. Chain tensioner plunger
NOTE: Before installing the chain tensioner make
Remove chain tensioner housing with its O-ring. sure, that the camshaft timing gear can be moved
back and forth.

vmr2008-128 119
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

529035926

vmr2007-036-004_a

TYPICAL — MOVE GEAR BACK AND FORTH

Apply engine oil on the plunger before installing.

NOTE: Slightly screw in the plunger until the ten-
sioned chain allows no more back and forth move-
ment of the camshaft timing gear. Then screw in
the plunger an additional 1/8 turn to reach the re-
quired torque of 0.1 N•m (.9 lbf•in).
CAUTION: Improper adjustment of the chain
tension will lead to severe engine damage. vmr2008-128-102_a

Install the O-ring no. 5 on chain tensioner plug 1. Camshaft locking tool
2. Camshaft timing gear screw
no. 7. 3. Camshaft timing gear
Fit the spring on one side into the slot of the plug
screw and on the other side into the plunger. Turn Lock crankshaft at the TDC compression posi-
spring only clockwise in order to fit the spring end tion to have the crankshaft position defined for
into the notch of the plunger and to avoid loosen- reassembly (refer to CRANKCASE/CRANKSHAFT
ing the plunger during spring installation. Do not section.
preload the spring. Remove the decompressor and the camshaft tim-
Then compress the spring and screw in the plug ing gear no. 16.
screw. NOTE: Secure timing chain no. 17 with a retaining
Finally tighten the plug screw to 4.5 N•m wire.
(40 lbf•in).
Camshaft Timing Gear Inspection
CAMSHAFT TIMING GEAR Check camshaft timing gear for wear or deteriora-
tion.
Camshaft Timing Gear Removal If teeth are worn or damaged, replace timing gear
Remove: as well as the timing chain.
– Valve cover NOTE: For crankshaft gear, refer to
– Chain tensioner. CRANKCASE/CRANKSHAFT.
Using the camshaft locking tool (P/N 529 035 926), Camshaft Timing Gear Installation
lock the camshaft at TDC compression position to
prevent timing chain stretching. For installation, reverse the removal procedure.
Pay attention to the following details.
Clean mating surface and threads of camshaft
prior to assemble camshaft timing gear.
120 vmr2008-128
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

vmr2008-128-102_a
vmr2008-128-103_a

1. Mating surface on camshaft 1. Camshaft locking tool

2. Camshaft timing gear screw
2. Threads for camshaft timing gear screw 3. Camshaft timing gear

Camshaft timing gear must be at TDC compres- When the camshaft timing gear and the timing
sion before installing the timing chain. chain are installed, remove the crankshaft locking
Install camshaft timing gear so that the tabs are bolt as well as the camshaft locking tool.
located into the flat zone of the camshaft. The Reinstall all other removed parts.
printed marks on the camshaft timing gear have
to be parallel to the cylinder head edge. See the
following illustration for a proper positioning. TIMING CHAIN
Timing Chain Inspection
The timing chain tensioner plunger protrusion
gives a general information about the valve train
(chain) condition.

vmr2008-128-100_a

1. Printed marks on camshaft timing gear

2. Cylinder head edge
3. Camshaft timing gear
4. Tab
5. Decompressor shaft bore
vmr2008-128-104_a

CAUTION: Crankshaft and camshaft must be 1. Camshaft timing gear

locked on TDC position to place camshaft tim- 2. Timing chain guide
3. Chain tensioner plunger
ing gear and timing chain in the proper posi- A. Chain tensioner plunger protrusion
tion. Never use the mark on the magneto to
find the TDC. Only use the crankshaft locking CHAIN TENSIONER PLUNGER PROTRUSION
tool to locate the TDC.
18.5 mm to 20 mm
SERVICE LIMIT
(.71 in to .79 in)

vmr2008-128 121
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

If protrusion exceeds service limit, replace tim- – Magneto cover and rotor (refer to MAGNE-
ing chain, camshaft timing gear and timing chain TO/STARTER)
guides at the same time. – Bearing screw at the bottom of chain tensioner
Check timing chain on camshaft timing gear for guide.
excessive radial play. Pull the chain guide downward to remove it.
Check chain condition for wear and teeth condi-
tion. Guide Inspection
Check chain guide for wear, cracks or other dam-
ages. Replace if necessary.

Guide Installation
Clean bearing screw threads then apply Loctite
243 (blue) (P/N 293 800 060) on the screw threads.
vmr2006-044-018_a Install the guide in crankcase housing then torque
1. Timing chain bearing screw to 10 N•m (89 lbf•in).

If chain is excessively worn or damaged, replace 3 1 2

it as a set (camshaft timing gear and timing chain).

Timing Chain Removal

Remove:
– Engine from vehicle (refer to ENGINE
REMOVAL/INSTALLATION)
– Valve cover, chain tensioner and camshaft tim-
ing gear
– Magneto cover and rotor (refer to
MAGNETO/STARTER section)
– Output shaft (refer to GEARBOX/OUTPUT
SHAFT section).
NOTE: Mark the operating direction of the timing
chain before removal.
R400motr48A

Timing Chain Installation 1. Timing chain guide

2. Bearing screw
The installation is essentially the reverse of the re- 3. Crankcase MAG side
moval procedure but, pay attention to the follow-
ing details. Reinstall all removed parts in accordance with the
Ensure to perform proper valve timing. Lock proper installation procedures.
crankshaft and camshaft at TDC compression
(refer to CRANKCASE/CRANKSHAFT section and ROCKER ARM
CAMSHAFT TIMING GEAR in this section).
Install timing chain then, adjust chain tension (re- Rocker Arm Removal
fer to TIMING CHAIN TENSIONER in this section). Lock crankshaft to TDC compression, refer to
CRANKCASE/CRANKSHAFT.
CAUTION: Improper valve timing will damage
engine components. Remove:
– Valve cover
TIMING CHAIN GUIDE – Chain tensioner
(TENSIONER SIDE) – Camshaft timing gear no. 16
– Camshaft retaining plate.
Guide Removal
Remove:
– Engine from vehicle (refer to ENGINE
REMOVAL/INSTALLATION)
122 vmr2008-128
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

1 2 1

R400motr67A 4
1. 2 thrust washers
2. Rocker arm (exhaust side)
3. Cylinder head — spark plug side
4. Big taper to PTO side
vmr2008-128-105_a

1. Cylinder head
2. Camshaft retaining plate screw Rocker Arm Inspection
3. Camshaft retaining plate
Inspect each rocker arm for cracks and scored fric-
Remove rocker arm shafts. tion surfaces. If so, replace rocker arm assembly.
Remove rocker arms assembly (exhaust side and Check the rocker arm rollers for free movement,
intake side) with adjustment screws and nuts. wear and excessive radial play. Replace rocker
arm assembly if necessary.
3 4 5
2 1

A
R400motr68A

1. Rocker arm (exhaust side)

2. Roller
A. Bore for rocker arm shaft

Measure rocker arm bore diameter. If diameter is

R400motr66A 2
out of specification, change the rocker arm assem-
1. Rocker arm shaft bly.
2. Rocker arm (exhaust side)
3. Rocker arm (intake side)
4. Adjusting screw ROCKER ARM BORE DIAMETER
5. Locking nut
12.036 to 12.050 mm
NEW
Remove thrust washers no. 19 and no. 22. (.4739 to .4744 in)
CAUTION: Pay attention not to lose thrust SERVICE LIMIT 12.060 mm (.4748 in)
washers or drop them into the timing chain
compartment. Check adjustment screws for free movement,
cracks and/or excessive play.

vmr2008-128 123
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

R400motr69A

1. Free movement of adjustment screw top

Rocker Arm Shaft

Check for scored friction surfaces; if so, replace R400motr66B 1 2 3
parts.
1. Rocker arm shaft
Measure rocker arm shaft diameter. 2. Thrust washer (MAG side)
3. Thrust washer (PTO side)

Place the other thrust washer no. 22 and push

rocker arm shaft to end position.
Install the other rocker arm by using the previous
procedure.
R400motr70A A
Install the camshaft retaining plate no. 23.
A. Measure rocker arm shaft diameter here
Install all other removed parts.
ROCKER ARM SHAFT DIAMETER
CAMSHAFT
12.000 to 12.018 mm
NEW
(.4724 to .4731 in) Camshaft Removal
SERVICE LIMIT 11.990 mm (.4720 in) The camshaft no. 28 can be removed with the
cylinder head installed.
Any area worn excessively will require parts re-
Remove:
placement.
– Valve cover
Rocker Arm Installation – Chain tensioner
NOTE: Use the same procedure for exhaust or – Camshaft timing gear
intake rocker arm. – Camshaft retaining plate.
Apply engine oil on rocker arm shafts no. 18.
Install the rocker arm shafts with the chamfered
edge first and use following procedure:
Insert a rocker arm shaft through rocker arm shaft
bore.
Install thrust washer no. 19 then the proper rocker
arm (exhaust no. 20 or intake no. 21).
Push in rocker arm shaft until its chamfer reaches
the end of rocker arm bore.

124 vmr2008-128
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

C B
A
D

R400motr76A

A. Camshaft lobe (exhaust valves)

B. Camshaft lobe (intake valves)
C. Camshaft journal MAG side
D. Camshaft journal PTO side
vmr2008-128-105_a

1. Cylinder head CAMSHAFT LOBE — EXHAUST VALVES

2. Camshaft retaining plate screw
3. Camshaft retaining plate 31.937 to 32.137 mm
NEW
(1.2574 to 1.2652 in)
Remove rocker arms (see ROCKER ARM above).
SERVICE LIMIT 31.920 mm (1.2567 in)
Remove the camshaft.
CAMSHAFT LOBE — INTAKE VALVES
NOTE: For removal rotate camshaft so that
intake/exhaust lobe shows to upper side of cylin- 32.253 to 32.453 mm
NEW
der head. (1.2698 to 1.2777 in)
SERVICE LIMIT 32.235 mm (1.2691 in)
CAMSHAFT JOURNAL — MAG SIDE
34.959 to 34.975 mm
NEW
(1.3763 to 1.3770 in)
SERVICE LIMIT 34.950 mm (1.3760 in)
CAMSHAFT JOURNAL — PTO SIDE
21.959 to 21.980 mm
NEW
(.8645 to .8654 in)
SERVICE LIMIT 21.950 mm (.8642 in)

Measure clearance between both ends of

camshaft and cylinder head.

vmr2008_128-106_a

1. Area for camshaft lobes

2. Camshaft
3. Camshaft retaining plate

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

vmr2008-128 125
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

R400motr77A

A. Cylinder head camshaft bearing MAG side

B. Cylinder head camshaft bearing PTO side vmr2008_128-106_b

1. Camshaft retaining plate position

CYLINDER HEAD CAMSHAFT BEARING — 2. Slot retaining camshaft
MAG SIDE 3. Direction of movement

35.000 to 35.025 mm
NEW For other parts, refer to proper installation proce-
(1.3780 to 1.3789 in)
dure.
SERVICE LIMIT 35.040 mm (1.3795 in)
CYLINDER HEAD CAMSHAFT BEARING — CYLINDER HEAD
PTO SIDE
Cylinder Head Removal
22.000 to 22.021 mm
NEW Lock crankshaft at TDC compression, refer to
(.8661 to .8670 in)
CRANKCASE/CRANKSHAFT.
SERVICE LIMIT 22.040 mm (.8677 in)
Drain coolant (refer to COOLING SYSTEM).
Replace parts that are not within specifications. Disconnect:
– Spark plug cable
Camshaft Installation – Coolant temperature sensor (CTS) connector.
For installation, reverse the removal procedure. Remove/disconnect:
Pay attention to the following details.
– Both side panels and both inner fenders (refer
Install camshaft in the opposite way of the re- to BODY)
moval then place the camshaft retaining plate – Air filter housing
no. 23 in the slot.
– Radiator inlet hose
CAUTION: Blow out spilled coolant from en-
gine. Otherwise coolant would contaminate
engine oil at cylinder head removal.
– MAPS, IACV and TPS connectors
– Fuel hose at fuel rail
– Injector connector
– LH upper engine support
– Exhaust pipe nuts
– Intake socket clamp (cylinder head side only)
– Chain tensioner
– Valve cover
– Camshaft timing gear
– Cylinder head screws M6

126 vmr2008-128
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

– Cylinder head screws M10 retaining cylinder

head no. 24 and cylinder no. 25 to crankcase
housings.

vmr2008_128-107_a

1. Oil port to lubricate camshaft lobes intake/exhaust

2. Oil supply to camshaft bearing journal MAG side
3. Oil supply to camshaft bearing journal PTO side
R400motr71A 2
1. Cylinder head screws M6
2. Cylinder head screws M10 Cylinder Head Installation
For installation, reverse the removal procedure.
Pull up cylinder head. Pay attention to the following details.
Remove: Ensure dowel pins are in place.
– Chain guide no. 27 (opposite chain tensioner) Install a new cylinder head gasket no. 26.
– Cylinder head gasket (discard).
First, torque cylinder head screws M10 in criss-
cross sequence to 20 N•m (15 lbf•ft) then finish
tightening to 60 N•m (44 lbf•ft).
Torque cylinder head screws M8 to 10 N•m
(89 lbf•in).
4
2

1 1

R400motr72A 3
1. Cylinder head
2. Timing chain
3. Chain guide
4. Cylinder head gasket
R400motr71A 2
1. Cylinder head screws M6
Cylinder Head Inspection 2. Cylinder head screws M10
Check for cracks between valve seats, if so, re-
place cylinder head. Check timing chain guide no. 27 for movement.
Check mating surface between cylinder and cylin- CAUTION: Chain guide has to be fixed between
der head for contamination. If so, clean both sur- cylinder and cylinder head.
faces.
Clean oil support through the cylinder head from
contamination.
vmr2008-128 127
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

1 3 2

vmr2008_128-108_a
R400motr78A
1. Chain guide (fixed between cylinder and cylinder head)
2. Chain guide on tensioner side (mounted in crankcase) 1. Valve spring compressor clamp
2. Valve spring compressor cup
Remove crankshaft locking bolt then reinstall all 3. Valve cotter
other removed parts.

VALVE SPRING
Valve Spring Removal
Remove:
– Rocker arms no. 20 and no. 21
– Cylinder head no. 24.
Compress valve spring no. 29; use the valve
spring compressor clamp (P/N 529 035 764) and
the valve spring compressor cup (P/N 529 035
725).
R400motr79A

LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF

THE VALVE

Remove valve cotters no. 30.

Withdraw valve spring compressor, valve spring
retainer no. 31 and valve spring no. 29.

Valve Spring Inspection

vmr2006-043-019
Check valve springs for visible damages. If so,
replace them.
Check valve springs for free length and straight-
ness.

vmr2006-043-020

 WARNING
Always wear safety glasses when disassem-
bling valve springs. Be careful when unlock-
ing valves. Components could fly away be-
cause of the strong spring preload.
128 vmr2008-128
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

Push valve stem then pull valves out of valve guide

no. 32.

R400motr80A A
A. Valve spring length

VALVE SPRING FREE LENGTH

NEW 40.81 mm (1.607 in)
SERVICE LIMIT 39.00 mm (1.535 in)
vmr2006-043-021_a
Replace valve springs if not within specifications.
1. Intake valve 31 mm (1.22 in)
2. Exhaust valve 27 mm (1.06 in)
Valve Spring Installation
For installation, reverse the removal procedure. Remove valve stem seal no. 33 with the valve
Pay attention to the following details. stem seal pliers (P/N Snap-on YA 8230).
Colored area of the valve springs must be placed
on top.
NOTE: Valve cotters must be properly engaged in
valve stem grooves.

2
vmr2006-043-022

R400motr81A

1. Position of the valve spring

2. Valve cotters

After spring is installed, ensure it is properly

locked by tapping on valve stem end with a soft
hammer, so that valve opens and closes a few
times.
CAUTION: An improperly locked valve spring vmr2006-043-023

will cause engine damage.

Valve Inspection
VALVE Valve Stem Seal
Valve Removal Inspection of valve stem seals is not needed be-
cause new seals should always be installed when-
Remove valve spring(s) no. 29.
ever cylinder head is removed.

vmr2008-128 129
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

Valve Valve Face and Seat

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

VALVE OUT OF ROUND

(intake and exhaust valves)
2
NEW 0.005 mm (.0002 in) 3
SERVICE LIMIT 0.06 mm (.0024 in)

Valve Stem and Valve Guide Clearance 1

Measure valve stem and valve guide in three
places using a micrometer and a small bore R400motr84A
gauge.
1. Valve seat
NOTE: Clean valve guide to remove carbon de- 2. Exhaust valve contaminated area
posits before measuring. 3. Valve face (contact surface to valve seat)

Change valve if valve stem is out of specification Check valve face and seat for burning or pittings
or has other damages such as wear or friction sur- and replace valve or cylinder head if there are signs
face. of damage.
Ensure to seat valves properly. Apply some lap-
ping compound to valve face and work valve on its
seat with a lapping tool (see VALVE GUIDE PRO-
CEDURE below).
Measure valve face contact width.
NOTE: The location of contact area should be in
center of valve seat.
A Measure valve seat width using a caliper.

VALVE SEAT CONTACT WIDTH

EXHAUST VALVE
R400motr83A 1.25 to 1.55 mm
NEW
A. Valve stem diameter
(.049 to .061 in)
SERVICE LIMIT 2.00 mm (.078 in)
VALVE STEM DIAMETER INTAKE VALVE
EXHAUST VALVE 1.05 to 1.35 mm
NEW
4.956 to 4.970 mm (.041 to .053 in)
NEW
(.1951 to .1957 in) SERVICE LIMIT 1.80 mm (.070 in)
SERVICE LIMIT 4.930 mm (.1941 in)
INTAKE VALVE If valve seat contact width is too wide or has dark
4.966 to 4.980 mm spots, replace the cylinder head.
NEW
(.1955 to .1960 in)
SERVICE LIMIT 4.930 mm (.1941 in)

Replace valve guide no. 32 if it is out of specifica-

tion or has other damages such as wear or friction
surface.

VALVE GUIDE DIAMETER

(intake and exhaust valves)
SERVICE LIMIT 5.050 mm (.1988 in)

130 vmr2008-128
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

VALVE GUIDE
B
Valve Guide Removal
A
Remove:
– Cylinder head
– Valve spring
– Valves.
NOTE: Clean valve guide area from contamination
before removal.
Using the valve guide remover (P/N 529 035 924)
and a hammer, remove valve guide.

V01C1HA

A. Valve face contact width

B. Valve seat contact width
vmr2006-043-024

2
Valve Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Install a NEW valve stem seal. Make sure thrust 1
washer is installed before installing seal.
1 2

R400motr86A

1. Valve guide remover

2. Valve guide

R400motr85A

1. Thrust washer
Valve Guide Inspection
2. Sealing lips of valve stem seal Always replace valve stem seals whenever valve
guides are removed.
Apply engine oil on valve stem and install it.
Clean the valve guide bore before reinstalling the
CAUTION: Be careful when valve stem is valve guide into cylinder head.
passed through sealing lips of valve stem seal.
To ease installation of valve cotters, apply oil or Valve Guide Installation
grease on them so that they remain in place while For installation, reverse the removal procedure.
releasing the spring. Pay attention to the following details.
After spring is installed, ensure it is properly Apply Loctite 767 (antiseize lubricant) (P/N 293
locked by tapping on valve stem end with a soft 800 070) on valve guide no. 32 prior to install it
hammer so that valve opens and closes a few into the cylinder head no. 24.
times.
Use the valve guide installer (P/N 529 036 140) to
CAUTION: An improperly locked valve spring install valve guide in the cold cylinder head.
will cause engine damage.

vmr2008-128 131
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

3 A
2
1

vmr2006-043-025

R400motr89A

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

NOTE: Ensure to seat valves properly. Apply

2 marking paste to ease checking contact pattern.
R400motr87A
Repeat procedure until valve seat/valve face fits
together.
1. Valve guide installer
2. Valve guide
CYLINDER
Valve guide must be adjusted in diameter by using
a reamer. Cylinder Removal
Lock crankshaft at TDC compression position, re-
VALVE GUIDE
fer to CRANKCASE/CRANKSHAFT.
(intake and exhaust valves)
4.998 to 5.018 mm Using the camshaft locking tool (P/N 529 035 926),
NEW lock the camshaft at TDC compression position to
(.1968 to .1976 in)
prevent timing chain stretching.
1 Remove:
– Chain tensioner
– Decompressor
A – Camshaft timing gear
– Cylinder head.
Pull cylinder no. 25.
Discard cylinder base and cylinder head gasket.

R400motr88A

1. Valve guide
A. Valve guide diameter

NOTE: Ensure to turn reamer in the right direction.

Use cutting oil and make brakes to clean reamer/
valve guide from metal shavings.
Apply some lapping compound to valve face and
work valve on its seat with a lapping tool.

132 vmr2008-128
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

4 Cylinder Out of Round

Measure cylinder diameter in piston axis direction
from top of cylinder. Take another measurement
90° from first one and compare.
NOTE: Take the same measuring points like de-
1
scribed in CYLINDER TAPER above.

2
3

B
R400motr90A

A
1. Cylinder
2. Piston assembly
3. Cylinder base gasket
4. Camshaft timing chain

R400motr92A

Cylinder Inspection A. Perpendicular to crankshaft axis

B. Parallel to crankshaft axis
Check cylinder for cracks, scoring and wear ridges
on the top and bottom of the cylinder. If so, re-
CYLINDER OUT OF ROUND
place cylinder.
Cylinder Taper NEW 0.015 mm (.0006 in)
Measure cylinder bore and if it is out of specifica- SERVICE LIMIT 0.020 mm (.0008 in)
tions, replace cylinder and piston ring set no. 35.
Measure cylinder bore at 3 recommended posi- Cylinder Installation
tions. See the following illustration. For installation, reverse the removal procedure.
Pay attention to the following details.
3
Install a new cylinder base gasket no. 36.
C
Apply engine oil in the bottom area of the cylinder
1 bore and also on the band of the piston ring com-
pressor tool (P/N 529 035 919).
A
B

2
R400motr91A

1. First measuring of diameter

2. Second measuring of diameter
3. Third measuring of diameter
A. 7 mm (.276 in) from cylinder bottom
B. 68 mm (2.68 in)
C. 32 mm (1.260 in)

CYLINDER TAPER
vmr2006-043-026
NEW 0.038 mm (.0015 in)
SERVICE LIMIT 0.090 mm (.0035 in)

Distance between measurements should not ex-

ceed the service limit mentioned above.

vmr2008-128 133
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

1 1
3

4
R400motr94A

2
1. Piston circlip
R400motr93A

1. Timing chain NOTE: The removal of both piston circlips is not

2. Piston ring compressor tool
3. Piston necessary to remove piston pin.
4. Cylinder
Push piston pin out of piston.
NOTE: Put timing chain through the chain pit then
put the cylinder in place.
Install cylinder head and the other parts in accor-
dance with the proper installation procedures. 1

PISTON
2
Piston Removal
Remove:
– Cylinder head no. 24
R400motr95A
– Cylinder no. 25.
1. Piston
Place a rag under piston no. 37 and in the timing 2. Piston pin
chain area.
Detach piston from connecting rod.
 WARNING
Piston circlips are spring loaded. Piston Inspection
Inspect piston for scoring, cracking or other dam-
Remove one piston circlip and discard it. ages. Replace piston and piston rings if neces-
sary.
Using a micrometer, measure piston at 8 mm
(.315 in) perpendicularly (90°) to piston pin.

A
R400motr96A

1. Measuring perpendicularly (90°) to piston pin

A. 8 mm (.315 in)
134 vmr2008-128
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

The measured dimension should be as described

in the following table. If not, replace piston.

PISTON MEASUREMENT
90.950 to 90.966 mm
NEW
(3.5807 to 3.5813 in)
SERVICE LIMIT 90.850 mm (3.577 in)

Piston/Cylinder Clearance
Adjust and lock a micrometer to the piston dimen-
sion. 1
1
F00B0AA

TYPICAL
1. Indicator set to 0 (zero)

Position the dial bore gauge 20 mm (.787 in) above

cylinder base, measuring perpendicularly (90°) to
piston pin axis.
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance.
F00B08A

1. Micrometer set to the piston dimension PISTON/CYLINDER CLEARANCE

0.027 to 0.057 mm
With the micrometer set to the dimension, adjust NEW
(.0011 to .0022 in)
a cylinder bore gauge to the micrometer dimen-
sion and set the indicator to 0 (zero). SERVICE LIMIT 0.010 mm (.004 in)

NOTE: Make sure used piston is not worn. See

PISTON MEASUREMENT above.
If clearance exceeds specified tolerance, replace
cylinder.
2 1 NOTE: Make sure the cylinder bore gauge indica-
tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
Piston Pin
Using synthetic abrasive woven, clean piston pin
no. 38 from deposits.
Inspect piston pin for scoring, cracking or other
F00B09A damages.
1. Use the micrometer to set the cylinder bore gauge Measure piston pin. See the following illustration
2. Dial bore gauge for the proper measurement position.

vmr2008-128 135
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

Place piston no. 37 over connecting rod. Position

the piston with the punched arrow towards the
exhaust side.
Insert piston pin no. 38 into piston and connecting
rod.

R400motr30A A
A. Piston pin diameter 2
PISTON PIN DIAMETER

NEW
19.996 to 20.000 mm 1
(.7872 to .7874 in)
SERVICE LIMIT 19.980 mm (.7866 in)

Replace piston pin if diameter is out of specifica- R400motr99A

tions. 1. Arrow should indicate to the exhaust side

2. Timing chain location
Piston Pin/Connecting Rod Bushing Clearance
Measure inside diameter of connecting rod. Use the piston circlip installer (P/N 529 035 921)
to assemble the new piston circlip no. 39 as per
CONNECTING ROD SMALL END DIAMETER following procedure:
20.010 to 20.020 mm
NEW
(.7878 to .7882 in)
SERVICE LIMIT 20.060 mm (.7898 in)

vmr2006-043-030

CAUTION: Always replace disassembled pis-

ton circlip(s) by new ones. Place a rag on cylin-
der base to avoid dropping the circlip inside the
engine.
Place circlip in sleeve as per following illustration.

A 3
1

R400motr98A
1
1. Connecting rod small end
A. Connecting rod small end diameter 2

Replace connecting rod if diameter of connect-

ing rod small end is out of specifications. Refer
to CRANKCASE/CRANKSHAFT for removal proce-
dure.

Piston Installation R400motr100A

For installation, reverse the removal procedure. 1. Circlip

2. Sleeve
Pay attention to the following details. 3. Assembly jig from piston clip installer
Apply engine oil on the piston pin.
Push taper side of assembly jig until circlip reaches
middle of sleeve.
136 vmr2008-128
 Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

Align sleeve with piston pin axis and push assem- RING/PISTON GROOVE CLEARANCE
bly jig until circlip engages in piston. UPPER COMPRESSION RING
3 4 NEW
0.030 to 0.070 mm
(.0012 to .0028 in)
SERVICE LIMIT 0.150 mm (.0059 in)
2 1 LOWER COMPRESSION RING
0.020 to 0.060 mm
5 NEW
(.0008 to .0024 in)
SERVICE LIMIT 0.150 mm (.0059 in)
OIL SCRAPER RING
0.010 to 0.180 mm
NEW
(.0004 to .0071 in)
R400motr101A
SERVICE LIMIT 0.250 mm (.0098 in)
1. Arrow should indicate to the exhaust side
2. Hold piston while pushing circlip in place
3. Sleeve 1
4. Assembly jig
5. Direction to push circlip
2

NOTE: Take care that the hook of the piston circlip

is positioned properly.

R400motr103A

1. Piston
2. Feeler gauge

Ring End Gap

RING END GAP

UPPER COMPRESSION RING
0.20 to 0.40 mm
NEW
(.008 to .016 in)
SERVICE LIMIT 1.50 mm (.059 in)
R400motr102A
LOWER COMPRESSION RING
CORRECT POSITION OF THE PISTON CIRCLIP 0.20 to 0.40 mm
NEW
(.008 to .016 in)
SERVICE LIMIT 1.50 mm (.059 in)
PISTON RINGS OIL SCRAPER RING
Ring Removal 0.20 to 0.70 mm
NEW
(.008 to .028 in)
Remove: SERVICE LIMIT 1.50 mm (.059 in)
– Cylinder head no. 24
– Cylinder no. 25 Measure position for ring end gap in the area of 8
– Piston pin no. 37. to 16 mm (.315 to .630 in) from top of cylinder.
NOTE: In order to correctly position the ring in the
Ring Inspection cylinder, use piston as a pusher.
Ring/Piston Groove Clearance Using a feeler gauge, check ring end gap. Replace
Using a feeler gauge measure each ring/piston ring if gap exceeds above described specified tol-
groove clearance. If the clearance is too large, the erance.
piston and the piston rings should be replaced.
Ring Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
vmr2008-128 137
Section 03 ENGINE
Subsection 09 (CYLINDER HEAD/CYLINDER)

NOTE: First install spring and then rings of oil

scraper ring.
Install the oil scraper ring first, then the lower com-
pression ring with the word “N and TOP “ fac-
ing up, then the upper compression ring with the
word “N and TOP“ facing up.

3
vmr2007-036-009_a

1. Upper compression ring

2. Lower compression ring
3. Oil scraper ring

CAUTION: Ensure that top and second rings are

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

A
A A

A31C2OA

1. DO NOT align ring gap with piston thrust side axis

2. DO NOT align ring gap with piston pin bore axis
A. 120°

138 vmr2008-128
 Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

CRANKCASE/CRANKSHAFT
SERVICE TOOLS
Description Part Number Page
dial gauge ............................................................................. 414 104 700 ......................................... 153
insertion handle .................................................................... 420 877 650 ......... 143–144, 147, 150–151
crankshaft locking bolt.......................................................... 529 035 617 ................................. 154, 158
crankcase support PTO ........................................................ 529 035 754 ......................................... 148
needle bearing remover........................................................ 529 035 756 ......................................... 151
oil seal installer ..................................................................... 529 035 760 ......................................... 144
oil seal installer ..................................................................... 529 035 761 ......................................... 143
needle bearing installer......................................................... 529 035 762 ......................................... 150
needle bearing installer......................................................... 529 035 763 ......................................... 150
crankcase support MAG ....................................................... 529 035 916 ......................................... 148
plain bearing remover/installer.............................................. 529 035 917 ......................................... 147
oil seal installer ..................................................................... 529 035 933 ......................................... 147
needle bearing installer......................................................... 529 035 934 ......................................... 151
oil seal installer ..................................................................... 529 035 941 ......................................... 143

SERVICE PRODUCTS
Description Part Number Page
pulley flange cleaner............................................................. 413 711 809 ......................................... 158

vmr2008-129 139
Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

CRANKCASE

T1
5 NEW
Loctite 5910

T2 T2 Multi-purpose
grease
NEW
T1 10
T2
T2 Engine Loctite
19 oil 243
T1
14 17 Multi-
Loctite T1 16 purpose
5910 grease
18 9 NEW
15
12 13 1
T1
Loctite 12 Loctite
5910 T2 243
Engine
oil 2
Loctite
Multi-purpose 5910 20
grease T3
NEW 11
21 NEW
T2
Multi-
purpose Loctite
grease 243

T1 25 N•m (18 lbf•ft)

T2 10 N•m (89 lbf•in)
T3 4 N•m (35 lbf•in)
vmr2008-129-001_a

140 vmr2008-129
 Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

CRANKSHAFT/BALANCER SHAFT

8
Engine oil

4
Engine oil

6 20 N•m
(15 lbf•ft)
+ 60°
7
NEW

Engine oil

R400motr16T

vmr2008-129 141
Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

GENERAL
This section includes the procedures pertaining
to the crankcase, crankshaft and balancer shaft.
For the gearbox, follow the procedure for the
CRANKCASE then refer to GEARBOX/OUTPUT
SHAFT section.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

 WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic vmr2007-027-010_a

stop nuts, self-locking fasteners, etc.) must 1. Starter drive cover

be installed or replaced with new ones where 2. Starter drive
specified. If the efficiency of a locking device 3. Screws
4. Shim
is impaired, it must be renewed. 5. Spring

Starter Drive Inspection

PROCEDURES
Check if starter drive pinion is free of movement.
STARTER DRIVE NOTE: Centrifugal weights avoid disengaging of
the pinion while starting the engine.
Starter Drive Removal 3
Remove drive pulley (refer to CONTINUOUSLY 2
VARIABLE TRANSMISSION).
Remove screws retaining starter drive cover.
NOTE: Do not lose shims and/or spring during re-
moval of starter drive cover.
Withdraw starter drive cover and pull out starter
drive no. 2.

R400motr217A 1
1. Starter drive pinion
2. Starting position (spring released)
3. Gear is engaged drive pulley fixed half (spring loaded)

Replace needle bearing if damaged (see BEARING

REPLACEMENT PROCEDURE in CRANKCASE
further in this section).
Check starter drive cover for cracks and clean it
before reinstallation.
Check bore inside starter drive cover if damaged,
worn or otherwise damaged. Replace as neces-
sary.

142 vmr2008-129
 Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

Starter Drive Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
Apply multi-purpose grease inside starter drive
pinion cover.

OUTPUT SHAFT OIL SEAL

Output Shaft Oil Seal Removal
NOTE: The output shaft oil seal no. 5 can be re-
moved and installed without removing the engine
from vehicle. R400motr242A 2 1
Drain engine oil, refer to LUBRICATION SYSTEM. 1. Oil seal installer
Disconnect the rear propeller shaft from output 2. Installer handle
shaft, refer to REAR DRIVE.
Install all removed parts.
Using a small screwdriver, remove the output
shaft oil seal no. 5 from bearing flange.
COUNTER SHAFT OIL SEAL
CAUTION: Avoid scratching the bearing flange
or output shaft during oil seal removal. Counter Shaft Oil Seal Removal
NOTE: The counter shaft oil seal no. 9 can be re-
Output Shaft Oil Seal Inspection moved without removing the engine from vehicle.
Check bearing behind oil seal for contamination
Remove the driven pulley. Refer to CONTINU-
and/or metal shavings.
OUSLY VARIABLE TRANSMISSION.
Check oil seal seating surface for grooves. Re-
Using a small screwdriver, remove the counter
place bearing flange if necessary.
shaft oil seal.
Output Shaft Oil Seal Installation CAUTION: Avoid scratching the crankcase or
Use the oil seal installer (P/N 529 035 941) and counter shaft during oil seal removal.
insertion handle (P/N 420 877 650) for installation
of the oil seal.
Counter Shaft Oil Seal Installation
Using a suitable tube with the proper diameter,
install the oil seal.
If the engine is removed and crankcase is split,
use the oil seal installer (P/N 529 035 761) and the
insertion handle (P/N 420 877 650) to install seal.

vmr2008-129-002_a

1. Oil seal installer

2. Installer handle

vmr2008-129-003_a

1. Oil seal installer

2. Installer handle

vmr2008-129 143
Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

3 2 1 Shift Shaft Oil Seal Installation

Using a suitable tube, with the proper diameter,
install the seal.
Align the previous scribing marks and install the
shifting plate.
Torque shifting plate bolt to 10 N•m (89 lbf•in).

CRANKSHAFT OIL SEAL

Crankshaft Oil Seal Removal
NOTE: The crankshaft oil seal no. 11 can be re-
moved without removing the engine from vehicle.
Remove the drive pulley. Refer to the appropriate
CONTINUOUSLY VARIABLE TRANSMISSION.
R400motr206A
Using a small screwdriver, remove the crankshaft
1. Counter shaft seal oil seal.
2. Oil seal installer
3. Installer handle CAUTION: Avoid scratching the crankcase or
crankshaft during oil seal removal.
Install all removed parts.
Crankshaft Oil Seal Installation
SHIFT SHAFT OIL SEAL Using a suitable tube with the proper diameter,
install the seal.
Shift Shaft Oil Seal Removal
If the engine is removed and crankcase is split,
NOTE: The shift shaft oil seal no. 10 can be re- use the oil seal installer (P/N 529 035 760) and the
moved without removing the engine from vehicle. insertion handle (P/N 420 877 650).
Scribe a mark on the end of shift shaft and on
shifting plate.
Unscrew shifting plate bolt then remove shifting
plate.

vmr2008-129-003_a

1. Oil seal installer

2. Installer handle

V07C1QA

Using a small screwdriver, remove the shift shaft

seal.
CAUTION: Avoid scratching the crankcase or
shift shaft during oil seal removal.

144 vmr2008-129
 Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

1
2

R400motr22A

1. Feeler gauge
R400motr47A
CRANKSHAFT AXIAL CLEARANCE
1. Oil seal (crankcase PTO side)
2. Oil seal installer 0.1 to 0.4 mm
3. Installer handle NEW
(.0039 to .0157 in)

If measurement is out of specification, in-

CRANKCASE spect butting faces of crankshaft and crankcase
(MAG/PTO side) for excessive wear.
Crankcase Disassembly
Remove drive gear and intermediate gear of water
NOTE: Oil pump removal from crankcase MAG
pump and oil pump.
side is not necessary, but recommended to see
condition of oil pump (refer to LUBRICATION SYS- 2 3 1
TEM ).
Remove:
– Engine from vehicle (refer to ENGINE RE-
MOVAL/INSTALLATION)
– Magneto cover and rotor (refer to MAGNE-
TO/STARTER)
– Output shaft (refer to GEARBOX/OUTPUT
SHAFT)
– Cylinder head and cylinder (refer to CYLINDER
HEAD/CYLINDER)
– Drive and driven pulley (refer to CONTINUOUS-
LY VARIABLE TRANSMISSION).
R400motr23A
Measure axial clearance between the crankshaft
and crankcase PTO with a feeler gauge. 1. Timing chain
2. Intermediate gear, oil pump
3. Drive gear, water pump

Remove crankcase retaining screws.

vmr2008-129 145
Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

Crankcase mating surfaces are best cleaned us-

ing a combination of the chisel gasket remover
(P/N 413 708 500) and a brass brush. Brush a first
pass in one direction then make the final brushing
perpendicularly (90°) to the first pass cross (hatch).
CAUTION: Do not wipe with rags. Use a new
clean hand towel only.

Crankcase Inspection
NOTE: To check some parts, it is recommended
to remove all components from crankcase.
Crankshaft Plain Bearing
R400motr40A
Check plain bearings no. 12 and no. 13 for scor-
ings or other damages.
19 SCREWS
Measure plain bearing inside diameter. Replace if
Place the crankcase on a wood stand, MAG side the measurement is out of specification (refer to
upwards. BEARING REPLACEMENT PROCEDURE) further
in this section.
Split crankcase with 2 screwdrivers.
3 2 1

R400motr199A
A
POSITION FOR BIG FLAT SCREWDRIVER

R400motr41A

1. MAG plain bearing without groove

2. Oil bore
3. Split of the plain bearing halves
4. Cylinder base direction
A. Plain bearing inside diameter to be measured in area of oil bore

R400motr200A

POSITION FOR BIG FLAT SCREWDRIVER

Crankcase Cleaning
Clean all metal components in a solvent.
Clean oil passages and make sure they are not
clogged.
146 vmr2008-129
 Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

3 2 1 Use the oil seal installer (P/N 529 035 933) and
the insertion handle (P/N 420 877 650) to install
oil seal.

529036069

R400motr42A

1. PTO plain bearing without groove

2. Oil bore
3. Split of the plain bearing halves
4. Cylinder base direction
A. Plain bearing inside diameter to be measured in area of oil bore

PLAIN BEARING INSIDE DIAMETER (MAG/PTO)

SERVICE LIMIT 42.070 mm (1.6563 in)
vmr2008-129-004_a
Crankshaft Oil Seal
1. Balancer shaft oil seal (crankcase PTO side)
Check oil seal no. 11 if brittle, hard or otherwise 2. Bore for engine blow-by
damaged. Replace if necessary.
NOTE: The oil seal is removed easily with a flat Bearing Replacement Procedure
screwdriver.
CAUTION: Clean oil, outside and inside, from
Ball and Needle Bearings crankcase.
Check bearings no. 14, no. 15, no. 16 and no. 17 CAUTION: Always support crankcase properly
as well as needle bearings no. 18, no. 19 and when ball bearings, needle bearings or plain
no. 20 for excessive play and smooth operation. bearings are removed; otherwise, crankcase
Replace if necessary. could be damaged.
Balancer Shaft Oil Seal Unless otherwise instructed, never use hammer
to install ball bearings, needle bearings or plain
Check oil seal no. 21 if brittle, hard or otherwise bearings. Use press machine only.
damaged. Replace if necessary.
CAUTION: Ball bearings have to be installed
Balancer Shaft Oil Seal Replacement with closed bearing cage to the engine outside.
Procedure Crankshaft Plain Bearing Removal
Balancer Shaft Oil Seal Removal NOTE: Always use a press for removal or installa-
The oil seal no. 21 is removed easily with a flat tion of plain bearing halves.
screwdriver. Remove plain bearings no. 12 and no. 13 with the
CAUTION: Avoid scoring bearing seat or oil plain bearing remover/installer (P/N 529 035 917).
seal bore in crankcase.
Balancer Shaft Oil Seal Installation
CAUTION: Oil seal must be installed with seal-
ing lip towards balancer shaft.

vmr2008-129 147
Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

vmr2006-044-026

NOTE: Use crankcase support MAG (P/N 529 035

916) and crankcase support PTO (P/N 529 035
754) when removing plain bearings.
2 1

R400motr45A 2 3
PUSH PLAIN BEARINGS OUTSIDE
1. Plain bearing remover/installer
2. Plain bearing
3. Crankcase PTO

Crankshaft Plain Bearing Installation

To install the plain bearing turn the plain bearing
remover/installer up side down.
NOTE: Use crankcase support MAG (P/N 529 035
916) and crankcase support PTO (P/N 529 035
754) when pushing plain bearing in place.
R400motr43A

1. Crankcase support MAG 2 1

2. Crankcase MAG side

R400motr43A

1. Crankcase support MAG

2. Crankcase MAG side
R400motr44A 1
1. Crankcase support PTO
2. Crankcase PTO side

148 vmr2008-129
 Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

2 2 1 3 4

R400motr44A 1
1. Crankcase support PTO
2. Crankcase PTO side R400motr42B

1. Mark on crankcase and oil bore position

NOTE: Mark oil bore position on crankcase to align 2. Split between bearing halves
new plain bearing with crankcase thrust surface. 3. Perpendicular axle to cylinder base
4. Crankcase PTO
2 1 3 4
CAUTION: Push plain bearings MAG/PTO cor-
rectly in place to ensure oil supply to crank-
shaft (oil bore and split between plain bearing
halves).
1

R400motr41B

1. Mark on crankcase and oil bore position

2. Split between bearing halves
3. Perpendicular axle to cylinder base R400motr46A

4. Crankcase MAG
PUSH PLAIN BEARINGS INSIDE
1. Plain bearing installer

Bevel Gear Needle Bearing Removal

To remove bevel gear needle bearing no. 18, use
a punch as follows.

vmr2008-129 149
Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

Counter Shaft Needle Bearing Removal

To remove counter shaft needle bearing no. 19,
use a punch as follows.
2 1

tra

R400trans12A 1 2
1. Bevel gear needle bearing
2. Punch

Bevel Gear Needle Bearing Installation

R400trans13A
Install needle bearing no. 18 with the needle bear-
ing installer (P/N 529 035 763) and insertion handle 1. Counter shaft needle bearing location
2. Punch
(P/N 420 877 650).
Counter Shaft Needle Bearing Installation
Install needle bearing no. 19 with the needle bear-
ing installer (P/N 529 035 762) and insertion handle
(P/N 420 877 650).

vmr2006-022-114_a

1. Needle bearing installer

2. Installer handle

1 2 3
vmr2006-022-114_a

1. Needle bearing installer

2. Installer handle

R400motr203A

BEVEL GEAR
1. Bevel gear needle bearing
2. Needle bearing installer
3. Installer handle

150 vmr2008-129
 Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

1 2 3

vmr2008-126-010_a

1. Needle bearing installer

2. Handle

R400motr202A

COUNTER SHAFT 2
1. Counter shaft needle bearing
2. Needle bearing installer 1
3. Installer handle

Starter Drive Needle Bearing Removal

Use needle bearing remover (P/N 529 035 756) to
remove needle bearing no. 20.
529 035 756 R400motr241A

STARTER DRIVE PINION

1. Starter drive needle bearing PTO side
2. Needle bearing installer

Balancer Shaft (PTO side) and Bevel Gear

Ball Bearing Removal
To remove ball bearings no. 15 and no. 16, use a
blind hole bearing puller.

R610outi03A

BLIND HOLE BEARING PULLER

Balancer Shaft (PTO side) and Bevel Gear

R400motr201a Ball Bearing Installation
Use a suitable installer for installing ball bearings
Starter Drive Needle Bearing Installation no. 15 and no. 16.
Install needle bearing no. 20 with the needle bear-
Balancer Shaft (MAG side) Ball
ing installer (P/N 529 035 934) and insertion handle Bearing Removal
(P/N 420 877 650).
Ball bearing no. 14 can be easily removed with a
suitable pusher from outside in.

vmr2008-129 151
Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

Balancer Shaft (MAG side) Ball Bearing NOTE: It is recommended to apply this specific
Installation sealant as described here to get a uniform appli-
Use a suitable installer for installing ball bearing cation without lumps. If you do not use the roller
no. 14. method, you may use your finger to uniformly dis-
tribute the sealant (using a finger will not affect the
Counter Shaft (PTO side) Ball Bearing Removal adhesion). Do not apply in excess as it will spread
For counter shaft ball bearing no. 17 remove out inside crankcase.
screw, then push bearing from outside in with a
punch.
1 2

F12R17A

Torque crankcase screws by hand as per follow-

ing sequence. Repeat procedure, retightening all
R400trans14a
screws according to the exploded views.
1. Screw M6
2. Counter shaft ball bearing (PTO side) 17 16 15 14 9 5 7 3 1 2
Counter Shaft (PTO side) Ball Bearing
Installation
Use a suitable installer for installing ball bearing
no. 17.

Crankcase Assembly
The assembly of crankcase is essentially the re-
verse of removal procedure. However, pay atten-
tion to the following details.
Use the silicone-based Loctite 5910 (P/N 293 800
081) on mating surfaces.
IMPORTANT: When beginning the application of
the crankcase sealant, the assembly and the first
torquing should be done within 10 minutes. It is 18 19 8 4 6 10 11 12 13
R400motr207A
suggested to have all you need on hand to save
time.
Use a plexiglas plate and apply some sealant on BALANCER SHAFT
it. Use a soft rubber roller (50 - 75 mm (2 - 3 in))
(available in arts products suppliers for printmak- Balancer Shaft Removal
ing) and roll the sealant to get a thin uniform coat Split crankcase (refer to CRANKCASE).
on the plate (spread as necessary). When ready, Remove the crankshaft locking bolt.
apply the sealant on crankcase mating surfaces.
Align the dot of crankshaft gear with the balancer
shaft gear dot then remove balancer shaft no. 4.

152 vmr2008-129
 Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

2 3 CRANKSHAFT
Crankshaft Locking Procedure
Unplug spark plug cable then remove the spark
plug.
Install the dial gauge (P/N 414 104 700).

R400motr24A 1 5
1. Crankshaft
2. Balancer shaft
3. Connecting rod
4. Rotate crankshaft for balancer shaft removal vmr2007-019-001_a
5. Groove for fixation at TDC
TYPICAL
1. Dial gauge
Balancer Shaft Inspection
Pull rewind starter to rotate crankshaft until piston
Check balancer shaft and replace if damaged. is at TDC.
Check ball bearings on MAG and PTO side for
TDC compression
excessive play and smooth operation. Replace if
necessary. CAUTION: Never use the mark on the magneto
to find the TDC. Only use the crankshaft locking
If the gear on the balancer shaft is damaged, re-
tool to locate the TDC.
place balancer shaft.
Remove valve cover and verify if the printed marks
Check gears on the crankshaft and replace crank-
on the camshaft timing gear are parallel with the
shaft if necessary (refer to CRANKSHAFT below).
cylinder head edge. If so, the engine is at TDC
Balancer Shaft Installation compression position.
For installation, reverse the removal procedure.
Pay attention to following detail.
Align the dot on crankshaft gear with the balancer
shaft gear dot.

vmr2007-027-011_a

1. Printed marks on camshaft timing gear

2. Camshaft timing gear
3. Cylinder head edge

Remove screw and sealing ring.

R400motr25A 1
1. Punched marks located in the gears

vmr2008-129 153
Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

2
1 1
R400motr234A

R400motr236A
1. Screw
2. Sealing ring
3. Output shaft on front side of vehicle 1. Crankshaft locking bolt
2. Front output shaft area

Use a screwdriver to check if groove in crankshaft

is aligned with the hole. Crankshaft Removal
Remove:
– Balancer shaft (see BALANCER SHAFT)
– Crankshaft no. 3.

R400motr235A

1. Screwdriver R400motr26A 1 2
1. Crankshaft
Lock crankshaft with the crankshaft locking bolt 2. Crankcase PTO
(P/N 529 035 617).
Crankshaft Inspection and Disassembly
Replace crankshaft if the gears are worn or other-
wise damaged.
vmr2006-043-013

154 vmr2008-129
 Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

2
1

R400motr29A

1. Bore gauge
2. Connecting rod

R400motr27A 1 2
1. Balancer gear
2. Crankshaft timing gear

Connecting Rod Big End Axial Play

Using a feeler gauge, measure distance between
butting face of connecting rod and crankshaft R400motr30A A
counterweight. If the distance exceeds specified A. Piston pin diameter in the area of the plain bearing
tolerance, replace the crankshaft.
CONNECTING ROD SMALL END DIAMETER
1 2
20.010 to 20.020 mm
NEW
(.7878 to .7882 in)
SERVICE LIMIT 20.060 mm (.7898 in)
PISTON PIN DIAMETER
19.996 to 20.000 mm
NEW
(.7872 to .7874 in)
SERVICE LIMIT 19.980 mm (.7866 in)
CONNECTING ROD/PISTON PIN CLEARANCE
SERVICE LIMIT 0.080 mm (.0035 in)

R400motr28A
If the connecting rod small end diameter is out of
specification, replace connecting rod.
1. Crankshaft
2. Feeler gauge Connecting Rod Big End Radial Play
CONNECTING ROD BIG END AXIAL PLAY NOTE: Prior to remove connecting rod from the
crankshaft, mark big end halves together to en-
0.100 to 0.352 mm sure a correct reinstallation (cracked surface fits
NEW
(.004 to .014 in)
in only one position).
SERVICE LIMIT 0.500 mm (.020 in) Remove connecting rod no. 6 from crankshaft
no. 3.
Connecting Rod/Piston Pin Clearance
CAUTION: Always replace connecting rod
Measure piston pin. Compare to inside diameter screws no. 7 if removing the connecting rod. It
of connecting rod no. 6. is also recommended to replace plain bearings
no. 8.

vmr2008-129 155
Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

1
R400motr31A

1. Connecting rod screw

A
Measure crankpin. Compare to inside diameter of
connecting rod big end.
R400motr33A

A. Connecting rod big end plain bearing

1 CRANKSHAFT PIN DIAMETER

40.009 to 40.025 mm
NEW
(1.575 to 1.576 in)
SERVICE LIMIT 39.980 mm (1.574 in)

2 CONNECTING ROD BIG END DIAMETER

SERVICE LIMIT 40.100 mm (1.579 in)
CONNECTING ROD BIG END RADIAL PLAY
SERVICE LIMIT 0.09 mm (.0035 in)

Crankshaft Radial Play MAG/PTO Side

Measure crankshaft on MAG/PTO side. Compare
to inside diameter of MAG/PTO plain bearings.

2
R400motr32A
1
1. Micrometer
2. Crankpin area for plain bearings

To measure the connecting rod big end diameter,

use the OLD screws no. 7.
Install the OLD plain bearings no. 8 as they were
mounted initially.
Do the torque procedure as described further.

R400motr34A

1. Micrometer
2. Crankshaft area for MAG plain bearing

156 vmr2008-129
 Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

CAUTION: Always use NEW connecting rod

screws for the final assembly of the crankshaft.
2 Torque NEW connecting rod screws no. 7 as per
following procedure:
– Install screws with half of recommended torque
1 in the exploded view. Do not apply any thread
locker product.
– Torque with the recommended values in the ex-
ploded view.
– Finish tightening the screws with an additional
60° turn using an angle torque wrench.
CAUTION: Failure to strictly follow this proce-
dure may cause screw to loosen and lead to en-
gine damage.
R400motr35A

1. Micrometer 1
2. Crankshaft area for PTO plain bearing

CRANKSHAFT MAG/PTO DIAMETER

42.024 to 42.040 mm
NEW
(1.6545 to 1.6551 in)
SERVICE LIMIT 42.000 mm (1.6535 in)
CRANKSHAFT MAG RADIAL PLAY
SERVICE LIMIT 0.07 mm (.0028 in)

Crankshaft Assembly
Use NEW bearings no. 8, when connecting rod
big end diameter is out of specification.
R400motr37A
Put plain bearings correctly in place and clean the
split surface on both sides (cracked area) carefully. 1. Angle torque wrench

3
Crankshaft Installation
For installation, reverse the removal procedure.
Pay attention to following details.
1
Install crankshaft first then balancer shaft.

R400motr36A

1. Half plain bearing of connecting rod big end

2. Split surface of the connecting rod
3. Nose of bearing in line with connecting rod groove

vmr2008-129 157
Section 03 ENGINE
Subsection 10 (CRANKCASE/CRANKSHAFT)

R400motr39A 1 2
R400motr38A
1. Crankshaft locking bolt
1. Installer of balancer shaft 2. Engagement groove for TDC position of the piston

Align the marks of crankshaft and balancer shaft. Using pulley flange cleaner (P/N 413 711 809),
clean both crankshaft tapers before installing the
rotor or the drive pulley.
CAUTION: Make sure the woodruff key on
crankshaft MAG is present and correctly in
place.

R400motr25A 1
1. Punched marks located in the gears

After reinstalling of crankcase MAG, measure axial

clearance of crankshaft with a feeler gauge on the
PTO side between PTO crankcase and crankshaft
thrust surface.
Install the crankshaft locking bolt (P/N 529 035
617) to keep the crankshaft in TDC position be-
fore installing the camshaft timing chain (refer to
CRANKSHAFT LOCKING PROCEDURE).

158 vmr2008-129
 Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

GEARBOX/OUTPUT SHAFT

Engine oil

8
11 10
Engine
14 oil
38
34 18
6 36 Engine
Engine
oil 12 oil

35 13 17
28
9 24 15
31 30 37 19

20 Engine
7 25
32 27 oil
Engine Engine oil 16
oil 26
Loctite 243 33 22
10 N•m 23
(89 lbf•in) 29 Engine
oil 21

vmr2006-058-001_aen

vmr2008-130 159
Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

GENERAL Remove:
– Output shaft bearing cover
During assembly/installation, use the torque val-
ues and service products as in the exploded view. – Magneto cover and rotor (refer to
MAGNETO/STARTER).
 WARNING Use a soft hammer to remove output shaft no. 6
Torque wrench tightening specifications from housing.
must strictly be adhered to. Remove both O-rings and both bearings from out-
Locking devices (e.g.: locking tabs, elastic put shaft.
stop nuts, self-locking fasteners, etc.) must NOTE: Both bearings on output shaft have a tran-
be installed or replaced with new ones where sition fit.
specified. If the efficiency of a locking device
is impaired, it must be renewed.

PROCEDURES
OUTPUT SHAFT
Output Shaft Removal
Remove the engine from the vehicle. Refer to EN-
GINE REMOVAL/INSTALLATION section.
Measure output shaft axial clearance prior to re-
move it.
2 1 R400trans04A 2 1
1. O-ring
2. Bearing on front side

R400motr195A

1. Output shaft
2. Dial indicator R400trans05A 2 1
1. O-ring
OUTPUT SHAFT AXIAL CLEARANCE 2. Bearing on rear side

SERVICE LIMIT 0.30 mm (.012 in) Withdraw thrust washer.

If the output shaft axial clearance is out of specifi-
cation, crankcase must be split and the bevel gear
must be adjusted. See GEARBOX ADJUSTMENT
in this section.
CAUTION: If the output shaft must be changed,
always replace the bevel gear shaft at the same
time.
160 vmr2008-130
 Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

R400trans06A 1 2
R400trans07A 1
1. Thrust washer
2. Output shaft ring gear 1. Soft hammer

Push output shaft as per following illustration.

Output Shaft Inspection
Check output shaft for bending, cracks and other
visible damages.
CAUTION: Always replace output shaft and
bevel gear shaft at the same time.
Check output shaft gear for wear and teeth dam-
ages.
Check if output shaft bearings no. 7 and no. 8 turn
freely and smoothly. Replace if necessary.
Replace output shaft seal if brittle, hard or dam-
aged. Refer to CRANKCASE/CRANKSHAFT for
replacement procedure.
R400trans08A
Replace O-rings no. 9 and no. 10 if brittle, hard or
damaged. WAY TO PUSH THE BEVEL GEARS TOGETHER

Clean crankcase and magneto cover mating sur- Install output shaft bearing cover and measure axi-
face and especially the bearing areas from metal al gap between bearing and output shaft gear with
particles or other contamination. a feeler gauge.
Output Shaft Installation
For installation, reverse the removal procedure.
Pay attention to following details.
Adjust axial play as per following procedure:
Install output shaft in housing without thrust
washer no. 11.
Use a soft hammer to put bearings exactly in place
against crankcase.

R400trans09A

Remove output shaft again and rebuild it with

proper thrust washer.
vmr2008-130 161
Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

Use the measured thickness to choose the re-

quired thrust washer as per the following table.

MEASURED THRUST WASHER

THICKNESS THICKNESS
0.79 to 0.88 mm
0.70 mm (.0276 in)
(.0311 to .0346 in)
0.89 to 0.98 mm
0.80 mm (.0315 in)
(.0350 to .0386 in)
0.99 to 1.08 mm
0.90 mm (.0354 in)
(.0390 to .0425 in)
R400trans11A

1.09 to 1.18 mm
1.00 mm (.0394 in) MEASURE AXIAL CLEARANCE OF BEVEL GEAR
(.0429 to .0465 in)
1.19 to 1.28 mm
1.10 mm (.0433 in)
Separate crankcase, refer to CRANKCASE/
(.0469 to .0504 in) CRANKSHAFT.
1.29 to 1.38 mm Remove balancer shaft, parking lever and shift
1.20 mm (.0472 in)
(.0508 to .0543 in) shaft.
1.39 to 1.48 mm
1.30 mm (.0512 in)
(.0547 to .0583 in)
1.49 to 1.58 mm
1.40 mm (.0557 in)
(.0587 to .0622 in)

NOTE: Output shaft axial clearance of 0.09 to

0.18 mm (.0035 to .0071 in) is included in the
above table.
Install output shaft and output shaft bearing cover.
Install magneto cover. Refer to MAGNE-
TO/STARTER section in this manual for proce-
dure.

GEARBOX
Gearbox Disassembly R400trans15A 2 1
Remove engine from vehicle (refer toENGINE RE- 1. Parking lever
MOVAL/INSTALLATION section). 2. Shift shaft

NOTE: During gearbox disassembly, inspect the Remove shift fork shaft.
condition of each part closely.
Remove magneto cover and rotor.
Remove output shaft.
Measure the axial clearance of bevel gear with a
feeler gauge.
NOTE: Bevel gear axial clearance should be mea-
sured before crankcase separation.

BEVEL GEAR AXIAL CLEARANCE

0.02 to 0.11 mm
NEW
(.0008 to .0043 in)
SERVICE LIMIT 0.15 mm (.006 in)

162 vmr2008-130
 Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

1 1 2

R400trans16A

1. Shift fork shaft

R400motr208A

Remove shift fork. 1. Shift fork engagement pin

2. Shift drum
1
Insert a flat screwdriver in the slot of index lever.
Turn screwdriver counterclockwise and remove
shift drum.

R400trans17A

1. Shift fork (engaged in main shaft gear)

Disengage shift fork from shift drum. R400trans18A 1 2

1. Index lever
2. Shift drum

Remove:
– Shift fork no. 12
– Bevel gear shaft no. 13 with low range gear
assembly
– Main gear no. 14
– O-ring no. 15 including distance sleeve no. 16
from main shaft no. 17 on engine PTO side
– Main shaft with high range gear no. 18 assem-
bly
– Gear selection no. 19, thrust washer no. 20,
reverse gear no. 21, needle bearing no. 22 and
thrust washer no. 23

vmr2008-130 163
Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

– Distance sleeve no. 24, thrust washer no. 25, 1 A 2

intermediate gear no. 26, needle bearing
no. 27 and intermediate gear shaft no. 28.
NOTE: It is not necessary to remove index lever
no. 29. Check index lever for visible damage and
if it moves freely. Replace if necessary.

Gearbox Inspection
Always verify for the following when inspecting
gearbox components:
– Gear teeth damage
– Worn or scored bearing surfaces
– Bent, worn or scored shift fork
– Worn shift fork engagement pins
– Bent, worn or scored shift fork shaft
R400motr211A
– Rounded engagement dogs and slots of gears
– Worn grooves on shift drum 1. Main gear
2. Caliper
– Worn gear engagement groove A. Engagement groove width
– Worn splines on shafts and gears.
Levers
Bearings Parking lever no. 30 for cracks or other damages.
Check all bearings for smooth operation. If rough Roller of index lever no. 29 must have free move-
or any excessive play is detected, replace bearing. ment.
Gears Shafts
Check tooth flanks of gears. Check taper grooves and annular grooves of
Replace gears only together with the correspond- shafts. Annular grooves must have sharp edges.
ing meshing gears. Check shift shaft no. 31 for worn splines and
NOTE: Always replace circlips and use special pli- gears.
ers to install them. Check main shaft no. 17 for wear.
Measure the engagement groove width of gears.
NOTE: Both gears no. 14 and no. 19 have the MAIN SHAFT SERVICE LIMIT
same width specifications and service limit. MAG SIDE 17.990 mm (.708 in)

GEAR GROOVE WIDTH PTO SIDE 24.950 mm (.982 in)

5.00 to 5.10 mm 2 1
NEW
(.197 to .201 in)
SERVICE LIMIT 5.20 mm (.205 in)

R400trans20A

1. Mag side
2. PTO side

Check bevel gear shaft no. 13.

BEVEL GEAR SHAFT SERVICE LIMIT

PTO SIDE 24.990 mm (.984 in)

164 vmr2008-130
 Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

1 SHIFT FORK CLAW THICKNESS

4.800 to 4.860 mm
NEW
(.189 to .191 in)
SERVICE LIMIT 4.750 mm (.187 in)

R400trans21A

1. PTO side

Shift Drum A

Check tracks of shift drum no. 32 for scoring or

heavy wear like rounded engagement slots.
Check index washer on shift drum for scoring or
visible damages. R400trans19A 1
Replace isolating washer no. 33 if there are signs 1. Micrometer
of wear or visible damages. A. Shift fork claw thickness

1 2 Thrust Washers
Check thrust washers no. 23 and no. 35 for wear.
Always replace thrust washer by a new one with
the same thickness, when reassembling the gear-
box with existing output shaft no. 6 and bevel gear
no. 13.

1 3
R400motr210A 3 R610motr183A

1. Track for the low/reverse gear shift fork

2. Track for the high gear shift fork 1. Thrust washer for adjusting the bevel gear axial clearance on
3. Isolating washer on the shift drum PTO side
2. Area where wear signs appear
3. Adjustment thickness of the washer
Shift Forks
Check both shift forks no. 12 and no. 34 for visible
damage, wear or bent shift fork claws. Gearbox Adjustment
Measure the shift fork claw thickness. NOTE: When the output shaft axial clearance is
out of specification or if the following parts are
changed (output shaft, bevel gear or crankcase),
the bevel gear adjustments must be verified.

vmr2008-130 165
Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

The bevel gear adjustment includes: The bevel gear axial clearance is adjusted by find-
– Bevel gear backlash on MAG side crankcase ing the proper thrust washer thickness J as per
– Bevel gear axial clearance on PTO side following illustration.
crankcase. NOTE: Clean mating surface of crankcase
The bevel gear backlash is adjusted by finding the before taking measurements. Refer to
proper thrust washer thickness E as per following CRANKCASE/CRANKSHAFT.
illustration.

B H

C G F

D (E) I (J)

Crankcase mating surface

MAG/PTO

Magneto cover
mating surface Output shaft mating surface
R400trans27U

166 vmr2008-130
 Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

Bevel Gear Backlash Procedure

(MAG Side Crankcase)
Use the following course of calculation to deter-
mine the theoretical thickness D of thrust washer
no. 35 on MAG side crankcase:
D=B-C-A

B = Distance between the thrust surface of bevel

gear and the theoretical center of its taper.
This is defined by manufacturer and written
on the bevel gear shaft.

NOTE: Bevel gear reference number is a value

between - 10 and + 10.
R400trans25A 2 1
1. Depth gauge
2. Washer thrust surface

A = 2 mm (.0787 in) nominal thickness of axial

needle bearing no. 36.
2 When all the measurements are taken, calculate
the theoretical thickness D of thrust washer using
the formula (D = B - C - A).
Take the obtained theoretical thrust washer thick-
ness D and choose the proper thrust washer num-
1
ber E according to the following table.
R400tran24B
THEORETICAL
THRUST WASHER
1. Bevel gear THRUST WASHER
2. Bevel gear reference number location NUMBER E
THICKNESS D
Use following course of calculation to find out val- 1.20 mm to 1.29 mm
120
ue B. (.0472 to .0508 in)
1.30 mm to 1.39 mm
130
(.0512 to .0547 in)
B=( bevel gear reference number ) + 37.8
1.40 mm to 1.49 mm
100 140
(.0551 to .0587 in)
1.50 mm to 1.59 mm
C = Distance between the washer thrust surface 150
(.0591 to .0626 in)
in the MAG side and the mating surface of
crankcase magneto cover. 1.60 mm to 1.69 mm
160
(.0630 to .0665 in)
1.70 mm to 1.79 mm
170
(.0669 to .0705 in)
1.80 mm to 1.89 mm
180
(.0709 to .0744 in)

Example
Take the reference number on the bevel gear
shaft: - 3.
B = (- 3/100) + 37.8
B = 37.77

vmr2008-130 167
Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

Measure the distance C with a depth gauge,

between the washer thrust surface in the MAG
side and the mating surface of crankcase MAG/
magneto cover.
C = 34.040 mm (1.340 in)
The nominal thickness A of needle bearing is al-
ways 2 mm (.0787 in).
A = 2 mm (.0787 in)
The theoretical thrust washer thickness D is cal-
culated as follows:
D=B-C-A
D = 37.77 - 34.040 - 2
D = 1.73 mm (.0681 in)
NOTE: Take the obtained theoretical thrust wash- R400trans28A 1
er thickness D and choose the proper thrust wash-
1. Butting surface
er according to table above.
In this example, the correct thrust washer number H = Distance between thrust surfaces of bevel
is 170. gear shaft.
NOTE: The thrust washer number 170 represents
a value equal at 1.70 mm (.0669 in).
Bevel Gear Axial Clearance Procedure
(PTO Side Crankcase)
Use the following course of calculation to deter-
mine the theoretical thickness I of thrust washer
no. 23 on PTO side crankcase:
I=F+G-H-A-E

F = Distance between mating surface (crankcase

R400trans29A
PTO) to ball bearing inner race.

A = 2 mm (.0787 in) nominal thickness of needle

bearing no. 36.
E = The thrust washer number nominal value
as found in the BEVEL GEAR BACKLASH
PROCEDURE. For example, thrust washer
number 170 represents a value of 1.70 mm
(.0669 in).

When all the measurements are taken, calculate

the theoretical thrust washer thickness I using the
formula (I = F + G - H - A - E).
Take the obtained theoretical thrust washer thick-
ness I and choose the proper thrust washer num-
ber J according to the following table.
R400trans26A 2 1 3
1. Ball bearing inner race
2. Mating surface of crankcase PTO
3. Depth gauge

G = Distance between mating surface of

crankcase MAG and butting face.

168 vmr2008-130
 Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

THEORETICAL Gearbox Assembly

THRUST WASHER
THRUST WASHER For assembly, reverse the disassembly procedure.
NUMBER J
THICKNESS I Pay attention to the following details.
1.22 mm to 1.31 mm Install:
120
(.0480 to .0516 in)
– Intermediate gear shaft no. 28, needle bearing
1.32 mm to 1.41 mm
130
no. 27, intermediate gear no. 26, thrust washer
(.0519 to .0555 in) no. 25 and distance sleeve no. 24
1.42 mm to 1.51 mm – Thrust washer no. 23, needle bearing no. 22,
140 reverse gear no. 21, thrust washer no. 20 and
(.0559 to .0594 in)
gear selection no. 19
1.52 mm to 1.61 mm
150 – Main shaft no. 17 with high range gear no. 18
(.0598 to .0634 in)
assembly
1.62 mm to 1.71 mm
160 – Main gear no. 14
(.0638 to .0673 in)
– Bevel gear shaft no. 13 with low range gear
1.72 mm to 1.81 mm no. 37 assembly.
170
(0.0677 to .0713 in)
NOTE: If a new bevel gear is used, it is necessary
1.82 mm to 1.91 mm to perform the bevel gear adjustments (see GEAR-
180
(.0717 to .0752 in) BOX ADJUSTMENT). If the existing bevel gear is
used, it is mandatory to use new thrust washers
NOTE: Bevel gear axial clearance of 0.02 to no. 23 and no. 35 with the same thickness and
0.11 mm (.00079 to .00433 in) is included in the also a new axial needle bearing no. 36.
above table.
First install intermediate gear then main shaft and
Example afterward the bevel gear.
Measure the distance F. 3 1 4 2
F = 51.800 mm (2.039 in)
Measure the distance G.
G = 39.080 mm (1.539 in)
Measure the distance H, between both butting
surfaces of bevel gear shaft.
H = 85.680 mm (3.373 in)
The nominal thickness A of needle bearing is al-
ways 2 mm (.0787 in).
A = 2 mm (.0787 in)
E = The thrust washer number nominal value. R400trans30A

E = 1.70 mm (.0669 in) 1. Intermediate gear

The theoretical washer thickness I is calculated as 2. Main shaft
3. Thrust washer after gear selection on bevel gear
follows: 4. Thrust washer between distance sleeve and reverse gear
I=F+G-H-A-E
Install shift forks no. 12 and no. 34.
I = 51.800 + 39.080 - 85.680 - 2 - 1.70
Put shift forks in place and afterward insert pin
I = 1.50 mm no. 38 with the chamfer on top for a better instal-
NOTE: Take the obtained theoretical thrust wash- lation of crankcase MAG side.
er thickness I and choose the corresponding thrust Insert a flat screwdriver in the slot of index lever
washer number J according to table above. no. 29. Turn screwdriver counterclockwise and in-
In this example, the correct thrust washer number stall shift drum on park position as per the follow-
is 140. ing illustration.
NOTE: The thrust washer number 140 represents
a value equal at 1.40 mm (.0551 in).

vmr2008-130 169
Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

1 8
7
5

6
2
3 4
R400motr212A

1. Parking stop location

2. Reverse stop location
3. Neutral stop location
4. High gear stop location
5. Low gear stop location
6. Contact to stop location for neutral/park position R400motr215A 2 1 3
7. Contact to reverse stop location
8. Pin to align isolating and index washer 1. O-ring
2. Distance sleeve
3. Main shaft end PTO side
Insert shift shaft no. 31 with mark in line to first
tooth on shift drum. Install all other removed parts.

GEARBOX POSITION SWITCHES

NOTE: First ensure shifter link rod is properly ad-
justed, Refer to SHIFTER.
The multifunction gauge uses one switch state
(open or closed) for each P, N and R switch to de-
termine the gearbox position.

Gearbox Position Switch Test

with B.U.D.S.
Connect B.U.D.S. Refer to COMMUNICATION
TOOLS/B.U.D.S. SOFTWARE.
Select the Monitoring tab and go to page 2 then
use the Sub-transmission area.
R400trans23A 1 2
Set the vehicle shifter lever to the position to test.
1. Mark on shift shaft
2. First tooth on shift drum In B.U.D.S., select the position matching the
shifter selection under Mechanically set to:.
Install parking lever no. 30.
Look at the “LED” area in B.U.D.S.
Run all gears as a final function check.
Install balancer shaft then close crankcase hous-
ings. Refer to CRANKCASE/CRANKSHAFT.
Install O-ring no. 15 including distance sleeve
no. 16 on main shaft end PTO side.
CAUTION: Place O-ring including distance
sleeve right away. Chamfered bore of distance
sleeve has to face the engine.

170 vmr2008-130
 Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

Measure the resistance of the pertaining switch

using the following table.

SHIFTER
WIRE LOCATION RESISTANCE
POSITION
PARK 1 (BLUE)
2
REVERSE
(BROWN) Battery
Close to 0
ground
3
NEUTRAL (YELLOW/
GREEN)

vmr2008-129-055_a

1. Selected shifter position of vehicle

2. Choose position that matches the vehicle shifter selection
3. Test result (see table below): GREEN is good, RED is bad

LED AREA IN B.U.D.S.

NUMBER SHOWN
MATCHING SWITCH
IN B.U.D.S.
1 Park
2 Reverse
3 Neutral
vmr2008-129-052_a

A GREEN LED should appear at the proper shifter

position. If so, the switch is working.
A RED LED means the switch or wiring/connector
is faulty. Carry out the resistance test.

Gearbox Position Switch

Resistance Test
Remove air filter housing. Refer to AIR INTAKE
SYSTEM.
Unplug gearbox position switch connector.

vmr2008-129-052_b

If test succeeded, switch is good.

If any switch is defective, check wiring/connector.
If they it is good, replace switch with a new one.

Gearbox Position Switch Removal

NOTE: The engine removal is not necessary to
reach the gearbox position switches.
To reach the gearbox position switches, remove:
vmr2008-129-051_a
– CVT cover
– Driven pulley
Use a multimeter and set it to . – Protection plate no. 1.
Set vehicle shifter in the position to test (P, R, N).
vmr2008-130 171
Section 03 ENGINE
Subsection 11 (GEARBOX/OUTPUT SHAFT)

NOTE: Clean area from dirt and belt dust before

removing gearbox position switch(es).
Disconnect terminal.

vmr2008-129-054_a

Unscrew the gearbox position switch.

Gearbox Position Switch Installation

For installation, reverse the removal procedure.
Pay attention to the following details.
Take care not to damage gearbox position switch-
es threads during installation.
If all terminals were removed, put them back at
the proper location as shown.

R400motr213A 1 2 3
1. Parking switch — BLUE wire
2. Reverse switch — BROWN wire
3. Neutral switch — GREEN/YELLOW wire

172 vmr2008-130
 Section 03 ENGINE
Subsection 12 (SHIFTER)

SHIFTER
SERVICE PRODUCTS
Description Part Number Page
XP-S synthetic grease........................................................... 293 550 010 ......................................... 175
Loctite 243 (blue).................................................................. 293 800 060 ......................................... 174

15 N•m
(133 lbf•in)
Loctite 243

10 N•m
(89 lbf•in)

15 N•m XP-S synthetic grease

(133 lbf•in) 10 N•m
(89 lbf•in)

24 N•m
(18 lbf•ft)
10 N•m
(89 lbf•in)

10 N•m
(89 lbf•in)
10 N•m
(89 lbf•in)

vmr2006-046-001_b

vmr2008-131 173
Section 03 ENGINE
Subsection 12 (SHIFTER)

GENERAL SHIFT LEVER

Before performing any servicing on the shifter link- Shift Lever Removal
age system, be sure the shift lever is in NEUTRAL
position and the parking brake is applied. Remove RH side panel (refer to BODY).
During assembly/installation, use the torque val- Remove the shift lever handle.
ues and services products as in the exploded view. Remove the link rod bolt.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

 WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pins,
etc.) must be installed or replaced with new
vmr2007-040-003_a
one where specified. If the efficiency of a
locking device is impaired, it must be re- 1. Link rod bolt
2. Link rod
newed. 3. Shift lever

Remove the tension spring.

PROCEDURES
HANDLE
Handle Removal
Loosen the nut under shift lever handle.

vmr2007-040-004_a

1. Tension spring
2. Shift lever

Remove the tie rod from bracket.

vmr2007-040-002_a

1. Shift lever handle

2. Handle nut

Unscrew shift lever handle.

Handle Installation
The installation is the reverse of removal proce-
dure. vmr2007-040-005_a

1. Tie-rod
Apply Loctite 243 (blue) (P/N 293 800 060) on shift 2. Shift lever
lever threads then screw the shift lever handle 3. Link rod
completely to the proper position. Lock it with the
handle nut. Remove the shift lever.

174 vmr2008-131
 Section 03 ENGINE
Subsection 12 (SHIFTER)

Shift Lever Inspection Check both O-rings on threaded fitting and apply
Check the shift lever for bending or cracks. XP-S synthetic grease (P/N 293 550 010) on the
bushing inside threaded fitting. Replace O-rings if
Check the tie-rod at the end of lever. necessary.
Replace the lever or the tie-rod if necessary.

Shift Lever Installation

For installation, reverse the removal procedure.

LINK ROD
Link Rod Removal
Remove the RH side panel (refer to BODY).
vmr2006-046-008_A
Remove the link rod bolt.
1. Threaded fitting
2. O-rings
3. Bushing

Link Rod Installation

For installation, reverse the removal procedure.
However, pay attention to the following details.
Place the shift lever on NEUTRAL position.
Install link rod.
Adjust the link rod so that the shift lever is located
vmr2007-040-003_a in the middle of NEUTRAL slot.
1. Link rod bolt
2. Link rod
3. Shift lever

Remove the link rod from shifting plate.

vmr2007-040-007_b

1. Neutral slot

Torque jam nuts.

vmr2007-040-006_a

1. Link rod
2. Shifting plate

Remove the link rod.

Link Rod Inspection

Check the link rod for bending or cracks.
Check the tie-rod at the end of link rod.
Replace the link rod if necessary.

vmr2008-131 175
Section 03 ENGINE
Subsection 12 (SHIFTER)

Mark the location of shifting plate before removing

it from shift shaft.

vmr2007-040-008_a

1. Threaded fitting
2. Jam nut
vmr2007-040-009_b
3. Link rod
1. Mark aligned with slot
Verify if the shift lever moves into the PARK and
LOW slots. Remove the shifting plate.
Install the side panel and test drive to confirm all
is working well.
Shifting Plate Inspection
Check shifting plate for cracks, bending or other
SHIFTING PLATE damages. Replace if necessary.

Shifting Plate Removal Shifting Plate Installation

Remove the RH side panel (refer to BODY). Align the shifting plate slot with the location with-
out splines on shift shaft.
Remove the link rod from shifting plate.

vmr2007-040-006_a

1. Link rod
2. Shifting plate

Remove the shifting plate bolt. vmr2008-131-001_a

1. No spline area
A. Shifting plate slot

NOTE: If the alignment spline is not present, align

shifting plate slot with shift shaft mark previously
traced. If you have no mark, turn ignition key ON
and check if the NEUTRAL light is on.

vmr2007-040-009_a

1. Shifting plate bolt

176 vmr2008-131
 Section 03 ENGINE
Subsection 12 (SHIFTER)

vmr2007-040-009_b

1. Mark aligned with slot

Install the shifting plate bolt.

Install link rod and adjust it (refer to LINK ROD
above).
Install side panel and check if the shifting system
works well.

vmr2008-131 177
 Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 01 (OVERVIEW)

OVERVIEW
Engine Management System (EMS)

ECM

GBPS CPS
OPS CTS
TPS
ECM IGNITION COIL
IACV INJECTOR
MAPTS

TPS Throttle Position Sensor

MAPTS Manifold Absolute Pressure and Temperature Sensor
CTS Coolant Temperature Sensor
inputs OPS Oil Pressure Switch
ECM CPS Crankshaft Position Sensor
outputs GBPS Gearbox Position Sensor
ECM IACV Idle Air Control Valve
ECM Engine Control Module
vmr2008-132-004_aen

vmr2008-132 179
180
ECM signal

vmr2008-132-002_aen
Fuel pump Fuel pump Fuel pump
relay fuse (F5)
Engine stop
ECM fuse (F1) Ignition switch ECM
switch
Power Distribution

Diagnostic
connector
ECM EMS sensors
Inj/ign and actuators
fuse (F3) Ignition coil
Subsection 01 (OVERVIEW)

Main fuse Main relay

(F8) Fuel injector
Sol/gauge
fuse (F4) VSS
ECM signal
Tail/brake light

Multifunction
gauge

Start switch Starter solenoid

Diagnostic
connector
Section 04 ENGINE MANAGEMENT SYSTEM

Light Hi-lo switch Headlight

switch
Accessories Accessory Accessories
fuse (F9) relay fuse (F6) Actuator switch Actuator
2wd/4wd 2wd/4wd

ECM signal Winch Winch relay Winch

switches

Power outlet

Cooling fan Cooling fan Cooling fan

relay relay fuse (F2)

ECM signal

vmr2008-132
 Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 01 (OVERVIEW)

ECM and VFB Interaction with the Electrical System

- TPS COMMUNICATION Diagnostic

LINK (CAN) connector
- MAPTS
- CTS WH/BE
ECM BE/GN
- OPS
Multifunction
- CPS gauge
- IDLE AIR CONTROL
VALVE
- OVERRIDE SWITCH - FUEL LEVEL SENSOR
- BRAKE SWITCH VFB - 2WD/4WD ACTUATOR SWITCH
- GBPS
- LIGHTS
- IGNITION SWITCH - WINCH
- ENGINE STOP SWITCH (if so equipped)
- START SWITCH - ACCESSORIES
- FUEL PUMP
- FUEL INJECTOR CPS Crankshaft Position Sensor
- IGNITION COIL CTS Coolant Temperature Sensor
ECM Engine Control Module
- COOLING FAN
GBPS Gearbox Position Sensor
- VSS MAPTS Manifold Absolute Pressure and Temperature Sensor
- RELAYS OPS Oil Pressure Switch
TPS Throttle Position Sensor
VFB Vehicle Fuse Block
VSS Vehicle Speed Sensor
vmr2008-132-003_aen

ECM Inputs/Outputs

Fuel pump

vmr2008-132-001_aen

vmr2008-132 181
Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 01 (OVERVIEW)

SYSTEM DESCRIPTION ENGINE CONTROL MODULE

A highly advanced engine management system (ECM)
(EMS) has been used to ensure a high power out-
put with cleaner combustion.
There are 4 main systems that are controlled by
the engine management system (EMS):
1. Electronic fuel injection (EFI)
2. Ignition system
3. Starting system
4. Cooling system.

CONTROLLER AREA NETWORK

(CAN) vmr2008-132-005

A communication link (CAN lines) is used to ECM

communicate between the ECM and the multi-
function speedometer. CAN lines consist of a The ECM controls the electrical system and the
pair of wires (WHITE/BEIGE and BEIGE/GREEN). engine management functions, by processing the
The communication link is also used to communi- information given by various sensors.
cate with the B.U.D.S. software. Refer to COM- The ECM is located behind the radiator.
MUNICATION TOOLS/B.U.D.S. SOFTWARE.

C1

ECM
B1
WH/BE
BE/GN

DC
WH/BE 1

BE/GN 2

19 4

vmr2008-132-006_a

DC Diagnostic connector
ECM LOCATION
MFG ECM Engine control module
MFG Multifunction gauge
WK/BE White/Beige
BE/GN Beige/Green
Engine RPM Limiter
vmr2008-132-007_aen The ECM will limit the maximum engine speed
when vehicle shifter is in:
– Forward position (Hi and LO individually)
– Neutral position
– Park position
– Reverse position.
The ECM uses the CPS and the GBPS (gearbox
position sensor) for this function.
An override switch, on the handlebar, allows the
engine speed to run higher than the RPM limiter
when more power is needed in reverse operation.
Refer to LIGHTS, GAUGE AND ACCESSORIES.

182 vmr2008-132
 Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 01 (OVERVIEW)

Vehicle Speed Limiter – Fuel pump relay

The ECM will limit the maximum vehicle speed – Accessory relay
both in 2WD and in 4WD. For this purpose, the – Cooling fan relay.
ECM uses the VSS (vehicle speed sensor) and the The ECM provides the trigger signal to activate
GBPS (gearbox position sensor). each relay individually.
Drowned Mode (Flooded Engine) When ignition key is turned ON and engine stop
switch is in RUN position, the main relay, the fuel
If engine is fuel-flooded and does not start, this pump relay and the accessory relay are energized.
special mode can be activated to prevent fuel in-
jection and ignition while cranking. Proceed as fol- While starting the engine, fan relay and accessory
lows to activate it. relay are temporary disabled to make all power
available for the starter, the fuel pump and the
With ignition key in ignition switch while engine is EMS.
stopped, press and HOLD throttle lever at WOT
position.
Press the start button. The mode is now on.
Releasing throttle lever will bring back the normal
mode.

Monitoring System
The ECM monitors the electronic components of
the fuel injection system and also parts of the elec-
trical system.
For more information, refer to MONITORING
SYSTEM/FAULT CODES.

Limp Home Mode vmr2008-139-004_g

The ECM may automatically set default parame- 1. Main

2. Fuel pump
ters to the engine management to ensure the ad- 3. Accessories
equate operation of the engine if a component of 4. Cooling fan
the fuel injection system is not operating properly.
The engine will operate with reduced performance NOTE: Some diodes are used in the electrical sys-
to protect the engine. In more severe cases, the tem. Diode failure may prevent engine cranking
engine RPM will be limited, also to protect the en- or may bring problem to the ECM. They are locat-
gine. ed in vehicle wiring harness. Refer to STARTING
SYSTEM and LIGHTS.
These performance-reduced modes allow the rid-
er to go back home which would not be otherwise Refer to the illustrations at the beginning of the
possible without this advanced system. Refer to section for a complete overview of the power dis-
the MONITORING SYSTEM/FAULT CODES. tribution.

Diagnostic Mode
The ECM features a self-diagnostic mode when
ignition key is turned on. However, some compo-
nents need the engine to be running so that they
can be monitored. Some problems will turn on a
warning lamp or will set the engine in limp home
mode. Refer to MONITORING SYSTEM/FAULT
CODES section for more information.

POWER DISTRIBUTION
Four relays are used to distribute power to differ-
ent components:
– Main relay

vmr2008-132 183
 Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 02 (COMMUNICATION TOOLS/B.U.D.S. SOFTWARE)

COMMUNICATION TOOLS/B.U.D.S.
SOFTWARE
SERVICE TOOLS
Description Part Number Page
Optional extension cable ...................................................... 529 035 697 ......................................... 185
MPI-2 .................................................................................... 529 036 018 ......................................... 185
Diagnostic cable ................................................................... 710 000 851 ......................................... 185

MULTI-PURPOSE INTERFACE-2 MPI-2 Power Supply

(MPI-2) The MPI-2 uses the PC computer USB port for for
its power supply.
PART REQUIRED
PC computer
Connections with Vehicle
B.U.D.S. software  WARNING
Use latest version compatible with the If the computer you are using is connected to
400 EFI available on BOSSWeb the power outlet, there is a potential risk of
MPI-2 (P/N 529 036 018) electrocution when working in contact with
water. Be careful not to touch water while
working with the computer.

Remove service compartment cover and locate

communication connector.

Optional extension cable

(P/N 529 035 697)

vmr2008-133-004_a

Unplug communication connector.

Diagnostic cable (P/N 710 000 851)

vmr2008-133 185
Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 02 (COMMUNICATION TOOLS/B.U.D.S. SOFTWARE)

mmr2006-079-200
vmr2008-133-005_a
Use B.U.D.S. software as described further in
Connect diagnostic cable to vehicle connector. B.U.D.S. SOFTWARE.

B.U.D.S. SOFTWARE
B.U.D.S. (Bombardier Utility and Diagnostic Soft-
ware) is designed to allow electrical component
inspection, to diagnose and monitor components
and to carry out settings such as the closed throt-
tle and idle actuator.
For more information pertaining to the use of the
B.U.D.S. software, use its help which contains de-
tailed information on its functions.
Ensure the appropriate connections are done for
B.U.D.S.
Ensure to use the latest B.U.D.S. version compat-
vmr2008-133-006_a
ible with the 400 EFI available on BOSSWeb.
Connect remaining connector to MPI-2 connector. Turn ignition switch ON and set engine stop
switch to RUN to activate the communication.
Start B.U.D.S.
Select the protocol “Kw2000 (500K)”.

vdd2006-001-151

Connect remaining MPI-2 connector to the USB

port of a PC (personal computer).

vmr2008-133-003

Ensure the status bar shows “Kw2000 (500K)”

with the number 2 to its right. Otherwise, refer to
COMMUNICATION ERRORS WITH B.U.D.S. fur-
ther.

186 vmr2008-133
 Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 02 (COMMUNICATION TOOLS/B.U.D.S. SOFTWARE)

NOTE: Number 2 means that 2 “ECU” are con- Communication Problems

nected (ECM and multifunction gauge). If an “X” is shown, this means there is no com-
munication between the MPI and the ECM or the
multifunction gauge.

vmr2008-133-002

CONNECTION SUCCESSFUL

mmr2009-020-001
Transfer data from the ECM to B.U.D.S. by clicking
the Read Data button in B.U.D.S. The possible causes are:
– Wrong protocol is used.
– Both ECM and multifunction gauge are not
communicating with the MPI.
NOTE: If a “1” is shown, either the ECM or the
multifunction gauge is not communicating with
the MPI.

vmr2006-012-100_aen

When finished, transfer data from B.U.D.S. to the

ECM by clicking the Write Data button in B.U.D.S.

vmr2006-012-100_ben

Disconnect MPI connections and reconnect vehi-

cle harness in protective cap.
NOTE: There is a 120 resistor in protective cap
to minimize the possibility of communication error.

Changes in ECM
Anytime a change is brought in ECM through
B.U.D.S., there will be an “EMS Tracking” mes-
sage that will say “Remove key from vehicle”.
When this occurs, remove the key from ignition
switch and wait until the message disappears
(it lasts approximately 30 seconds after key re-
moval).

vmr2008-133 187
 Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 03 (MONITORING SYSTEM/FAULT CODES)

MONITORING SYSTEM/FAULT CODES

MONITORING SYSTEM COMPONENT

The EMS features a monitoring system that self- EMS (TPS, CPS, MAPTS, CTS, OPS, IACV,
GBPS, ignition coil and fuel injector)
diagnose its electronic components (control mod-
ules, sensors and actuators) to ascertain they are Battery voltage
not faulty or defective. This mode comes active Engine RPM
when ignition key is turned on.
Brake monitoring
NOTE: Some components need the engine to be
running so that they can be monitored (fuel injec- CAN
tors for example). ECM
When a malfunction is currently detected, the
Starter solenoid
ECM:
– Sets an active fault code. Fuel pump
– Adapts the proper protection strategy according Cooling fan
to the failure.
Relays
– Sends out signals to the multifunction gauge to
inform the rider of a particular condition.
When a minor fault occurs, the check engine pi- FAULT CODES
lot lamp will turn on. The fault may disappear Verify if the check engine pilot lamp is ON or
automatically when the ignition key is turned off blinks. If so, look for fault codes to diagnose the
and kept off until lights turn off in multifunction trouble.
speedometer, then turned back on.
The fault codes recorded in the ECM can be
When an important fault occurs, LIMP MODE will checked by using the software B.U.D.S. (refer to
be displayed in the multi- function speedometer COMMUNICATION TOOLS/BUDS SOFTWARE
and check engine light will flash. section) or on the multi-function gauge.
In the following situations, engine RPM will be Stored fault codes are kept in the ECM even if the
limited. battery is disconnected.
MAX. For more information pertaining to the fault codes
CONDITION (state, count, first, etc.) and report, refer to
ALLOWED RPM
B.U.D.S. online help.
High engine temperature 4000
When using the service action suggested in the
Low battery voltage Fault section of B.U.D.S., the circuits are referred
Low oil pressure to as ECM pins A1-1, which means the wiring be-
5000 tween the ECM pin A1 and the sensor pin 1.
Safety fuel cut-off
(TPS or internal memory error) IMPORTANT: After a problem has been solved,
ensure to clear the fault(s) in the ECM using the
High battery voltage 7000 B.U.D.S. software. This will properly reset the ap-
propriate counter(s) and will also record that the
The following components or functions are moni- problem has been fixed in the ECM memory.
tored.
NOTE: Many fault codes at the same time is likely
to be burnt fuse(s) or a faulty relay.

How to Read Fault Codes Using

B.U.D.S. Software
Refer to COMMUNICATION TOOLS/B.U.D.S.
SOFTWARE section.

vmr2008-134 189
Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 03 (MONITORING SYSTEM/FAULT CODES)

How to Read Fault Codes on the

Multifunction Gauge
Fault codes starting with the letter “P” followed
by 4 digits (P-1234) can be displayed in the
multifunction gauge for troubleshooting.
NOTE: The multifunction gauge can display only
fault codes that are active. Occured non-active
faults can only be seen using B.U.D.S.
Proceed as follows:
Turn ignition key to “lights ON” position.

vmr2008-134-003_a

Press and HOLD mode button while QUICKLY tog-

gling HI - LO beam.

vmr2008-134-001

Use the mode button and scroll to Total Engine

Hour (EHr) on the gauge.

vmr2008-134-003_e

vmr2008-134-003_e

NOTE: Pay attention that the display shows EHr

and not Ehr.

vmr2008-134-002_a

190 vmr2008-134
 Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 03 (MONITORING SYSTEM/FAULT CODES)

NOTE: A minimum of 3 HI - LO toggles must be

completed within 2 seconds.
If there is no fault code, the NO ACTIVE P_CODE
will be displayed.
If there is any fault code, it will be displayed.

vmr2008-134-003_d

NOTE: To quickly exit the on-board diagnostic

mode, press and HOLD the mode button.

SPECIFIC FAULT CODES

vmr2008-134-003_b TPS (Throttle Position Sensor) Faults
If there is more than one fault code, the next one Faults which are reported in B.U.D.S. fall into two
will automatically appear after a small delay. groups: TPS faults and adaptation faults. These
are displayed on the B.U.D.S. system as TPS OUT
OF RANGE and TPS ADAPTATION FAILURE.
TPS “OUT OF RANGE” Fault
It is caused by the sensor reading going out of its
allowable range. This fault can occur during the
whole range of movement of the throttle.
To diagnose this fully, it is recommended to oper-
ate the throttle through its full range. It is also rec-
ommended to release the throttle quickly as this
may also reveal a fault that is intermittent.

vmr2008-134-003_c

Once the last fault code is displayed, the gauge

will display END OF P_CODE MODE then it will
default back to normal operation.

vmr2008-134 191
Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 03 (MONITORING SYSTEM/FAULT CODES)

POSSIBLE CAUSES ACTION POSSIBLE CAUSES ACTION

Check if connector is Fix. Sensor has been replaced Reset Closed Throttle and
disconnected from TPS and TPS closed position Idle Actuator.
not reset
Check if sensor is loose Tighten and reset Closed
Throttle and Idle Throttle body has been Reset Closed Throttle and
Actuator. replaced and TPS closed Idle Actuator.
position not reset
Inspect sensor for damage Replace and reset
or corrosion Closed Throttle and ECM has been replaced Reset Closed Throttle and
Idle Actuator. and TPS closed position Idle Actuator.
not reset
Inspect wiring Repair.
(voltage test) Throttle cable too tight Tighten and reset Closed
Throttle and Idle
Inspect wiring and sensor If bad wiring, repair.
Actuator.
(resistance test) If bad TPS, replace and
reset Closed Throttle and Sensor is loose Tighten and reset Closed
Idle Actuator. Throttle and Idle
Actuator.
Test sensor operation Replace and reset
(wear test) Closed Throttle and Throttle bracket is loose Tighten and reset Closed
Idle Actuator. Throttle and Idle
Actuator.
TPS “ADAPTATION FAILURE” Fault Idle speed screw (tamper Change throttle body.
It is caused by the idle position moving out of an proof) worn or loose
acceptable range. Idle bypass valve replaced Reset Closed Throttle
Following problems can be caused by a TPS but not reset and Idle Actuator using
“Adaptation Failure“: B.U.D.S.
– Idle speed is out of range.
– Engine stops when throttle is released quickly. Fault Code P1513 — Incorrect Match
– Engine runs inconsistent in low part load or low of ECM and Multifunction Gauge
RPM. The multifunction gauge is not matched for the
ECM/engine or the ECM is not matched for the
engine will crank but will not start. Refer to PARTS
CATALOGS for proper ECM/multifunction gauge
according to vehicle.

Fault Code P0705 — Gearbox

position sensor fault
This fault is not relevant. You can ignore it. The
switches are used individually for the gearbox po-
sition.

192 vmr2008-134
 Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 03 (MONITORING SYSTEM/FAULT CODES)

FAULT CODE TABLE

FAULT
DESCRIPTION POSSIBLE FAULT ACTION
CODE
Manifold absolute Faulty MAPTS - disconnected Make sure sensor's connector is fully
pressure sensor signal connector - faulty terminals inserted. Check for approximately 5 volts
shorted to GND or Open - cut wires - Dirty sensor - between sensor connector pins 1 and 2.
107
shorted wire - disconnected Check circuits between MAPTS pins and
sensor power ECM pins A1-1,G2-2 and F2-3 if open or
shorted to GND.
Manifold absolute Faulty MAPTS - disconnected Make sure sensor's connector is fully
pressure sensor signal connector - faulty terminals inserted. Check for approximately 5 volts
shorted to battery 12 V - cut wires - Dirty sensor - between sensor connector pins 1 and 2.
108
shorted wire - disconnected Check circuits between MAPTS pins and
sensor power ECM pins A1-1,G2-2 and F2-3 if shorted
to 12 V.
Manifold temperature Faulty MAPTS - disconnected Check for disconnected air temperature
sensor signal shorted to connector - faulty terminals sensor on the intake. Check the air
GND - cut wires - shorted wire to temperature sensor for approximately
112 GND 2511 ohms at 20°C. Replace the sensor
if necessary. Check circuits between
Sensor pin 2 and ECM pin F3, between
C3-1 and between A1-3.
Manifold temperature Faulty MAPTS - disconnected Check for disconnected air temperature
sensor signal shorted to connector - faulty terminals sensor on the intake. Check the air
battery 12 V or open - cut wires - shorted wire to temperature sensor for approximately
113 battery 2511 ohms at 20°C. Replace the sensor
if necessary. Check circuits between
Sensor pin 2 and ECM pin F3, between
C3-1 and between A1-3.
Manifold temperature Faulty MAPTS - partially Check for disconnected air temperature
sensor signal switched disconnected connector sensor on the intake. Check the air
intermittent fault - faulty terminals - cut temperature sensor for approximately
114 wires - incoherent change 2511 ohms at 20°C. Replace the sensor
in temperature reading if necessary. Check circuits between
Sensor pin 2 and ECM pin F3, between
C3-1 and between A1-3.
Coolant temperature too Refer to ENGINE AND/OR Refer to ENGINE AND/OR COOLING
115 high COOLING SYSTEM service SYSTEM service manual section.
manual section
Coolant temperature Faulty CTS - disconnected Check sensor resistor value between
sensor signal connector - faulty terminals 1800 and 2200 at 22°C. Check circuits
implausible low - cut wires - shorted wire - between sensor pins and ECM pin F4-1
116
temperature reading of cold temperature and C3-2. Replace sensor if necessary.
while engine is running and as Refer to service manual for complete
gone over 72°C (162°F) cooling system testing procedure.
Coolant temperature Faulty CTS - disconnected Check sensor resistor value between
sensor signal shorted to connector - faulty terminals - 1800 and 2200 ohm at 22°C. Check
117
battery 12 V cut wires - shorted wire circuits between sensor pins and ECM
pin F4-1 and C3-2.
Coolant temperature Faulty CTS - disconnected Check for disconnected engine
sensor signal shorted to connector - faulty terminals - temperature sensor. Check sensor
GND or disconnected cut wires - shorted wire resistor value between 1800 and
118
2200 ohm at 22°C. Check circuits
between sensor pins and ECM pin F4-1
and C3-2.
vmr2008-134 193
Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 03 (MONITORING SYSTEM/FAULT CODES)

FAULT
DESCRIPTION POSSIBLE FAULT ACTION
CODE
Coolant temperature Faulty CTS - partially Check for disconnected engine
sensor intermittent fault disconnected connector - temperature sensor. Check sensor
faulty terminals - cut wires resistor value between 1800 ohm and
119
- shorted wire - change in 2200 at 22°C. Check circuits between
temperature too high from the sensor pins and ECM pin F4-1 and C3-2.
sensed temperature
Throttle position sensor Faulty TPS - disconnected Check circuits between TPS pins and
shorted to GND or open connector - faulty terminals ECM pins A1-1, G3-3 and G2-2. Refer to
122
- cut wires - shorted wire to the service manual for complete throttle
GND - Sensor voltage missing position sensor testing procedure.
Throttle position sensor Faulty TPS - disconnected Check circuits between TPS pins and
shorted to Battery 12 V connector - faulty terminals ECM pins A1-1, G3-3 and G2-2. Refer to
123
- cut wires - shorted wire to the service manual for complete throttle
Battery position sensor testing procedure.
Fuel pump relay Faulty relay - faulty terminal Look for damaged or disconnected fuel
disconnected under the relay or at engine pump relay, damaged circuit wires,
230 connector - Dirt stuck on relay damaged connectors or damaged ECM
blades and/or terminals - wires output pins. Check circuit from relay pin
from the ECM to the relay cut 1B to ECM pin J1.
Fuel pump relay signal Faulty relay - faulty terminal Check for damaged or disconnected
pin shorted to GND under the relay or at engine fuel pump relay, damaged circuit wires,
connector - Dirt or water damaged connectors or damaged ECM
231
stuck on relay blades and/or output pins. Check circuit from relay pin
terminals - wires from the ECM 1B to ECM pin J1.
to the relay shorted to a GND
Fuel pump relay signal Faulty relay - faulty terminal Check for damaged or disconnected
pin shorted to battery under the relay or at engine fuel pump relay, damaged circuit wires,
12 V connector - Dirt stuck on relay damaged connectors or damaged ECM
232
blades and/or terminals - wires output pins. Check circuit from relay pin
from the ECM to the relay 1B to ECM pin J1.
shorted to a power source
Injector signal shorted Faulty injector - water and/or Check for approximately 12 ohms on
261 to GND dirt in injector connector - injector. Check circuit between Injector
shorted wires pin 1 and ECM L4 if shorted to GND.
Injector signal shorted Faulty injector - water and/or Check for approximately 12 ohms on
262 to battery 12 V dirt in injector connector - injector. Check circuit between Injector
shorted wires Pin 1 and ECM L4 if shorted to 12 V.
Starter solenoid not Faulty solenoid - faulty Check solenoid/gauge fuse. Look
connected terminal at solenoid or at for damaged or disconnected starter
engine connector - Dirt stuck solenoid, damaged circuit wires, damaged
267
on solenoid blades and/or connectors or damaged ECM output pins.
terminals - wires from the ECM Check circuit from solenoid OR/BR wire
to the solenoid cut to ECM pin L3.
Starter solenoid shorted Faulty solenoid - faulty terminal Check for damaged or disconnected
to GND at solenoid or at engine starter solenoid, damaged circuit wires,
connector - Dirt or water stuck damaged connectors or damaged ECM
268 on solenoid blades and/or output pins. Check circuit from solenoid
terminals - wires from the ECM OR/BR wire to ECM pin L3.
to the solenoid shorted to a
GND

194 vmr2008-134
 Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 03 (MONITORING SYSTEM/FAULT CODES)

FAULT
DESCRIPTION POSSIBLE FAULT ACTION
CODE
Starter solenoid shorted Faulty solenoid - faulty Check for damaged or disconnected
to battery 12 V terminal at solenoid or at starter solenoid, damaged circuit wires,
engine connector - Dirt stuck damaged connectors or damaged ECM
269 on solenoid blades and/or output pins. Check circuit from solenoid
terminals - wires from the ECM OR/BR wire to ECM pin L3.
to the solenoid shorted to a
power source
RPM signal lost Damaged encoder wheel - Check circuit between CPS and ECM
damaged CPS - metal dirt stuck pin E1 and D1. Check CPS coil resistor
on CPS - CPS wires damaged value approx 260 ohm. Check CPS AC
335 and/or shorted to the engine or voltage value approx 1 V. Check CPS
frame - squeezed CPS wires wires. Check if CPS is dirty with metal
between the magneto cover particle. Check encoder wheel.
and engine
RPM signal fault Damaged encoder wheel - Check circuit between CPS and ECM
damaged CPS - metal dirt stuck pin E1 and D1. Check CPS coil resistor
on CPS - CPS wires damaged value approx 260 ohm. Check CPS AC
336 and/or shorted to the engine or voltage value approx 1 V. Check CPS
frame - squeezed CPS wires wires. Check if CPS is dirty with metal
between the magneto cover particle. Check encoder wheel.
and engine
RPM signal fault Damaged encoder wheel - Check circuit between CPS and ECM pin
damaged CPS - metal dirt stuck E1 and D1. Check CPS resistor value
on CPS - CPS wires damaged approx 260 ohm. Check CPS AC voltage
339 and/or shorted to the engine or value approx 1 V. Check CPS wires.
frame - squeezed CPS wires Check if CPS is dirty with metal particle.
between the magneto cover Check encoder wheel.
and engine
Ignition coil signal Faulty primary ignition coil - Check for 1 +/-0.5 ohm between ignition
351 shorted to Battery 12 V wire shorted to battery 12 V coil pins. Check circuit between ignition
coil (-) and ECM pin M1 if shorted to 12 V.
Engine cooling fan relay Faulty relay - faulty terminal Look for damaged or disconnected
disconnected under the relay or at engine cooling fan relay, damaged connectors or
480 connector - dirt stuck on relay damaged ECM output pins. Check circuit
blades and/or terminals - wires from relay pin 1E to ECM pin B3.
from the ECM to the relay cut
Engine cooling fan relay Faulty relay - faulty terminal Check cooling fan fuse. Check for
signal pin shorted to under the relay or at engine damaged or disconnected cooling fan
battery 12 V connector - Dirt stuck on relay relay, damaged circuit wires, damaged
484
blades and/or terminals - wires connectors or damaged ECM output pins.
from the ECM to the relay Check circuit from relay pin 1E to ECM
shorted to a power source pin B3.
Engine cooling fan relay Faulty relay - faulty terminal Check for damaged or disconnected
signal pin shorted to under the relay or at engine cooling fan relay, damaged circuit wires,
GND or disconnected connector - dirt or water damaged connectors or damaged ECM
485
stuck on relay blades and/or output pins. Check circuit from relay pin
terminals - wires from the ECM 1E to ECM pin B3.
to the relay shorted to a GND
Idle air control valve Faulty IACV - disconnected Make sure IACV connector is fully
pin(s) shorted to battery connector - faulty terminals - inserted. Check circuits between idle
508
12 V cut wires - shorted wire valve motor pins and ECM pins D3-1,
E4-2, C4-3 and D4-4.

vmr2008-134 195
Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 03 (MONITORING SYSTEM/FAULT CODES)

FAULT
DESCRIPTION POSSIBLE FAULT ACTION
CODE
Idle air control valve Faulty IACV - disconnected Make sure IACV connector is fully
pin(s) disconnected or connector - faulty terminals - inserted. Check circuits between idle
509
shorted to GND cut wires - shorted wire valve motor pins and ECM pins D3-1,
E4-2, C4-3 and D4-4.
Oil pressure switch fault Faulty OPS - disconnected Check for disconnected oil pressure
connector - faulty terminals switch on engine. Check the pressure
- cut wires - shorted wire to switch contact when engine is running
520
battery over idle speed. Replace the switch
if necessary. Check circuits between
switch and ECM pin F2.
Throttle position sensor Shorted wire - faulty TPS Check circuits between TPS pin 1, MAPTS
560 5 V power supply pin sensor pin 1 and pin 3 and ECM pin A1. Check
shorted to battery 12 V TPS and MAPTS.
Throttle position sensor Shorted wire - faulty TPS Check circuits between TPS pin 1, MAPTS
561 5 V power supply pin sensor pin 1 and pin 3 and ECM pin A1. Check
shorted to GND or open TPS and MAPTS.
Battery voltage under Battery voltage too low - Check battery voltage for 12 to 13 volts
8 V at main relay voltage disconnected connector - faulty with engine stopped. Check battery
562 input terminals - cut wires voltage for 13.8 to 15.0 volts with engine
idling. Check connections on magneto
and voltage regulator.
Battery voltage over Battery voltage too high - Check battery voltage for 13.8 to
563 16 V at main relay faulty voltage regulator - faulty 15.0 volts with engine idling. Replace
voltage input magneto voltage regulator if necessary.
CAN communication CAN communication port Check for damage circuit between
port off shorted - Incompatible CAN diagnostic connector 1 and 2 and ECM
600 communicating component B1 and C1. Replace multifunction gauge
connected on CAN port if necessary. Test with disconnected
multifunction gauge.
Starter solenoid not Faulty solenoid - faulty Check solenoid/gauge fuse. Look
connected terminal at solenoid or at for damaged or disconnected starter
engine connector - dirt stuck solenoid, damaged circuit wires, damaged
615
on solenoid blades and/or connectors or damaged ECM output pins.
terminals - wires from the ECM Check circuit from solenoid OR/BR wire
to the solenoid cut to ECM pin L3.
Starter solenoid shorted Faulty solenoid - faulty terminal Check for damaged or disconnected
to GND at solenoid or at engine starter solenoid, damaged circuit wires,
connector - dirt or water stuck damaged connectors or damaged ECM
616 on solenoid blades and/or output pins. Check circuit from solenoid
terminals - wires from the ECM OR/BR wire to ECM pin L3.
to the solenoid shorted to a
GND
Starter solenoid shorted Faulty solenoid - faulty Check for damaged or disconnected
to battery 12 V terminal at solenoid or at starter solenoid, damaged circuit wires,
engine connector - dirt stuck damaged connectors or damaged ECM
617 on solenoid blades and/or output pins. Check circuit from solenoid
terminals - wires from the ECM OR/BR wire to ECM pin L3.
to the solenoid shorted to a
power source

196 vmr2008-134
 Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 03 (MONITORING SYSTEM/FAULT CODES)

FAULT
DESCRIPTION POSSIBLE FAULT ACTION
CODE
Gearbox position sensor Not plaussible GBPS Check for disconnected transmission
fault combination - shorted to connector. Check switch continuity
GND wire - faulty sensor - worn separately in all position (PR & N). Replace
705
or erratic contact - mechanical the switch if necessary. Check circuits
failure between switch and ECM pin J3 H2 & H4.
Check for misplaced terminal on gearbox.
Neutral switch fault Faulty switch - disconnected Check circuit between neutral switch and
821 connector - faulty terminals - ECM H4. Check switch. Check pilot
cut wires - shorted wire lamp circuit.
Throttle position sensor Faulty TPS - disconnected Check cable adjustment. Check circuit
out of range at first connector - faulty terminals - between ECM and TPS: A1-1, G2-2 and
1104 initialization cut wires - shorted wire G3-3. Make sure throttle lever is against
throttle stop. Reset the ECM 3 times
(ON-OFF-ON X3).
Manifold absolute Faulty MAPTS - dirty sensor - Make sure sensor's connector is fully
1107 pressure sensor shorted connector loose - short wire inserted. Clean the sensor. Check circuit
to GND or open circuit MAPTS A1-3 and F2-4.
Manifold absolute Faulty MAPTS - dirty sensor - Make sure sensor's connector is fully
1108 pressure sensor shorted water or dirt in the connector- inserted. Clean the sensor. Check circuit
to battery 12 V shorted wire MAPTS G2-1 and F2-4.
Injector disconnected Faulty injector - cut wires - Check ignition fuse. Check for
faulty terminals approximately 12.2 ohms on injector.
1263
Check circuit between Injector pin 1 and
ECM L4 if open.
RPM signal too high Damaged encoder wheel - Check circuit between CPS and ECM pin
(12000) damaged CPS - metal dirt stuck E1-1 and D1-2. Check CPS coil resistor
on CPS - CPS wires damaged value approx 260 ohm. Check CPS AC
1335 and/or shorted to the engine or voltage value approx 0.95 V. Check CPS
frame - squeezed CPS wires wires. Check if CPS is dirty with metal
between the magneto cover particle. Check encoder wheel.
and engine - tampered engine
Ignition coil Faulty primary ignition coil - Check ignition fuse. Check for 1
disconnected disconnected coils - cut wires - +/- 0.5 ohm between ignition coil pins.
1351 faulty terminals Check circuit between ignition coil (-) and
ECM pin M1. Check circuit between
ignition coil (+) and ignition fuse.
Incorrect match of ECM The multifunction gauge is not Ensure the ECM is the correct one for the
and multifunction gauge matched for the ECM/engine - engine. Ensure the multifunction gauge is
1513 ECM is not matched for engine the correct one for the vehicle. Properly
match ECM and multifunction gauge with
B.U.D.S.
No detection of security Faulty multifunction gauge Check if multifunction gauge is powered.
exchange If not check fuse & power. Check
circuit between multifunction gauge
1514
communication (18 & 19) and (R & S) and
ECM (C1 & B1). Replace multifunction
gauge if necessary.
Oil pressure unplausible Refer to ENGINE AND/OR OIL Refer to ENGINE AND/OR OIL PRESSURE
1520 or too low PRESSURE SYSTEM in service SYSTEM in service manual section.
manual section

vmr2008-134 197
Section 04 ENGINE MANAGEMENT SYSTEM
Subsection 03 (MONITORING SYSTEM/FAULT CODES)

FAULT
DESCRIPTION POSSIBLE FAULT ACTION
CODE
Battery voltage under Battery voltage too low - Check battery voltage for 12 to 13 volts
8 V at key switch voltage disconnected connector - faulty with engine stopped. Check battery
1562 input terminals - cut wires voltage for 13.8 to 15.0 volts with engine
idling. Check connections on magneto
and voltage regulator.
Battery voltage over Battery voltage too high - Check battery voltage for 13.8 to 15.0
1563 16 V at key switch faulty voltage regulator -faulty volts with engine idling. Replace voltage
voltage input magneto regulator if necessary.
CAN communication Multifunction gauge missing, Check for damage circuit between
information 208 missing faulty or not connected diagnostic connector 1 and 2 and ECM
1600
properly B1 and C1. Replace multifunction gauge
if necessary.
CAN communication Multifunction gauge missing, Check for damage circuit between
information 514 missing faulty or not connected diagnostic connector 1 and 2 and ECM
1601
properly B1 and C1. Replace multifunction gauge
if necessary.
Accessory relay open Faulty relay - faulty terminal Check ACC fuse. Damaged connectors or
circuit under the relay or at engine damaged ECM output pins. Check circuit
1674 connector - Dirt stuck on relay from relay pin 12A to ECM pin K2. Check
blades and/or terminals - wires circuit from relay Pin 10A to ACC fuse 9B.
from the ECM to the relay cut
Accessory relay shorted Faulty relay - faulty terminal Damaged circuit wires, damaged
to GND under the relay or at engine connectors or damaged ECM output pins.
connector - dirt or water Check circuit from relay pin 12A to ECM
1675
stuck on relay blades and/or pin K2.
terminals - wires from the ECM
to the relay shorted to a GND
Accessory relay shorted Faulty relay - faulty terminal Check ACC fuse. Damaged circuit wires,
to battery 12 V under the relay or at engine damaged connectors or damaged ECM
connector - dirt stuck on relay output pins. Check circuit from relay pin
1676
blades and/or terminals - wires 12A to ECM pin K2.
from the ECM to the relay
shorted to a power source

198 vmr2008-134
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

ELECTRONIC FUEL INJECTION

SERVICE TOOLS
Description Part Number Page
tachometer ........................................................................... 529 014 500 ......................................... 201
cable luber ............................................................................ 529 035 738 ......................................... 202
Fluke 115 multimeter ........................................................... 529 035 868 ................ 205–206, 211–213,
215, 217–219, 223–225
ECM adapter......................................................................... 529 036 085 ........ 205–206, 211–212, 215,
217–218, 220, 222–224

SERVICE PRODUCTS
Description Part Number Page
cable lubricant....................................................................... 293 600 041 ......................................... 203
Loctite 243............................................................................ 293 800 060 ................................. 212, 219
Gunk Intake Medic ............................................................... Not sold by ......................................... 214
BRP

GENERAL The ECM reads the inputs from the sensors,

makes computations, uses pre-determined pa-
SYSTEM DESCRIPTION rameters and activates the outputs to the injector.
Signals from sensors are used by the ECM to de-
termine the injection and ignition parameters (fuel
maps required for optimum air-fuel ratio.

Air Induction
Air flows through the air filter housing mounted
under the seat. It contains an air filter that pre-
vent dust and particles from being drawn into the
engine.
Air is then drawn through the throttle body mount-
ed on the engine intake side.
Absolute pressure and air temperature are mea-
sured in the intake manifold.
Air then flows through the intake manifold to the
vmr2008-136-002_a combustion chamber.
1. Manifold absolute pressure and temperature sensor (MAPTS)
2. Throttle body Throttle Body
3. Throttle position sensor (TPS)
4. Idle air control valve (IACV) The 46 mm throttle body is connected to the in-
5. Intake manifold
6. Fuel rail take manifold. Fitted on the throttle body, there
7. Injector is the TPS and the idle air control valve which al-
8. Coolant temperature sensor
9. Crankshaft position sensor lows the ECM to control the idle speed while the
throttle plate is closed.
The ECM is the central point of the engine man-
agement system. It reads the signals from differ-
ent sensors which indicate engine operating con-
ditions at micro-second intervals.
vmr2008-136 199
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

Intake Manifold Slowly disconnect the fuel hose to minimize

The intake manifold is connected to the engine spilling. Cover the fuel line connection with an
cylinder head. It provides support for the throttle absorbent shop rag. Wipe off any fuel spillage.
body, fuel injector and the fuel rail.
The air intake manifold is a resonator between
 WARNING
the throttle body and the air intake at the cylinder Do not allow fuel to spill on hot engine parts
head. or electrical connectors. The evaporating fuel
on the hot components or on the electrical
Fuel Rail connectors produce highly inflammable fuel
vapors that can easily be ignited by the heat, a
One fuel rail is mounted on the intake manifold. spark, electrostatic discharge or stray current
The fuel rail ensures all the time, that enough fuel resulting in a fire or an explosion.
can be delivered to the fuel injector. The fuel rail is
fed by the fuel pump with the properly regulated
Never use a hose pincher on injection system high
fuel pressure.
pressure hoses.
Fuel Injector Replace any damaged or deteriorated fuel lines.
One fuel injector is used to inject fuel into the in- The fuel pump is activated each time electrical
take port of the cylinder head. power is turned on. A pressure test must be car-
ried out before turning the ignition key to ON and
GENERAL RECOMMENDATIONS setting the engine run/stop switch to RUN

Engine problems are not necessarily related to the  WARNING

electronic fuel injection system. Always carry out a fuel pressure test when-
It is important to ensure the engine is in proper ever a fuel system component has been dis-
operating condition and the electrical system is connected during a maintenance procedure.
not at fault. A missed fuel leak could result in severe in-
When replacing a component, always check its jury or death.
operation after installation.
After performing a fuel pressure test, use the
Fuel System valve on the fuel pressure gauge to release the
pressure (if so equipped).
 WARNING
Fuel is flammable and explosive under cer- Electrical System
tain conditions. Ensure work area is well ven- It is important to check that the electrical system
tilated. Do not smoke or allow open flames or is functioning properly:
sparks in the vicinity. – Battery
– Fuses
 WARNING – Relay(s)
Always disconnect battery prior to working – Ground connections
on the fuel system. Always disconnect bat- – Wiring connectors.
tery exactly in the specified order, BLACK (-)
Never use a battery charger to substitute tem-
cable first.
porarily the battery as it may cause the ECM
 WARNING
(engine control module) to work erratically or not
to work at all. Check related-circuit fuse solidity
Fuel lines remain under pressure at all times. and condition with an ohmmeter. Visual inspec-
Always proceed with caution and use appro- tion could lead to false results.
priate safety equipment when working on Ensure that all electronic components are gen-
pressurized fuel system. Wear safety glass- uine. Any modification on the wiring harness may
es. lead to generate fault codes or bad operation.
Proceed with care when removing or installing NOTE: For diagnostics purposes, use B.U.D.S.
pressure test equipment or disconnecting fuel line software. See MONITORING SYSTEM/FAULT
connections. CODES subsection.

200 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

Check related-circuit fuse solidity and condition Also remember this validates the operation of the
with an ohmmeter. Visual inspection could lead sensor at room temperature. It does not validate
to false results. the over temperature functionality. To test it, the
After a problem has been solved, ensure to clear sensor could be removed from the engine and
the fault(s) in the ECM using the B.U.D.S. soft- heated with a heat gun while it is still connected to
ware. Refer to MONITORING SYSTEM/FAULT the harness to see if the ECM will detect the high
CODES subsection. temperature condition and generate a fault code.

 WARNING BASIC ADJUSTMENTS

Some EMS components are continuously
powered by the battery when ignition key IDLE SPEED
is turned on and engine stop switch is set
in RUN position. The ECM switches the cir- The idle speed is not adjustable. The ECM con-
cuit to the ground to complete the electrical trols the idle speed of the engine.
circuits it controls. Take this into account CAUTION: Never attempt to adjust the sealed
when troubleshooting. Always disconnect idle stop screw. It is calibrated at the factory.
the battery prior to disconnecting any electric If the screw adjustment is changed, the throttle
or electronic parts. body must be replaced.
If desired, the engine RPM can be verified with a
Electrical Connectors tachometer (P/N 529 014 500).
Pay particular attention to ensure that pins are not Remove LH side panel. Refer to BODY.
out of their connectors or out of shape. Install the tachometer wire on spark plug cable.
Make sure terminals are properly crimped on
wires and fastened in housing, and that they are
free of corrosion or moisture.
When probing terminals, pay attention not to bend
the terminal as this could bring a loose connection
that would be difficult to troubleshoot.
Pay attention to the following:
– ECM connectors: Do not apply dielectric
grease or any other lubricant.
– Other connectors: Apply a silicon-based dielec-
tric grease or other appropriate lubricant.
Resistance Measurement
When measuring the resistance with an ohmme-
ter, all values are given for a temperature of 20°C
(68°F). The resistance value of a resistance varies vmr2008-136-011

with the temperature. The resistance value for

usual resistor or windings (such as injectors) in- CLOSED THROTTLE AND IDLE
creases as the temperature increases. However, ACTUATOR RESET
our temperature sensors are NTC types (Negative
Temperature Coefficient) and work the opposite NOTE: This operation performs a reset of the val-
which means that the resistance value decreases ues in the ECM.
as the temperature increases. Take it into account This reset is very important. The setting of the
when measuring at temperatures different from TPS will determine the basic parameters for all fu-
20°C (68°F). Use the proper table for resistance el mapping and several ECM calculations and the
variation relative to temperature for temperature setting of the idle air control valve will determine
sensors. See the specific sensor. the basic parameters for the idle speed control of
The resistance value of a temperature sensor may the engine.
test good at a certain temperature but it might be Closed throttle and idle actuator reset must be
defective at other temperatures. If in doubt, try a done if:
new sensor.
– TPS is loosened, removed or replaced.

vmr2008-136 201
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

– Throttle body is replaced. Start engine and make sure it operates normally
– IACV is replaced. through its full engine RPM range. If fault codes
– ECM is replaced. appear, refer to MONITORING SYSTEM/FAULT
CODES section for more information.
CAUTION: An improperly set TPS or idle air
control valve may lead to poor engine perfor-
mance and emission compliance could possi- PROCEDURES
bly be affected. In addition, improper idle air
control valve reset may lead to poor engine THROTTLE CABLE
starting, improper idle (too low or too high) and
engine stop on deceleration. Throttle Cable Lubrication
Use the B.U.D.S. software to perform this adjust- Remove THROTTLE LEVER from handlebar. See
ment. procedure in the STEERING section.
Remove throttle body cover and ensure the throt- Refer to BODY section to remove the following
tle cam of throttle body rests against set screw parts:
without any tension in the cable. – LH side panel
– Console.
Remove the throttle body cover.

vmr2006-014-064_b vmr2008-145-017_a

1. Contact here 1. Throttle body cover screw

2. Free-play here 2. Exhaust pipe

Open throttle approximately one quarter then Install the cable luber (P/N 529 035 738) on cable
quickly release. Repeat 2 - 3 times to settle throt- end, against the throttle cable adjuster.
tle plate. If stopper does not rest against its stop
lever, perform throttle cable adjustment. Refer to
THROTTLE CABLE in this section.
To reset valve and TPS, click on the Reset button
in the Setting section of B.U.D.S.
529 035 738

NOTE: If the cable luber is not available, insert

the needle of the lubricant can into the end of the
throttle cable adjuster.
Place a rag around the throttle cable adjuster to
vmr2006-014-084_aen
prevent lubricant from splashing.
NOTE: If throttle was opened more than 3°, while
clicking the Reset button, a fault code will appear.
202 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

Spray the cable lubricant (P/N 293 600 041) into

the cable until the lubricant runs out at throttle
body end of the throttle cable.
NOTE: If the recommended lubricant is not avail-
able, an equivalent silicone lubricant can be used.

 WARNING
Always use a silicone-based lubricant. Us-
ing another lubricant (like a water-based lu-
bricant) could cause the throttle lever/cable vmr2008-145-018_a
sticking or stiffness.
1. Cable barrel
2. Throttle body cam
Install all removed parts and adjust throttle cable.
Unscrew the cable from throttle body.
Throttle Cable Removal
At Handlebar
Use the same procedure as the throttle lever in
the STEERING section.
At Throttle Body
Refer to BODY section to remove the following
parts:
– LH side panel
– Console.
Remove the throttle body cover.
vmr2008-145-019_a

1. Cable screwed connection

2. Throttle cable

Cut all locking ties retaining throttle cable to frame.

Remove the throttle cable from the vehicle noting
its correct routing.

Throttle Cable Installation

The installation is the reverse of the removal pro-
cedure.
Proceed with throttle cable adjustment.
vmr2008-145-017_a

1. Throttle body cover screw

Throttle Cable Adjustment
2. Exhaust pipe Slide rubber protector back to expose throttle ca-
ble adjuster.
Detach throttle cable from the throttle body cam.
Loosen lock nut then turn the adjuster to obtain
correct throttle lever free play.
NOTE: Measure throttle free play at the tip of
throttle lever.

vmr2008-136 203
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

FUEL INJECTOR

vmo2008-019-005_c

1. Throttle lever
A. 2 to 4 mm (5/64 to 5/32 in)
vmr2008-136-008_a

Tighten lock nut and reinstall the rubber protector.

Turn handlebar from lock to lock and ensure and Injector Leakage Test
ensure there is still free-play in each position. The leakage test is validated when performing the
To ensure there is no strain in the cable at wide fuel pump pressure test. Refer to FUEL TANK/
open position: FUEL PUMP.
Fully depress throttle lever and hold. Injector Test with B.U.D.S.
Loosen adjuster lock nut/adjuster until it just re- Turn ignition key ON and set engine stop switch
leases lever. to RUN.
Using the B.U.D.S. software, energize the fuel in-
jector from the Activation section.

vmr2006-014-068_a

1. Adjuster lock nut vmr2008-136-022_a

2. Adjuster
You should hear the injector working.
Turn adjuster clockwise until it touches lever This validates the injector mechanical and electri-
again. cal operation.
From there, tighten adjuster 1/2 turn (to remove If the injector does not work, check injector input
strain in cable). voltage.
Tighten lock nut.
Release throttle lever.
Injector Input Voltage Test
Disconnect the connector from the injector.
NOTE: If connector is hard to unlock, gently use a
screwdriver to release connector.

204 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

vmr2008-139-004_h

vmr2006-014-001_a Use the Fluke 115 multimeter (P/N 529 035 868)
and select .
NOTE: It is not necessary to activate the injector
since it is continuously powered. Read resistance.
Use the Fluke 115 multimeter (P/N 529 035 868)
and select Vdc. Read voltage. INJECTOR CIRCUIT
MEASUREMENT
WIRE
INJECTOR CONNECTOR
MEASUREMENT Main relay
WIRE VIOLET/BLUE Close to 0
socket pin 12E
Battery
VIOLET/BLUE Battery voltage
ground

vmr2008-136-009_a

– If continuity is good, check relay and wiring

from battery.
vmr2006-014-075_a
– If continuity is faulty, repair/replace wiring from
relay socket to injector.
If input voltage is good, carry out the INJECTOR
CONTROL CIRCUIT TEST. Injector Control Circuit Test
If input voltage is not good, check continuity be- Disconnect ECM connector.
tween main relay and injector as follows. Install ECM adapter (P/N 529 036 085) on ECM
Remove main relay from its socket. connector.
Use the Fluke 115 multimeter (P/N 529 035 868)
and select .
Probe terminals as follows.

INJECTOR CONTROL CIRCUIT

MEASUREMENT
ECM INJECTOR
L4 1 Close to 0
vmr2008-136 205
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

vmr2008-136-009_b

vmr2006-014-075_c If resistance value is correct, injector coil is in good

condition.
If control circuit is faulty, repair/replace wiring/
connectors. If resistance value is incorrect, repeat test at injec-
tor connector.
If control circuit and all tests applicable to the in-
jector are good, try a new ECM. Refer to ECM . Injector Resistance Test (At Component)
Injector Resistance Test Remove injector connector and check resistance
(At ECM Connector) value between injector pins as follows.
Reconnect the injector connector. RESISTANCE
INJECTOR PIN
Disconnect the ECM connector. @ 20°C (68°F)
Install ECM adapter (P/N 529 036 085) on ECM 1 2 Approximately 12
connector.

vmr2008-022-005

Using the Fluke 115 multimeter (P/N 529 035 868),

check resistance value between terminals as fol-
lows.
vmr2008-136-017_a

RELAY If readings are out of specifications, replace injec-

ECM RESISTANCE
SOCKET tor.
CONNECTOR @ 20°C (68°F)
TERMINAL
If readings are good, repair/replace wiring/
Approximately connectors from ECM to injector.
12E L4
12
Injector Removal
Remove the fuel rail from the engine. Refer to
FUEL RAIL for the procedure.
The fuel injector can be easily pulled out of the fuel
rail.

206 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

vmr2006-014-072_a

Firmly push injector until it bottoms.

Reinstall fuel rail. See above.
vmr2006-014-079_a

FUEL RAIL ASS’Y

1. Fuel rail FUEL RAIL
2. Fuel injector
3. Injector top O-ring
4. Injector bottom O-ring Fuel Rail Removal
5. Manifold O-ring
Turn ignition key OFF.
Remove side panels. Refer to BODY.
Injector Installation Remove air filter housing. Refer to AIR INTAKE
For the installation, reverse the removal proce- SYSTEM.
dure. Pay attention to the following details.
Install new O-rings.
 WARNING
Prior to disconnecting the quick fitting, en-
Apply a thin film of engine oil to O-rings to ease
sure engine and exhaust system are not hot.
insertion in rail.
Position the manifold O-ring as shown on injector. Wrap a rag around the inlet hose and release the
quick fitting.

vmr2006-014-071_a

Carefully insert injector in manifold paying atten-

tion to the manifold O-ring. Gently push in evenly vmr2008-136-018_a

all around while inserting injector. O-ring must be

completely inserted and not visible, before finish- Unplug injector connector.
ing pushing injector. Unscrew rail retaining screws.

vmr2008-136 207
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

vmr2008-136-019_a vmr2008-136-019_a

NOTE: To reach the screws, a 1/4 inch drive, 8 mm Secure inlet hose to injector.
hexagonal socket works well.
Gently pull rail up by hand.  WARNING
Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL TANK/FUEL
PUMP. Run engine and check for leaks.

THROTTLE BODY

vmr2008-022-040

TYPICAL

Fuel Rail Installation

For installation, reverse the removal process but
pay attention to the following. vmr2008-022-010_a

1. Throttle body
Apply a thin film of injection oil to O-rings of fuel 2. Throttle cable attachment
injector to ease installation of fuel rail. 3. Throttle plate
4. TPS
Install new O-rings. 5. Idle air bypass channel
6. Idle air control valve
Install fuel rail and evenly tighten screws a little at
a time each side.
Tightening torque of the rail retaining screws is Mechanical Inspection
6 N•m (53 lbf•in). Check that the throttle plate moves freely and
smoothly when depressing throttle lever.
IMPORTANT: Never attempt to adjust the sealed
idle stop screw. It is calibrated at the factory. If
the screw adjustment is changed, the throttle
body must be replaced.

208 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

vmr2006-014-064_c vmr2008-136-021_a

Turn throttle lever and pull out cable barrel.

Throttle Body Removal
To remove the throttle body from engine, proceed
as follows:
Remove side panels. Refer to BODY.
Remove air filter housing. Refer to AIR INTAKE
SYSTEM.
Unplug TPS and IACV connectors.
Loosen throttle body clamp.

vmr2006-014-060_c

1. Throttle lever
2. Cable barrel

Remove barrel from cable.

Pull out throttle cable.

Throttle Body Installation

Installation of the throttle body is the reverse of
the removal procedure. Pay attention for the fol-
vmr2008-136-020_a lowing details.
Pull out throttle body. Properly install cable barrel to throttle cable end.
Remove throttle body cover.

vmr2008-136 209
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

vmr2006-014-65_a
vmr2006-014-063_a

When the throttle body has been replaced, ensure

Hook cable to throttle lever. to:
– Check throttle cable adjustment. Refer to
THROTTLE CABLE in this section.
– Reset the Closed Throttle and Idle Actuator.
Refer to BASIC ADJUSTMENTS in this section.

THROTTLE POSITION SENSOR

(TPS)
General
The throttle position sensor (TPS) is a potentiome-
ter that sends a signal to the ECM which is propor-
tional to the throttle shaft angle.

vmr2006-014-064_a

Do not reinstall cover yet.

Install throttle body on intake manifold. Ensure to
index throttle body tab with boot notch.

vmr2008-022-010_b

1. Throttle position sensor (TPS)

IMPORTANT: Prior to testing the TPS, ensure that

mechanical components/adjustments of throttle
body are adequate.
vmr2006-014-065_a

210 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

The EMS may generate several fault codes THROTTLE WIDE OPEN
pertaining to the TPS. Refer to MONITORING ECM CONNECTOR IDLE THROTTLE
SYSTEM/FAULT CODES section for more infor- POSITION POSITION
mation.
RESISTANCE
PIN
@ 20°C (68°F)
TPS Wear Test
G3 G2 990 - 1190 2569 - 2769
While engine is not running, activate throttle and
pay attention for smooth operation without physi- G2 A1 1919 - 2119 1919 - 2119
cal stops of the cable.
G3 A1 2617 - 2817 1042 - 1242
Using the B.U.D.S. software, use the Throttle
Opening display under Monitoring.

vmr2008-022-005_a

NOTE: The resistance value should change

vmr2006-014-083_aen smoothly and proportionally to throttle move-
ment. Otherwise, replace TPS.
Slowly and regularly depress the throttle. Ob-
serve the needle movement. It must change If resistance values are correct, perform the VOLT-
gradually and regularly as you move the throt- AGE TEST below.
tle. If the needle “sticks”, bounces, suddenly If resistance values are incorrect, check wiring har-
drops or if any discrepancy between the throttle ness. If wiring is faulty, repair/replace. If wiring is
movement and the needle movement is noticed, good, replace TPS.
it indicates that the TPS needs to be replaced or Reconnect ECM connector.
the computer used may be too slow to transfer
data fast enough for real time display. TPS Voltage Test
TPS Resistance Test Check the ECM voltage output to the TPS as fol-
lows.
Ensure TPS is connected to wiring harness.
Disconnect connector from TPS.
Disconnect the ECM connector.
Install ECM adapter (P/N 529 036 085) on ECM
connector.

vmr2008-022-005

Using the Fluke 115 multimeter (P/N 529 035 868),

check resistance values on ECM connector as per vmr2008-136-023_a

the following table.

vmr2008-136 211
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

Turn ignition key ON and set engine stop switch

to RUN.
Use the Fluke 115 multimeter (P/N 529 035 868)
and select Vdc.
Check the voltage readings from harness connec-
tor as follows.

CONNECTOR
VOLTAGE
PIN
1 2 5.0 Vdc
2 3 0 Vdc
1 3 4.75 - 5 Vdc

vmr2008-136-024_b

Remove TPS.

TPS Installation
Installation is the reverse of the removal. Howev-
er, pay attention to the following.
Apply Loctite 243 (P/N 293 800 060) on the TPS
retaining screws.
Torque screws to 3 N•m (27 lbf•in).
Reinstall remaining removed parts.
Proceed with the Closed Throttle and Idle Ac-
tuator Reset. See BASIC ADJUSTMENTS at the
beginning of this section.
vmr2008-136-024_a

If voltage test is not good, check/repair wiring har- IDLE AIR CONTROL VALVE
ness. If wiring and all tests applicable to the TPS An idle air control valve with good resistance mea-
are good, try a new ECM. Refer to ECM. surement can still be faulty. It is also possible
If voltage test is good, everything is in order (as- that a mechanical failure occurs which is not de-
suming resistance test was performed). tectable without measuring the air flow. Replac-
ing the idle air control valve may be necessary as
TPS Removal a test.
Remove RH side panel. Refer to BODY. If an erratic engine idle is experienced, clean the
Remove air filter housing. Refer to AIR INTAKE idle air bypass in throttle body.
SYSTEM.
IACV Resistance Test
Loosen two screws retaining the TPS. (At ECM Connector)
Remove RH front inner fender. Refer to BODY.
Disconnect ECM connector.
Install ECM adapter (P/N 529 036 085) on ECM
connector.

212 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

IDLE AIR CONTROL VALVE MEASUREMENT

RESISTANCE
PIN
@ 20°C (68°F)
1 4
45 - 55
2 3

vmr2008-022-005

Use the Fluke 115 multimeter (P/N 529 035 868)

and select .
Check the resistance of both windings.

ECM CONNECTOR MEASUREMENT

RESISTANCE
PIN
@ 20°C (68°F)
D3 D4
45 - 55
E4 C4

vmr2008-136-025_a

If the resistance of any winding is not good, re-

place the idle air control valve.
If resistance test of valve windings is good but the
resistance test at ECM failed, check continuity of
IACV wiring between ECM and IACV.

IACV Valve Circuit Resistance Test

vmr2008-022-005_a IDLE AIR CONTROL VALVE
MEASUREMENT
CIRCUIT
If resistance test of valve windings is good, valve
should work. IACV PIN ECM PIN
RESISTANCE
@ 20°C (68°F)
If the resistance of any winding is not good, mea-
sure resistance at the IACV valve. 1 D3
2 E4
IACV Valve Resistance Test Close to 0
(At Component) 3 C4
Remove RH side panel. Refer to BODY. 4 D4
Remove air filter housing. Refer to AIR INTAKE
SYSTEM.
Disconnect IACV valve connector.
Check the resistance between pins as shown.
NOTE: It is easier to remove IACV to measure the
resistance.

vmr2008-136 213
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

vmr2006-014-085_a

1. Clean bore from contamination

vmr2008-136-025_b
Clean all remaining parts and install the idle air con-
If resistance test failed, repair/replace wiring/con- trol valve on the throttle body.
nectors. Proceed with the Closed Throttle and Idle Actu-
ator Reset. See procedure in BASICS ADJUST-
IACV Visual Inspection MENTS at the beginning of this section.
CAUTION: Make sure the ignition key is turned
off during the following procedure. CRANKSHAFT POSITION
Remove idle air control valve from throttle body. SENSOR (CPS)
Check the piston and air bypass channel for dirt/
deposits which can cause a sticking or leaking pis-
ton.
CAUTION: Do not try to operate the piston of
the idle air control valve when it is dismount-
ed. Also do not move the piston by hand. The
drive screw is very sensitive and may be dam-
aged.
Use a throttle body cleaner such as Gunk Intake
Medic or the equivalent.

 WARNING
Only use an appropriate throttle body cleaner
that will not damage O-rings, MAPS sensor
and idle control valve.
vmr2008-136-002_b

Clean idle air bypass in throttle body from contam- NOTE: Take into account that a CPS fault can
ination then use an air gun to dry it. be triggered by bent or missing encoder wheel
 WARNING
teeth. First check fault codes (refer to MONI-
TORING SYSTEM/FAULT CODES) then check the
Always wear eye protector. Chemicals can teeth condition if necessary (refer to MAGNE-
cause a rash break out and injure your eyes. TO/STARTER).

CPS Voltage Test

Remove LH panel. Refer to BODY.
Unplug CPS connector.

214 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

vmr2008-136-026_A vmr2008-136-027_b

Use the Fluke 115 multimeter (P/N 529 035 868) If resistance is not within specifications, replace
and select Vac. the CPS.
Probe terminals as shown. If resistance tests good at component, reconnect
Crank engine and read voltage. the CPS connector and repeat the test at the ECM
connector.
CPS CONNECTOR MEASUREMENT
CPS Resistance Test
PIN VOLTAGE (At ECM Connector)
1 2 1 Vac min. Disconnect ECM connector.
Install ECM adapter (P/N 529 036 085) on ECM
connector.

vmr2008-022-005

Using the Fluke 115 multimeter (P/N 529 035 868),

vmr2008-136-027_a
recheck resistance as per table.
If test succeeded, CPS is good.
ECM CONNECTOR MEASUREMENT
If test failed, perform the resistance test.
RESISTANCE
PIN
CPS Resistance Test (At Component) @ 20°C (68°F)
Use the Fluke 115 multimeter (P/N 529 035 868) D1 E1 Approximately 910
and select .
Probe terminals as shown.

CPS CONNECTOR MEASUREMENT

RESISTANCE
PIN
@ 20°C (68°F)
1 2 Approximately 910

vmr2008-136 215
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

Ensure sensor is correctly installed on intake

manifold. Otherwise, the MAPTS could gener-
ate a fault code for an unexpected sensor range
at idle when it reads the absolute pressure.
Remove sensor and check for oil or dirt on its
end and if problem persists, check throttle plate
condition/position and the wiring harness. Per-
form the following tests.
MAPTS Test with B.U.D.S.
vmr2008-022-005_a Use B.U.D.S. software. Refer to COMMUNICA-
If resistance and all tests applicable to the CPS are TION TOOLS/B.U.D.S. SOFTWARE.
good, try a new ECM. Refer to ECM REPLACE- Select the Monitoring tab.
MENT. Start engine.
If resistance value is incorrect, repair the connec- Needle should move as you throttle the engine.
tors or replace the wiring harness between ECM Otherwise, perform the voltage and continuity
connector and the CPS. tests.
CPS Replacement
Refer to MAGNETO/STARTER.

MANIFOLD ABSOLUTE
PRESSURE AND TEMPERATURE
SENSOR (MAPTS)

vmr2008-136-028

MAPTS Input Voltage Test

Check the voltage output from ECM to the pres-
sure sensor.
Remove LH side panel. Refer to BODY.
Turn ignition key ON and set engine stop switch
to RUN.
Disconnect the MAPTS connector.
vmr2008-136-002_c

NOTE: This sensor is a multifunction device.

Sensor Pressure Function

When engine is started and it runs at idle speed,
the sensor reads the absolute pressure and stores
it in the ECM. Thereafter, it reads the manifold air
pressure at operating RPMs.

vmr2008-136-027_c

216 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

Use the Fluke 115 multimeter (P/N 529 035 868)

and select Vdc.
Read voltage.

MAPTS CONNECTOR MEASUREMENT

PIN VOLTAGE
1 3 5 Vdc

vmr2008-136-029_a

If continuity is good, replace MAPTS.

If continuity is not good, repair/replace wiring/
connectors between the ECM and the MAPTS.
MAPTS Power and Ground Circuits
Continuity Test
Disconnect the ECM connector.
vmr2008-136-029_b
Install ECM adapter (P/N 529 036 085) on ECM
connector.
If voltage test is good, test continuity of the pres- Use the Fluke 115 multimeter (P/N 529 035 868)
sure signal circuit. and select .
If voltage test is not good, check the continuity of Check the continuity as follows.
the power and ground circuits.
MAPTS Pressure Signal Continuity Test MAPTS CIRCUIT MEASUREMENT
Disconnect the ECM connector. MAPS RESISTANCE
ECM PIN
PIN @ 20°C (68°F)
Use the Fluke 115 multimeter (P/N 529 035 868)
and select . 1 G2
Close to 0
Check the continuity as follows. 3 A1

MAPTS CIRCUIT MEASUREMENT

MAPS RESISTANCE
ECM PIN
PIN @ 20°C (68°F)
4 F2 Close to 0

vmr2008-136-029_a

If continuity is not good, repair/replace wiring/

connectors between the ECM and the MAPTS.
If continuity and all tests applicable to MAPTS are
good, try a new ECM. Refer to ECM.
vmr2008-136 217
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

Sensor Temperature Function MAPTS Resistance Test (AT ECM Connector)

The sensor also monitors the temperature at in- Disconnect the ECM connector.
take manifold. Install ECM adapter (P/N 529 036 085) on ECM
MAPTS Resistance Test (At Component) connector.
Disconnect the MAPTS connector.
Use the Fluke 115 multimeter (P/N 529 035 868)
and select .
Measure resistance. Compare result with sensor
temperature table.

MAPTS PIN
1 2

vmr2008-022-005

Measure resistance between pins. Compare re-

sult with sensor temperature table.

ECM CONNECTOR PIN

F3 G2

vmr2008-136-030_a

SENSOR TEMPERATURE TABLE

vmr2008-022-005_a

RESISTANCE
TEMPERATURE If resistance value is incorrect, check the continu-
(OHMS)
ity of the temperature sensor circuits.
°C °F MAPTS
If resistance value and all tests applicable to the
- 30 - 22 28000 MAPTS are good, try a new ECM. Refer to ECM.
- 20 - 4 14500 MAPTS Power and Ground Circuits
0 32 5500 Continuity Test
20 68 2500 Disconnect the ECM connector.
40 104 1200 Install ECM adapter (P/N 529 036 085) on ECM
connector.
60 140 600
Use the Fluke 115 multimeter (P/N 529 035 868)
80 176 320 and select .
100 212 180 Check the continuity as follows.
130 266 90

If resistance is not within specification, replace the

MAPTS.
If resistance tests good, reconnect the MAPTS
and repeat test at ECM connector.

218 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

MAPTS CIRCUIT MEASUREMENT COOLANT TEMPERATURE

MAPTS RESISTANCE SENSOR (CTS)
ECM PIN
PIN @ 20°C (68°F)
1 G2
Close to 0
2 F3

If continuity is not good, repair/replace wiring/

connectors between the ECM and the MAPTS.
If continuity and all tests applicable to the MAPTS
are good, try a new ECM. Refer to ECM

MAPTS Removal
Remove LH side panel. Refer to BODY.
Disconnect MAPTS connector and remove the
MAPTS. vmr2008-136-031_a

RH SIDE OF VEHICLE

CTS Resistance Test (At Component)

Disconnect CTS connector.
Use the Fluke 115 multimeter (P/N 529 035 868)
and select .
Measure the resistance of the sensor. Compare
result with sensor temperature table.

CTS PIN
1 2

vmr2008-136-010_A
SENSOR TEMPERATURE TABLE
1. MAPTS
2. Retaining screw RESISTANCE
TEMPERATURE
(OHMS)
°C °F CTS
MAPTS Installation
Apply Loctite 243 (P/N 293 800 060) on screw then - 40 - 40 45000
torque to 6 N•m (53 lbf•in). - 30 - 22 28000
- 20 - 4 15000
0 32 5750
20 68 2600
40 104 1200
60 140 600
80 176 320
100 212 180
130 266 90

vmr2008-136 219
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

Disconnect CTS connector.

Remove CTS.

vmr2008-136-032_a

If resistance is out of specification, replace the

CTS.
vmr2008-136-032
If resistance tests good, reconnect the CTS con-
nector and repeat test at ECM connector. CTS Installation
CTS Resistance Test Install the new CTS.
(At ECM Connector) Torque CTS to 17 N•m (150 lbf•in).
Disconnect ECM connector. Reinstall remaining removed parts.
Install ECM adapter (P/N 529 036 085) on ECM Refill and bleed the cooling system. Refer to
connector. COOLING SYSTEM subsection.
Check resistance on the ECM connector. Com-
pare result with sensor temperature table. ENGINE CONTROL MODULE
(ECM)
ECM CONNECTOR MEASUREMENT
RESISTANCE
PIN
@ 20°C (68°F)
C3 F4 2280 - 2736

vmr2008-132-006_a

vmr2008-022-005_b ECM LOCATION

If resistance and all tests applicable to the CTS are NOTE: Prior to replacing an ECM, ensure to con-
good, try a new ECM. Refer to ECM REPLACE- duct all testing procedures.
MENT.
If resistance value is incorrect, repair the connec- ECM Connector Removal
tors or replace the wiring harness between ECM To reach ECM connector, remove RH front inner
connector and the CTS. fender. Refer to BODY.

CTS Removal
Drain coolant. Refer to COOLING SYSTEM.
220 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

vmr2008-136-013_a

FRONT RH SIDE vmr2008-022-014_a

TYPICAL

Pull out connector.

vmr2008-136-014_a

1. ECM
2. ECM connector
vmr2008-022-015_a

Push and hold the locking tab. TYPICAL

ECM Connector Installation

Fully open connector lock.

vmr2008-022-013_a

TYPICAL

Rotate connector lock until it stops.

vmr2008-136 221
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

529036085

Disconnect the ECM connector and reconnect on

the tool connector. Probe required terminals di-
rectly in the tool holes.
vmr2008-022-015_b

TYPICAL

Install connector to ECM.

Rotate connector lock until it snaps locked.

vmr2008-139-016_a

1. ECM connector
2. ECM adapter

CAUTION: Never probe directly on ECM har-

ness connector. This could change the shape
or enlarge the terminals and create intermittent
or permanent contact problems.

Power Supply to ECM

vmr2008-022-013 _b

TYPICAL Battery
1. Locked here
B
Main
fuse Main
ECM Connector Probing A
relay
12D
The most recommended and safest method to 6E
10D

probe ECM connector terminals is to use the ECM

ECM adapter (P/N 529 036 085). This tool will fuse 12E 10E

prevent deforming or enlarging terminals which 7E

would lead to bad ECM terminal contact creating C Ignition D 1 Engine stop
switch switch
intermittent or permanent problems. 5E
2
B4 Injection/
Power ignition
A4
Wake up fuse
ECM Switched L1 4E
power
K1
Signal
M3 M4 G1

vmr2008-136-001_en

222 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

When engine stop switch is set to STOP or igni-

tion key is turned OFF, ECM will turn off after ap-
proximately 30 seconds. All the electrical system
will then be cut-off.

ECM Quick Troubleshooting Tips

Turn ignition key to ON AND set engine stop
switch to RUN.

QUICK INDICATION THAT ECM IS NOT WORKING

(assuming the observed component is working)
Multifunction gauge does not turn on.
Rear light does not turn on. vmr2008-139-004_i

ECM FUSE IN FRONT SERVICE COMPARTMENT

Headlights do not turn on (with ignition key at light 1. Injector/ignition fuse
position). 2. ECM fuse

Fuel pump does not turn on for approx. 5 seconds

If fuses test good, carry out all the ECM tests.
(when turning key on and setting engine stop switch
RUN). If Engine Stop Running for no Reason,
Check the Following:
If ECM does not Turn on, Check the Following: It may be caused by the ECM that is improperly
Ensure battery power is good. reset (it restarts).
Check main fuse, ECM fuse and injector/ignition If it occurs when using the winch, check diodes
fuse. D5 and D6. Refer to LIGHTS, GAUGE AND AC-
CESSORIES.
NOTE: A short circuited diode (D5 or D6) will
cause the accessory fuse (F6) to burn.

ECM Grounds Test

Disconnect ECM connector.
Install ECM adapter (P/N 529 036 085) on ECM
connector.

vmr2008-139-015_b

MAIN FUSE

vmr2008-022-005

Use the Fluke 115 multimeter (P/N 529 035 868)

and select .
Check continuity of ground connections as fol-
lows.

vmr2008-136 223
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

ECM
CONNECTOR BATTERY MEASUREMENT
PIN
G1
Battery ground Close to 0
M3
post (continuity)
M4

vmr2008-136-003_A

ENGINE GROUND

vmr2008-022-005_d

If test succeeded, ECM grounds are adequate.

If test failed, ensure wiring/connectors are good
and repair/replace as necessary. If wiring/connec-
tors are good, check the following grounds.
vmr2008-136-015_a

BATTERY GROUND

ECM Power Circuit Test

Disconnect ECM connector.
Install ECM adapter (P/N 529 036 085) on ECM
connector.

vmr2008-136-004_a

FRAME GROUND

vmr2008-022-005

Use the Fluke 115 multimeter (P/N 529 035 868)

and select Vdc.

224 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

vmr2008-022-005_b

If voltage is out of specification, check wiring/

connectors from ECM fuse to ECM through igni-
529035868_a
tion and engine stop switches. Refer to IGNITION
SYSTEM.
Check voltage as follows.
If voltage is as per specification, carry out the
MAIN RELAY CIRCUIT TEST.
ECM CONNECTOR PIN MEASUREMENT
B4 G1 Battery voltage Main Relay Circuit Test
Remove service cover. Refer to BODY.
Pull out the main relay from its socket.

vmr2008-022-005_b

If voltage is out of specification, check wiring/

connectors from battery to ECM.
If voltage is as per specification, carry out the ECM
WAKE UP CIRCUIT TEST.
vmr2008-139-004_h

ECM Wake Up Circuit Test Remove the accessory relay and temporarily in-
Turn ignition key to ON. stall to the main relay location.
Set engine stop switch to RUN. If ECM is now working, replace the faulty main
Use the Fluke 115 multimeter (P/N 529 035 868) relay with a new one.
and select Vdc. If ECM still does not work:
Check voltage as follows. – Check control circuit wiring/connectors from
main fuse through the relay socket to ECM.
ECM CONNECTOR PIN MEASUREMENT – Check power circuit wiring/connectors from
main fuse through the relay socket and through
A4 G1 Battery voltage
the injector/ignition fuse to ECM.
If any circuit is faulty, repair/replace wiring/
connectors.
If everything tested good but ECM does not work,
try a new ECM.

vmr2008-136 225
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

ECM Removal
NOTE: If ECM is removed for replacement, refer
first to ECM REPLACEMENT.
Disconnect battery cables.

 WARNING
Battery BLACK negative cable must always be
disconnected first and connected last.
vmr2006-012-100_aen

Disconnect ECM connector. Refer to ECM CON- Keep B.U.D.S. running while replacing ECMs. The
NECTOR REMOVAL. data will remain stored in the PC computer as long
Unscrew retaining screws and remove the ECM as B.U.DS. is running.
from vehicle. Remove the faulty ECM.
Install and connect the new ECM.
From B.U.D.S., choose ECM, Replace under
Module.

mmr2009-023-077
vmr2008-136-016_a

B.U.D.S. will automatically write the data from the

ECM Installation PC computer into the new ECM.
Install the ECM to the vehicle. Go to the Setting tab.
Reconnect ECM connector. Reset the Closed Throttle and Idle Actuator.
If a new ECM is installed, transfer/enter data and Refer to CLOSED THROTTLE RESET.
perform the required resets to the new ECM. Re- In B.U.D.S., click the Write Data button to save
fer to ECM REPLACEMENT below. the information to ECM.

ECM Replacement
To transfer/enter data to the new ECM, there are
2 possible methods.
– If the faulty ECM can be read with B.U.D.S.,
refer to ECM AUTOMATED DATA TRANSFER.
– If the faulty ECM cannot be read with B.U.D.S.,
refer to ECM MANUAL DATA ENTRY.

ECM Automated Data Transfer

To transfer the previous ECM recorded informa- vmr2006-012-100_ben

tion to the new ECM, use the B.U.D.S. software

and proceed as follows. Reinstall remaining removed parts.
In B.U.D.S., click the Read Data button to load the ECM Manual Data Entry
information from the faulty ECM.
First, data needs to be collected.

226 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

There are 2 possible methods to collect the re- NOTE: You may have to go to another AutoSave
quired information. folder from a previous version of B.U.D.S.
– Use B.U.D.S. software and get the data from a Choose the latest file saved for this specific vehi-
saved .mpem file on your PC computer. cle.
– Collect the information from the vehicle.
1st Collecting Method: Get the Data
from a Saved .mpem File
Remove the faulty ECM.
Install and connect the new ECM.
Use B.U.D.S. software.
Click on the Open button.

mmr2009-023-083

TYPICAL

IMPORTANT: Ensure to use the file that specifi-

cally matches the vehicle you are servicing.

NOTE: The file name structure is as follows:

mmr2009-023-080

BUDS version_VIN_date read (yyyymmdd)_hour read

Click once on the Folder Up button in the open (hhmmss).mpem
box.
Example:
P2.3.18.3_2BPSMJ9A59V000262_20080201_142322.mpem
B.U.D.S. version = P2.3.18.3
VIN = 2BPSMJ9A59V000262
Date file was read = 2008-02-01
Hour file was read = 14h 23m 22s

Go to the Vehicle tab and record the following

information.
– Vehicle (V.I.N.) number
– Engine number (without the leading “M”)
– Model number
mmr2009-023-081_a – Customer.
Double click on the AutoSave folder.

vmr2008-022-008

mmr2009-023-082_a

vmr2008-136 227
Section 05 FUEL SYSTEM
Subsection 01 (ELECTRONIC FUEL INJECTION)

Enter data into ECM as detailed in ENTERING THE

COLLECTED INFORMATION INTO THE ECM be-
low.
2nd Collecting Method: Collect the
Information from the Vehicle
Remove the faulty ECM.
Install and connect the new ECM. vmr2006-020-058_a

Record vehicle serial number and model number. Click Yes to update the system to acquire the new
ECM and to allow engine starting.
3
2 Go to the Vehicle tab and enter the information
you recorded previously.
– Vehicle (V.I.N.) number
– Engine number
NOTE: Do not enter the leading “M”.
– Model number
NOTE: Do not enter leading or trailing 0s (zeros).
– Customer.
1
Go to the Setting tab.
Reset the Closed Throttle and Idle Actuator.
Refer to CLOSED THROTTLE RESET above.

V07M18a

TYPICAL
1. E.I.N. (Engine Identification Number)
2. V.I.N. (Vehicle Identification Number)
3. Model

Record engine serial number.

Enter data into ECM as detailed in ENTERING THE
COLLECTED INFORMATION INTO THE ECM be-
low.
vmr2006-014-084_aen

Entering the Collected Information

into the ECM Click on the Write Data button.
Use B.U.D.S. to enter the recorded data into the
new ECM.
In B.U.D.S., click the Read Data button to read the
new “empty” ECM.

vmr2006-012-100_ben

Reinstall remaining removed parts.

Test run engine.
vmr2006-012-100_aen

When you change an ECM you get the following

message.

228 vmr2008-136
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

FUEL TANK/FUEL PUMP

SERVICE TOOLS
Description Part Number Page
Oetiker pliers ........................................................................ 295 000 070 ......................................... 237
small hose pincher................................................................ 295 000 076 ......................................... 234
vacuum/pressure pump........................................................ 529 021 800 ......................................... 234
pressure gauge..................................................................... 529 035 709 ......................................... 236
Fluke 115 multimeter ........................................................... 529 035 868 ................................. 244, 249
T-fitting ................................................................................. 529 036 023 ......................................... 236
ECM adapter tool.................................................................. 529 036 085 ................................. 246, 250

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
Fluke rigid back probe........................................................... TP88 ......................................... 249

SERVICE PRODUCTS
Description Part Number Page
fuel pump nut tool ................................................................ 529 035 899 ......................................... 252

vmr2008-135 229
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

2008 MODELS

NEW

NEW

NEW

6 N•m
(53 lbf•in)
NEW
6.5 N•m
6.5 N•m (58 lbf•in)
(58 lbf•in)

NEW

NEW

* 1 N•m (9 lbf•in)
* 2 N•m (18 lbf•in)
6.5 N•m
(58 lbf•in) * See Pump Installation procedure
vmr2008-135-100_a

230 vmr2008-135
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

2009 MODELS
Engine
NEW

29 N•m
(21 lbf•ft)
NEW
NEW

7 N•m
(62 lbf•in)

NEW

7 N•m
7 N•m (62 lbf•in)
(62 lbf•in)

vmr2008-135-200_a

vmr2008-135 231
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

GENERAL Never use a hose pincher on injection system high

pressure hoses.
 WARNING Replace any damaged or deteriorated fuel lines.
Fuel is flammable and explosive under cer-
When the repair is complete, ensure that all hoses
tain conditions. Ensure work area is well ven-
are connected and secured. The fuel pump is ac-
tilated. Do not smoke or allow open flames or
tivated each time electrical power is turned on.
sparks in the vicinity.
A pressure test must be carried out before turn-
ing the ignition key to ON and setting the engine
 WARNING run/stop switch to RUN.
Always disconnect battery prior to working
on the fuel system. Always disconnect bat-  WARNING
tery exactly in the specified order, BLACK (-) Always carry out a fuel pump pressure test
cable first. and/or a fuel tank leak test whenever a relat-
ed fuel system component has been removed
Whenever working on fuel system, always verify during a maintenance procedure. A missed
for water or dust infiltration in reservoir. fuel leak could result in severe injury or death.
During assembly/installation, use the torque val-
ues and service products as in the exploded After performing a fuel pump pressure test, use
views. the valve on the fuel pressure gauge to release
Clean threads before applying a threadlocker. Re- the pressure (if so equipped).
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for Fuel Tank Vent System Operation
complete procedure. The fuel tank is equipped with a vent system that
provides over pressure relief and negative pres-
 WARNING sure relief of the fuel tank.
Torque wrench tightening specifications Air can enter the fuel tank at all times through
must be strictly adhered to. Locking de- the vent system INLET check valve. This prevents
vices (e.g.: locking tabs, elastic stop nuts, negative pressure within the fuel tank which could
self-locking fasteners, cotter pin, etc.) must cause fuel starvation.
be replaced with new ones. The vent inlet check valve also prevents fuel from
flowing out through the inlet of the vent system.
 WARNING
Fuel lines remain under pressure at all times.
Always proceed with caution and use appro-
priate safety equipment when working on
pressurized fuel system. Always wear safety
glasses.

Proceed with care when removing/installing pres-

sure test equipment or disconnecting fuel line con-
nections.
Slowly disconnect the fuel hose to minimize
spilling. Cover the fuel line connection with an
absorbent shop rag. Wipe off any fuel spillage.

 WARNING vmr2008-135-004_a

2008 MODELS
Do not allow fuel to spill on hot engine parts 1. Vent inlet check valve
or electrical connectors. The evaporating fuel
on the hot components or on the electrical
connectors produce highly inflammable fuel
vapors that can easily be ignited by the heat, a
spark, electrostatic discharge or stray current
resulting in a fire or an explosion.

232 vmr2008-135
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

vmr2008-135-201_a vmr2008-135-201_b

2009 MODELS 2009 MODELS

1. Vent inlet check valve 1. Inlet check valve blocks fuel
2. Outlet pressure relief valve allows pressure to go out
If the pressure in the fuel tank builds up and ex-
ceeds 2.5 - 7.6 kPa (.36 - 1.1 PSI), then the pres-
sure relief valve opens and lets the excess pres- INSPECTION
sure evacuate through the vent system OUTLET.
FUEL TANK LEAK TEST
 WARNING
Always carry out a fuel tank leak test when-
ever fuel tank shows signs of wear or dam-
age which may cause a leak, or when the fu-
el pump has been removed or replaced, or if
you suspect a leak. If damage is severe, fu-
el tank should be replaced even if no leak is
present. Do not attempt to repair a plastic fu-
el tank.

Refill fuel tank.

Remove seat.
vmr2008-135-004_b

2008 MODELS All Models except MAX Models

1. Inlet check valve blocks fuel
2. Outlet pressure relief valve allows pressure to go out Remove the seat reinforcement plate.

vmr2008-135 233
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

vmr2008-135-001_a
vmr2008-135-202_a

TYPICAL 2009 MODELS

1. Seat reinforcement plate 1. Vent system outlet
2. Exhaust heat shield 2. Small hose pincher
3. Retaining screws (5) 3. Vent pressure relief valve

All Models Using the vacuum/pressure pump (P/N 529 021

Install a small hose pincher (P/N 295 000 076) on 800), pressurize fuel tank through vent line (INLET
vent line (OUTLET side). side).

vmr2008-135-002_a
vmr2008-135-003_a

2008 MODELS
2008 MODELS
1. Vent system outlet 1. Fuel tank vent
2. Small hose pincher
3. Vent pressure relief valve 2. Vent inlet line
3. Vent check valve

234 vmr2008-135
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

vmr2008-135-005_a

vmr2008-135-203_a
Step 1: Block vent outlet with finger
Step 2: Remove hose pincher
2009 MODELS
1. Fuel tank vent
2. Vent inlet line
Alternately touch and release end of pressure re-
3. Vent check valve lief valve. You should feel pressurized air flowing
out indicating relief valve is working.
Pressurize fuel tank as follows.

TIME WITHOUT
PRESSURE
PRESSURE DROP
21 kPa (3 PSI) 3 minutes

If pressure drops, locate fuel leak(s) and repair/

replace leaking component(s).
To locate a leak, check for a fuel smell or leaking
fuel.
To ease locating leak(s), spray soapy water on all
hose connections and components; bubbles will
indicate the leak location(s). vmr2008-135-006_a

PRESSURE RELIEF TEST

Fuel Tank Check Valve and Pressure 1. Release vent outlet and feel for air flowing out

Relief Valve Test

Using the pressure/vacuum pump, increase fuel
While tank is still pressurized from the previous tank pressure until the pressure relief valve opens.
fuel tank leak test, carry out the following proce-
NOTE: Pressure relief valve should open when
dure:
the fuel tank pressure exceeds 2.5 - 7.6 kPa (.36 -
Block the vent outlet as you remove the hose 1.1 PSI) preventing fuel tank overpressure. This
pincher. validates pressure relief valve operation.
Remove fuel tank cap.
NOTE: You should hear remaining air pressure
within fuel tank escape as fuel cap seal is loos-
ened.
Blow air in through vent inlet check valve.
NOTE: Air must flow freely through inlet check
valve and out fuel tank filler neck.

vmr2008-135 235
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

 WARNING
If engine has been recently running, always
allow engine and exhaust system time to cool
before disconnecting any fuel component.

Ensure there is enough gas in fuel tank.

Remove the seat and the RH side body panel, re-
fer to the BODY section.
On 2009 models, remove air filter housing. Refer
to AIR INTAKE SYSTEM.
Wrap shop rags around the fuel hose at the quick
disconnect fitting on the RH side of the engine.
vmr2008-048-004_b
Carefully disconnect the fuel pump outlet hose at
2008 MODELS the fuel rail quick disconnect fitting by pressing on
1. Blow air through vent inlet check valve
2. Airflow out of filler neck the release tab.

vmr2008-135-010_a

1. Fuel hose quick disconnect at fuel rail

vmr2008-135-204_a
2. Fuel hose from fuel filter
2009 MODELS
1. Blow air through vent inlet check valve Install fuel pressure gauge (P/N 529 035 709) and
2. Airflow out of filler neck
T-fitting (P/N 529 036 023) between disconnected
Reinstall removed parts. hoses (in-line installation).

FUEL PUMP PRESSURE TEST

The pressure test will show the available pressure
at the fuel pump outlet. It validates the pressure
regulator, the fuel pump and tests for leaks in the
system.
NOTE: See also the diagnostic flow chart in the
TROUBLESHOOTING section to help diagnose a
fuel system related problem.
Ensure there are no leaks from hoses and fittings.
Repair any leak.
Before proceeding with the pressure test ensure vmr2008-135-013_a

the battery is fully charged. Battery voltage must TYPICAL

be over 12 volts. 1. Fuel rail fitting
2. T-fitting — In-line installation
3. Fuel pressure gauge connection
4. Vehicle fuel hose connection

Turn ignition key to ON.

236 vmr2008-135
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

Set engine run/stop switch to RUN and observe

fuel pressure.
 WARNING
Whenever removing a hose in the fuel sys-
tem, always use new Oetiker clamps at as-
FUEL PRESSURE 350 kPa (51 PSI)
sembly. Then validate fuel system tightness
by performing a fuel pump pressure test.
Turn ignition key OFF then back ON. Repeat the
test.
A rapid pressure drop indicates leakage either Oetiker Clamp Replacement
from the fuel rail or from the fuel pump check
To secure or cut Oetiker clamps on fuel lines, use
valve.
Oetiker pliers (P/N 295 000 070).
Check fuel rail for leaks. If it is not leaking, replace
fuel pump.
A slow pressure drop indicates leakage either
from the fuel injector or from the fuel pressure
regulator.
Check fuel injector for leaks. If it is not leaking,
replace fuel pump.
If there is no leakage, start engine and observe
fuel pressure. The fuel pressure should be the
same as above.
1
If pressure is within limits, fuel pump and pressure
regulator are functioning normally. F01B03A

Remove pressure gauge and T-fitting. 1. Cutting clamp

Reconnect fuel pump oulet hose quick disconnect
fitting to fuel rail.

 WARNING
Wipe off any fuel spillage. Fuel is flammable
and explosive under certain conditions. Al-
ways work in a well ventilated area.

Reinstall removed parts.

F01B04A 1
PROCEDURES 1. Securing clamp

FUEL HOSE AND OETIKER

CLAMPS
Fuel Hose Replacement
When replacing fuel hoses, be sure to use hoses
and clamps as available from BRP parts depart-
ment. This will ensure continued proper and safe
operation.

 WARNING
Use of fuel lines other than those recom-
mended by BRP may compromise fuel sys- F01B05A
1
tem integrity.
1. Securing clamp in limited access

vmr2008-135 237
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

IN-LINE FUEL FILTER Filter Installation

(2008 MODELS) Insert new Oetiker clamps on fuel hoses prior to
installing hoses on filter.
Replace fuel filter as per maintenance chart sched-
ule. Refer to MAINTENANCE. Use arrow on filter to position filter according to
fuel flow.
Filter Removal
Disconnect battery, refer to CHARGING SYSTEM
section.
Remove seat, refer to the BODY section.
Remove RH side panel, refer to BODY section.
Remove air filter housing, refer to the AIR INTAKE
SYSTEM section.
Slide a drainage pan under vehicle just below fuel
filter to collect any fuel that may drain when the
fuel lines are disconnected.
Remove fuel filter retaining screw.

vmr2008-135-008_b

FUEL FLOW DIRECTION

1. Flow direction arrow on fuel filter

Follow previous procedure for proper Oetiker

clamp installation.
Ensure there are no kinks in fuel lines and assure
proper routing.
Torque filter retaining screw to 6 N•m (53 lbf•in)

FUEL TANK
Fuel Tank Check Valve and Pressure
vmr2008-135-008_a
Relief Valve Installation
1. Fuel filter retaining screw
2. Oetiker clamps (2) Always install check valve with the black side con-
nected to vent line.
Remove fuel filter Oetiker clamps (2).
Wrap a shop rag around the top fuel hose and pull
hose off filter.
Repeat previous step for bottom fuel hose.
NOTE: Secure fuel hose in an upright position to
limit amount of fuel draining from hose.

Filter Inspection
If fuel filter is suspected of being clogged, it may
be tested as follows.
Using low pressure compressed air, blow air
through fuel filter.
NOTE: Air should flow easily through filter. If in vmr2008-135-004_d

doubt, install a new filter. 2008 MODELS

1. Black side connected to vent
2. White side open to atmosphere

238 vmr2008-135
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

Fuel Tank Draining

 WARNING
Never perform this operation when the en-
gine and/or the exhaust system is/are hot.
Never use a hose pincher on injection system
high pressure hoses.

Remove fuel tank cap and siphon gas into an ap-

proved fuel container.

Fuel Tank Removal

Drain fuel tank.
vmr2008-135-201_d
Release fuel pressure by running engine until it
2009 MODELS
1. Black side here runs out of gas.
2. White side open to atmosphere
Disconnect battery, refer to CHARGING SYSTEM
Always reinstall pressure relief valve according to section.
arrow on valve as shown. Remove seat, refer to the BODY section.
All Models except MAX Models
Remove the seat reinforcement plate.

vmr2008-135-004_e

2008 MODELS – FLOW DIRECTION

1. Pressure relief valve

vmr2008-135-001_a

TYPICAL
1. Seat reinforcement plate
2. Exhaust heat shield
3. Retaining screws (x5)

All Models
Remove side panels and rear fender assembly, re-
fer to BODY section.
Disconnect the fuel pump connector.

vmr2008-135-201_e

2009 MODELS – FLOW DIRECTION

1. Pressure relief valve

vmr2008-135 239
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

Disconnect fuel line at fuel rail quick disconnect

fitting.

vmr2008-135-009_a

2008 MODELS
1. Fuel pump connector vmr2008-135-010_a
2. Fuel tank
3. Rear drive shaft 1. Fuel rail quick disconnect
2. From fuel filter

Remove screw securing in-line fuel filter to vehicle

frame.

vmr2008-135-201_f

2009 MODELS
1. Fuel pump connector
vmr2008-135-008_c
2008 Models
1. Fuel filter mounting screw
Disconnect vent tube OUTLET from frame.
2009 Models
Pull out vent system OUTLET from frame.
Disconnect fuel hose at fuel pump fitting.

vmr2008-135-004_f

1. Vent tube

240 vmr2008-135
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

vmr2008-135-201_g
vmr2008-135-903_a
1. Pull out vent outlet
2. Fuel pump fitting TYPICAL – 2009 MODEL SHOWN

All Models except MAX All Models

Remove 2 fuel tank retaining screws on right side Remove the upper and the lower fuel tank retain-
of the tank. ing screws on the left side of the tank.

vmr2006-015-106_a

LH FUEL TANK MOUNTING SCREWS (2)

vmr2008-135-205_a

TYPICAL – 2009 MODEL SHOWN Remove voltage regulator/rectifier protector.

MAX Models
Remove 3 fuel tank retaining screws on right side
of the tank.

vmr2008-135-206_a

Lift frame sufficiently to extend RH rear shock ab-

sorber and remove its upper mounting screw.
Move shock absorber rearwards.

vmr2008-135 241
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

vmr2008-135-207_a

TYPICAL – 2009 MODEL SHOWN

Pull fuel tank out from the RH side of vehicle.

vmr2006-015-002_a

1. Tank protector
2. Protector retaining tab

Complete removal of protector from fuel tank.

For installation, reverse the removal procedure.
vmr2008-135-208_a 2009 Models
TYPICAL – 2009 MODEL SHOWN Cut plastic rivet locking protector to tank.

Fuel Tank Protector Removal

and Installation
2008 Models
To release protector from fuel tank, carry out the
following procedure:
NOTE: This procedure should be carried out with
parts at room temperature to prevent possible
cracking of plastic.
Work on a stable table.
Lay front of fuel tank on table.
Firmly press on top of fuel tank and hold. vmr2008-135-209_a

Unhook protector from retaining tab on fuel tank.

Pull out tank from protector.
For installation, use a new plastic rivet.

Fuel Tank Inspection

Inspect fuel tank for any damages or cracks which
may result in fuel leaks.

242 vmr2008-135
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

Inspect tank and protector attachment points for

damages.
Inspect protector for damages.
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.

Fuel Tank Installation

Reverse the removal procedure. However, pay at-
tention to the following.
2008 Models Only
CAUTION: Ensure wiring harness is on top of
fuel tank. vmr2008-135-904_a

Torque in-line fuel filter retaining screw to 6 N•m TYPICAL – 2009 MODEL SHOWN
(53 lbf•in).
All Models
All Models except MAX
Refuel tank and ensure there are no leaks by per-
Reinstall the seat reinforcement plate. forming a FUEL TANK LEAK TEST and a FUEL
Install and torque fuel tank retaining screws to PUMP PRESSURE TEST as described in this sec-
7 N•m (62 lbf•in) as per following sequence. tion.

FUEL PUMP (2008)

Fuel Pump Quick Test
Set engine stop switch to RUN.
Turn ignition key to ON and listen for fuel pump
operation.
NOTE: Fuel pump will come ON for a few seconds
(up to 5 sec.), then stop. This is to pressurize the
fuel injector system prior to engine start.
If the fuel pump came on for a few seconds and
shut off, the fuel pump, ECM, and associated cir-
cuits are functioning normally. However, this does
not validate fuel pump pressure.
vmr2008-135-210_a
If fuel pump did not come on, check in B.U.D.S.
TYPICAL – 2009 MODEL SHOWN for applicable fault codes. Refer to COMMUNI-
CATION TOOLS/B.U.D.S. SOFTWARE section.
All MAX Models
Then carry out a FUEL PUMP INPUT VOLTAGE
Install and torque fuel tank retaining screws to
TEST.
7 N•m (62 lbf•in) as per following sequence.
Set ignition switch to OFF.

Fuel Pump Activation In B.U.D.S.

The fuel pump can be activated using B.U.D.S.
software as per following procedure.
NOTE: The fuel pump cannot be disabled using
B.U.D.S. software. It can only be activated for 5
second intervals for pump testing.
Connect vehicle to the latest applicable B.U.D.S.
software, refer to the COMMUNICATION
TOOLS/B.U.D.S. SOFTWARE section.
vmr2008-135 243
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

In B.U.D.S., select Read Data.

Select the Activation page tab.
On the RH side of the page in the Activate field,
select Fuel Pump. This will turn on the fuel pump
for 5 seconds.

vmr2008-023-012_a

PLASTIC PIN LOCK TABS

Set Fluke 115 multimeter (P/N 529 035 868) to

Vdc.
Connect multimeter between pins 3 and 4 of the
fuel pump wiring connector.
Turn ignition key ON.
Set engine run/stop switch to RUN.
vmr2008-135-007_a
Read voltage as follows.
FUEL PUMP ACTIVATION IN B.U.D.S.
1. Select the Activation page tab FUEL PUMP INPUT VOLTAGE TEST
2. Select Fuel Pump button
VOLTAGE
TEST PROBES
READING
Fuel Pump Input Voltage Test Fuel pump Fuel pump
From the LH side of the vehicle, locate the fuel connector connector
pump connector. Pin 3 Pin 4
Battery voltage
Disconnect the fuel pump connector. Fuel pump
connector Battery ground
Pin 3

vmr2008-135-009_a

vmr2006-015-009_b
1. Fuel pump connector
2. Fuel tank TYPICAL
3. Rear driveshaft

Remove the red plastic pin lock from the connec-

tor.

244 vmr2008-135
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

Fuel Pump Relay Input Voltage Test

Remove front compartment cover and fuse box
cover.
Remove fuel pump relay.

vmr2006-015-009_c

TYPICAL

OBSERVATION SIGNIFICATION
Battery voltage is – Validates fuel pump relay R2
read for approx supplies power to fuel pump. vmr2008-139-004_m
5 seconds, then – Validates the fuel pump relay
it will drop to ground circuit through ECM.
1. Fuel pump relay
2. Fuel pump fuse
approx. 6 Vdc for
– Validates fuel pump ground
1 second, then to
0 Vdc
circuit. Measure for fuel pump relay input voltage at fuse
– When voltage drops to box contacts as per following table.
approx 6 Vdc, it validates
the ECM functions to switch FUEL PUMP RELAY INPUT VOLTAGE TEST
fuel pump ON and OFF.
TEST PROBES READING

OBSERVATION POSSIBLE CAUSE Contact 1A

Chassis ground Battery voltage
Battery voltage is – Fuel pump power supply Contact 3A
not read circuit from fuel pump relay R2
is defective.
– Fuel pump ground circuit to
ECM is defective.
– ECM is faulty.

If battery voltage was read for both fuel pump in-

put voltage tests, carry out a fuel pump winding
continuity test.
If battery voltage is not read between pins 3 and 4
of the fuel pump connector but is good to chassis
ground, test for continuity of the fuel pump ground
circuit wire (fuel pump connector pin 4 to chassis
ground). Repair or replace wiring as required. vmr2008-139-004_a

If battery voltage is not read to chassis ground, FUSE BOX PIN-OUT

carry out the following:
– Fuel pump fuse (see following illustration) If battery voltage is read, test wiring for continu-
– Fuel pump relay input voltage test ity between fuse box (contact 3B) and fuel pump
– Fuel pump relay test (refer to connector (pin 3).
LIGHTS/GAUGE/ACCESSORIES) Also test fuel pump relay ground circuit continuity
– Fuel pump motor circuit wiring continuity to ECM connector.
– Fuel pump relay ground circuit continuity. Repair or replace wiring as required.

vmr2008-135 245
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

Fuel Pump Relay Continuity

(Ground Circuit)
Remove RH inner fender panel, refer to the BODY
section.
Disconnect ECM connector.

vmr2008-135-012_a

If ground circuit continuity is good, check ECM.

Refer to ENGINE MANAGEMENT SYSTEM sec-
tion.
Remove tools.
Install removed parts and connectors.
vmr2008-139-008_a Fuel Pump Winding Continuity Test
1. Press to release connector lock NOTE: This test is valid assuming that continuity
2. Push to rotate connector lock upwards
of wiring to fuel pump was tested good.
Install ECM connector onto the ECM adapter tool Remove the fuel pump relay.
(P/N 529 036 085).

vmr2008-139-016_a

1. ECM connector vmr2008-139-004_m

2. Adapter tool
1. Fuel pump relay
2. Fuel pump fuse
Check continuity of fuel pump relay ground circuit
to ECM as per following table.
Set multimeter to .
FUEL PUMP RELAY CONTINUITY Measure the fuel pump motor winding as per fol-
(GROUND CIRCUIT) lowing table.
ECM FUSE BOX RESISTANCE
FUEL PUMP WINDING CONTINUITY TEST
ADAPTER CONTACT @ 20°C (68°F)
RESISTANCE
Pin J-1 Contact 1-b Close to 0 TEST PROBES
@ 20°C (68°F)
Fuse box Chassis
Approximately 1.5
contact 3B ground

246 vmr2008-135
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

vmr2008-135-012_b

FUEL PUMP WINDING CONTINUITY TEST

If fuel pump motor winding resistance is not as

per table, replace the fuel pump. vmr2006-015-012_a

Fuel Pump Removal GASKET AND FLANGE NOT SHOWN FOR CLARITY OF
ILLUSTRATION
Remove fuel tank, see procedure in this section. 1. Fuel line on this side

Remove fuel pump retaining screws. Tighten retaining screws as per sequence in fol-
Gently push pump up as illustrated. lowing illustration. For the initial pre-torque se-
quence (1 to 10), turn screws only enough for gas-
ket to make proper contact between parts, 1 N•m
(9 lbf•in). For the final torque sequence 11 to 19,
properly torque screws to 2 N•m (18 lbf•in).
Install hoses on IN and OUT fittings using new
Oetiker clamps.

7 17
1 11 9 19
3 13
20 10
5 15

vmr2006-015-006_a In 18 8
GASKET AND FLANGE NOT SHOWN FOR CLARITY OF 12 2
ILLUSTRATION 6 16 4 14
Out
CAUTION: While pulling out the fuel pump, pay vmr2006-015-008_aen
attention to fuel sensor float arm. Float arm
can get stuck and bend reducing fuel sensor Fuel Pump Strainer Replacement
accuracy.
Remove fuel pump as per procedure in this sec-
Fuel Pump Installation tion.
For installation, reverse the removal process but Remove push nut securing strainer to fuel pump.
pay attention to the following.
Install a new gasket.
Pay attention to pump orientation as in following
illustration.

vmr2008-135 247
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

– Substitute fuel pump relay with a known

working relay in fuse box.

vmr2008-135-015_a

Pull strainer off fuel pump.

vmr2008-139-004_o

Insert new strainer on fuel pump making sure that

it pressed in tightly against pump face. – Check in B.U.D.S. for applicable fault
codes. Refer to COMMUNICATION
Press in new push nut to secure strainer. TOOLS/B.U.D.S. SOFTWARE section.
Reinstall fuel pump as per procedure described in – Carry out a fuel pump input voltage test.
this section.
Set ignition switch to OFF.
FUEL PUMP (2009) Fuel Pump Activation In B.U.D.S.
Fuel Pump Quick Test The fuel pump can be activated using B.U.D.S.
software.
Set engine stop switch to RUN.
Connect the latest applicable B.U.D.S. software
Turn ignition key to ON. to the vehicle. Refer to the COMMUNICATION
Listen to fuel pump operation. TOOLS/B.U.D.S. SOFTWARE section.
Fuel pump should come ON for for a few seconds, In B.U.D.S., click Read Data.
then stop. Click the Activation tab.
If so, the fuel pump, ECM, and associated cir- In the Activate area, click Fuel Pump button. This
cuits are functioning normally. However, keep in will turn on the fuel pump for 5 seconds.
mind this does not validate fuel pump pressure.
Otherwise, carry out the following step(s) until
the pump works.
– Check fuel pump fuse.

vmr2008-135-007_a

FUEL PUMP ACTIVATION IN B.U.D.S.

1. Click the Activation tab
2. Click Fuel Pump button

vmr2008-139-004_p
Fuel Pump Input Voltage Test
Remove seat.
248 vmr2008-135
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

From the RH side of the vehicle, ldisconnect the FUEL PUMP INPUT VOLTAGE TEST
fuel pump connector.
FUEL PUMP
NOTE: It may be necessary to remove seat re- BATTERY VOLTAGE READING
CONNECTOR
inforcement plate and/or LH side panel to make
room. Pin 3 Ground Battery voltage

vmr2008-135-224_a vmr2008-135-212_b

Use the Fluke 115 multimeter (P/N 529 035 868) If battery voltage is now read, check fuel pump
and the Fluke rigid back probe (P/N TP88). ground circuit. Refer to FUEL PUMP WINDING
Set multimeter to Vdc. RESISTANCE TEST.
Turn ignition key ON. If battery voltage is still not read, check fuel pump
supply circuit. Refer to FUEL PUMP RELAY IN-
Set engine run/stop switch to RUN. PUT VOLTAGE TEST.
Read voltage as follows.
Fuel Pump Relay Input Voltage Test
FUEL PUMP INPUT VOLTAGE TEST Remove front compartment cover and fuse box
FUEL PUMP CONNECTOR VOLTAGE READING cover.
Pin 3 Pin 4 Battery voltage Remove fuel pump relay.

vmr2008-139-004_o

vmr2008-135-212_a
Turn ignition key ON.
If battery voltage is read, carry out a fuel pump
Set engine run/stop switch to RUN.
winding resistance test.
Measure fuel pump relay input voltage at fuse box
If battery voltage is not read carry out this voltage
contacts.
test.

vmr2008-135 249
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

FUEL PUMP RELAY INPUT VOLTAGE TEST

TEST PROBES READING
Fuse box
contact 1A
Battery ground Battery voltage
Fuse box
contact 3A

vmr2008-139-008_a

1. Press to release connector lock

2. Push to rotate connector lock upwards

Install ECM adapter tool (P/N 529 036 085) onto

ECM connector.

vmr2008-135-213_a

CONTACT 1A

vmr2008-139-016_a

1. ECM connector
2. Adapter tool

Use a multimeter and select .

Check continuity as follows.
vmr2008-135-213_b

CONTACT 3A FUEL PUMP RELAY GROUND CONTROL CIRCUIT

FUSE BOX ECM RESISTANCE
If battery voltage is not read, test wiring for conti- CONTACT ADAPTER @ 20°C (68°F)
nuity between battery and fuse box.
Contact 1B Pin J1 Close to 0
If battery voltage is read, test wiring for continu-
ity between fuse box (contact 3B) and fuel pump
connector (pin 3).
Repair or replace wiring as required.

Fuel Pump Relay Ground Control Circuit

Remove RH inner fender panel, refer to the BODY
section.
Disconnect ECM connector.

250 vmr2008-135
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

vmr2008-135-012_a vmr2008-135-012_c

If continuity is good, check ECM. Refer to ENGINE If resistance test failed, disconnect fuel pump con-
MANAGEMENT SYSTEM section. nector and measure winding again directly to fuel
If continuity is not good, repair/replace wiring/con- pump connector.
nectors between ECM and fuse box.
Remove tool.
Install removed parts and connectors.

Fuel Pump Winding Resistance Test

Remove the fuel pump relay.

vmr2008-135-212_c

If test failed, check pump wiring/connector and if

good, replace fuel pump.
If test succeeded check wiring/connectors from
fuse box and to battery ground. Repair/replace as
necessary.
vmr2008-139-004_o

Fuel Pump Removal

Set multimeter to .
Remove seat.
Measure winding as follows.
All Models except MAX: Remove seat reinforce-
FUEL PUMP WINDING RESISTANCE TEST
ment plate.

RESISTANCE
TEST PROBES
@ 20°C (68°F)
Fuse box Battery
Approximately 2.5
contact 3B ground

vmr2008-135 251
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

vmr2008-135-001_a vmr2008-135-214_a

TYPICAL
1. Seat reinforcement plate Carefully pull out fuel pump.
2. Exhaust heat shield
3. Retaining screws (x5)

Disconnect electric connector, vent line and fuel

hose from fuel pump.
NOTE: Wrap shop rags around the fuel hose prior
to removal.

vmr2008-135-215

Discard gasket.
CAUTION: While pulling out the fuel pump, pay
attention to fuel sensor float arm. Float arm
can get stuck and bend reducing fuel sensor
vmr2008-135-201_h
accuracy.
1. Electric connector Wipe off any fuel spillage.
2. Vent line
3. Fuel hose Fuel Pump Installation
Use the fuel pump nut tool (P/N 529 035 899). For installation, reverse the removal process but
pay attention to the following.
CAUTION: Never install a damaged pump or a
dropped pump.
Install a NEW gasket.
Place gasket so that its flange will be between
pump and tank mounting surface.

529035899

Unscrew fuel pump retaining nut.

CAUTION: Replace fuel pump gasket whenever
fuel pump retaining nut is loosen.
252 vmr2008-135
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

While maintaining pump seated, rotate pump to

align its mark with the mark on the fuel tank as
per the following specification.

vmr2008-135-216_a

1. Gasket flange here

vmr2008-135-300_a

Pay attention to pump orientation as in following ANGLE PURPOSELY EXAGGERATED IN ILLUSTRATION FOR
CLARITY
illustration.
While firmly holding pump against tank, engage
fuel pump nut threads. Slightly tighten nut while
holding pump to prevent it from turning.

vmr2008-135-215

Firmly push against pump to align its gasket paral-

lel with tank surface (all around).
vmr2008-135-218_a

Ensure pump is still aligned as per specification.

vmr2008-135-900_a

FUEL TANK REMOVED FROM VEHICLE FOR CLARITY

A. Gasket parallel with tank surface (all around)

vmr2008-135 253
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

vmr2008-135-220_a

vmr2008-135-217_a
Remove rubber pad.
ANGLE PURPOSELY EXAGGERATED IN ILLUSTRATION FOR
CLARITY

To apply the proper torque to the pump nut, use

a torque wrench and install it perpendicularly (90°)
to the tool handle.

vmr2008-135-221_a

Remove push nut securing strainer to fuel pump.

Be careful not to break the plastic pin.

vmr2008-135-219_a

TORQUE WRENCH PERPENDICULAR TO TOOL HANDLE

Torque nut while ensuring pump does not rotate

as nut is tightened. Reposition as necessary.
Secure fuel hose with a new clamp.
Reinstall remaining removed parts.
Refuel tank and ensure there are no leaks by per-
forming a FUEL TANK LEAK TEST and a FUEL vmr2008-135-222_a
PUMP PRESSURE TEST as described in this sec-
tion. Pull strainer off fuel pump.
Check fuel level sensor operation.

Fuel Pump Strainer Replacement

Remove fuel pump.
Unlock 2 tabs of plastic ring on opposite sides.

254 vmr2008-135
 Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

Fuel Level Sensor Resistance Test

Remove and disconnect multifunction gauge,
refer to the LIGHTS/GAUGE/ACCESSORIES sec-
tion.

vmr2008-135-223_a

NOTE: A non serviceable filter is located in fuel

pump. If it is clogged, replace fuel pump.
Insert the new strainer on fuel pump making sure
topressit in tightly against pump face.
vmr2008-140-009_a
Press in a NEW push nut to secure strainer.
Step 1: Press to release
Reinstall remaining removed parts. Step 2: Pull connector off gauge

Use a multimeter and select .

FUEL LEVEL SENSOR
Measure the resistance of the sensor as follows.
The fuel level sensor is a float actuated variable re-
sistance type sensor that is part of the fuel pump. FUEL LEVEL SENSOR RESISTANCE TEST
GAUGE RESISTANCE
FUEL LEVEL
CONNECTOR @ 20°C (68°F)
Full 5 ± 2
Pins 4 and 21
Empty 100 ±7

vmr2008-135-014_a

FUEL PUMP (2008 MODEL)

1. Fuel level sensor

vmr2008-135-901_a

FUEL PUMP (2009 MODEL) vmr2006-020-052_c

1. Fuel level sensor

If readings are out of specification check
wiring/connectors between multifunction gauge
and fuel level sensor. If wiring is good, replace
fuel level sensor.
vmr2008-135 255
Section 05 FUEL SYSTEM
Subsection 02 (FUEL TANK/FUEL PUMP)

If readings are as per specification, test sensor If continuity was not obtained, repair/replace
input voltage from multifunction gauge. wiring.
Connect and install multifunction gauge.
Fuel Level Sensor Replacement
Fuel Level Sensor Input Voltage Test Replace fuel pump.
Set engine stop switch to RUN.
Set ignition switch to ON.
Disconnect fuel level sensor connector.

vmr2008-135-224_a

TYPICAL – 2009 MODEL SHOWN

Use a multimeter and select Vdc.

Measure the input voltage as follows.

FUEL LEVEL SENSOR INPUT VOLTAGE TEST

FUEL LEVEL
VOLTAGE
SENSOR BATTERY
READING
CONNECTOR
Pin 1 Ground Battery voltage

vmr2008-135-212_b

TYPICAL – 2009 MODEL SHOWN

If battery voltage is not read, test wiring continuity

between sensor and multifunction gauge.
If wiring was good, replace multifunction gauge.
256 vmr2008-135
 Section 06 ELECTRICAL SYSTEM
Subsection 01 (IGNITION SYSTEM)

IGNITION SYSTEM
SERVICE TOOLS
Description Part Number Page
Fluke 111 multimeter ........................................................... 529 035 868 ......................... 259, 261–263
ECM adapter tool.................................................................. 529 036 085 ......................................... 262

SERVICE PRODUCTS
Description Part Number Page
Super lube ............................................................................ 293 550 030 ......................................... 265
heat sink paste ..................................................................... 420 897 186 ......................................... 265

GENERAL The ECM controls the ignition system and can de-
tect an open or short circuit in the ignition coil pri-
IGNITION SYSTEM OPERATION mary winding. However, it does not monitor the
secondary winding.
The battery supplies 12 Vdc from fuse F3, to the
primary side of the ignition coil. The ECM com- Ignition Testing Sequence
pletes the circuit by switching it to ground at the Set engine stop switch to RUN.
right moment.
Turn the ignition switch to the ON position.
As the engine rotates, a signal from the CPS
(crankshaft position sensor) relative to the po- No Multifunction Gauge and Taillight
sition of the piston in the cylinder, is produced If the multifunction gauge and taillight do not func-
and sent to the ECM. The ECM uses this signal tion, the ECM may not be powered. Check the
as well as engine RPM to establish the exact following:
moment at which the ignition spark is required. It
then provides the ground to the primary winding 30 A main fuse (F8)
of the ignition coil.
With the ground provided by the ECM, current
flows through the primary coil winding which in-
duces a higher current potential in the secondary
winding. This high current potential jumps across
the spark plug gap and ignites the fuel/air mixture
within the cylinder.

Ignition Timing
Ignition timing is not adjustable.

TROUBLESHOOTING vmr2008-139-015_a

1. Main fuse (F8)

IGNITION SYSTEM TESTING 2. Spare fuse
3. Fan/accessories fuse (F9)
NOTE: It is good practice to check for fault codes
using B.U.D.S. software as a first troubleshoot- 5 A ECM fuse (F1)
ing step. Refer to MONITORING SYSTEM/FAULT
CODES subsection.

vmr2008-137 257
Section 06 ELECTRICAL SYSTEM
Subsection 01 (IGNITION SYSTEM)

Some intermittent problems may be attributable

to loose, dirty or corroded connections, or wa-
ter infiltration, and may be resolved by cleaning
the contacts and applying a dielectric grease for
protection. Always check for these problems be-
fore replacing expensive components and apply
the protective grease as specified in the proce-
dures.

Multiple Problems
There is always the possibility of more than one
component being at fault. If, after a component
has been replaced, the problem still persists, care-
vmr2008-139-004_d
fully repeat the testing procedure to find the other
1. Fuse F1 faulty part.
Battery (refer to CHARGING SYSTEM).
PROCEDURES
If the items in the previous list tested good, the
problem may also be related to one of the follow- Safety Precautions
ing:
– Fuse F4  WARNING
– Main relay To prevent powerful electric shock while
– Ignition switch cranking engine, do not touch any of the ig-
– Engine STOP switch nition components (ignition coil, spark plug
– ECM. wire, etc.) nor tester leads. Also make sure
that tester leads do not touch any metallic
For the main relay circuit and ECM testing, refer to object.
the ELECTRONIC FUEL INJECTION (EFI) section.
Multifunction Gauge and Taillight Turn ON
If the multifunction gauge and taillight turn ON, IGNITION SWITCH
the ignition switch and engine shut off switch are
functioning normally. Ignition Switch Operation
Test the following items in the indicated order: The ignition switch is a three position switch, OFF,
ON with headlights, ON without headlights.
1. Spark plug
2. Battery (refer to CHARGING SYSTEM section)
3. Ignition coil
4. CPS (refer to ELECTRONIC FUEL INJECTION
(EFI) section)
5. ECM (refer to ELECTRONIC FUEL INJECTION
(EFI) section).

Intermittent Ignition Problems

In dealing with intermittent problems there is no
easy diagnosis. Problems that occur only during
normal engine operation may be related to vibra- vmr2008-137-002_a
tions, or the engine operating temperature, and
TYPICAL
have to be tested under similar conditions. 1. OFF
2. ON with headlights
3. ON without headlights

The primary function of the ignition switch is to

provide a signal to the ECM of the intent to start
(wake up signal) and run the engine.

258 vmr2008-137
 Section 06 ELECTRICAL SYSTEM
Subsection 01 (IGNITION SYSTEM)

The ignition switch receives 12 Vdc directly from If you do not obtain battery voltage, test the fol-
the ECM fuse (F1). When the ignition switch is lowing:
set to ON (with or without headlights), it sends a – Main fuse F8
power signal to the ECM through the engine stop – ECM fuse F1
switch (RUN position). This wakes up the ECM
– Wiring harness.
which then waits for the START switch signal to
engage the starter, and control ignition timing for If ignition switch input voltage is good, test the
proper engine operation. following:
If the engine is running and the ignition switch is – Ignition switch continuity
turned to the OFF position, ignition will cease im- – Engine stop switch
mediately, the engine will shut down, but the ECM – Wiring and connectors.
will maintain power on the vehicle for 30 seconds.
Ignition Switch Continuity Test
Ignition Switch Input Voltage Test Set the Fluke 111 multimeter (P/N 529 035 868)
Remove console, refer to the BODY section. to .
Disconnect the ignition switch connector. Measure the resistance through the ignition
switch between the following pins.
NOTE: Connector pins “B” and “E” are not used.

IGNITION SWITCH CONTINUITY TEST

IGNITION
IGNITION
SWITCH RESISTANCE
SWITCH PINS
POSITION
Pins “A” to “F”
OFF Infinite (OL)
Pins “C” to “D”

vmr2008-137-001_a ON Pins “A” to “F”

0.2 ± 0.2 max.
(w/lights) Pins “C” to “D”
Set the Fluke 111 multimeter (P/N 529 035 868)
to Vdc. ON Pins “A” to “F” Infinite (OL)
Measure the ignition switch input voltage as fol- (w/o lights) Pins “C” to “D” 0.2 ± 0.2 max.
lows.

IGNITION SWITCH INPUT VOLTAGE TEST

IGNITION SWITCH
VOLTAGE
CONNECTOR
Pin “C” (BE wire) Battery ground Battery voltage

vmr2008-137-001_c

IGNITION SWITCH CONTINUITY TEST

Replace switch if defective.

Ignition Switch Removal

Remove the console, refer to the BODY section.
vmr2008-137-001_b

IGNITION SWITCH INPUT VOLTAGE TEST

Disconnect the ignition switch connector.

vmr2008-137 259
Section 06 ELECTRICAL SYSTEM
Subsection 01 (IGNITION SYSTEM)

vmo2006-016-001_e

V07G1BA 1 1. Engine stop switch button

2. STOP position
TYPICAL 3. RUN position
1. Disconnect ignition switch connector
When the engine stop switch is set to RUN, it
While holding switch with one hand, unscrew the
completes a circuit between the ignition switch
ignition switch retaining nut with the other.
and the ECM. This circuit provides the 12 Vdc
power used to initialize the ECM.
If the engine is running and the engine stop switch
is set to OFF, the ignition will cease immediately,
the engine will shut down, but the ECM will main-
tain power on the vehicle for 30 seconds.
When the switch is set to STOP, it opens the
12 Vdc circuit to pin “A4” of the ECM and applies
a ground to pin “K3”.
If the engine stop switch is left in the STOP po-
sition when the ignition switch is turned to ON,
vmr2008-137-002_b
the ECM will not be initialized, the multifunction
gauge and tail light will not turn ON.
TYPICAL
1. Remove retaining nut
Engine Stop Switch Continuity Test
Remove the front steering cover, refer to the
Ignition Switch Installation BODY section.
For installation of the ignition switch, reverse the Disconnect the multifunction switch connectors,
removal procedure. MG1 and MG2.
Torque the switch retaining nut to 4 N•m
(35 lbf•in).

ENGINE STOP SWITCH

Engine Stop Switch Operation
The engine stop switch functions as an engine
shutoff switch for a normal shutdown or for an
emergency situation. It can be quickly activated
without letting go of the handlebars.

260 vmr2008-137
 Section 06 ELECTRICAL SYSTEM
Subsection 01 (IGNITION SYSTEM)

IGNITION COIL
The ignition coil is mounted under the top RH side
of the frame, along the steering column, in front
of the engine.

vmr2008-139-002_b

MULTIFUNCTION SWITCH CONNECTORS

1. Disconnect MG1
2. Disconnect MG2

Set the Fluke 111 multimeter (P/N 529 035 868)

vmr2008-138-006_b
to .
IGNITION COIL LOCATION
Measure the resistance through the stop switch
(steering harness side) as per following table. When troubleshooting an ignition coil problem,
first carry out a spark occurrence test, refer to
ENGINE STOP SWITCH CONTINUITY TEST SPARK PLUG in this section.
POSITION CONNECTOR RESISTANCE If there is no spark, carry out the coil input voltage
MG2 pin 3 MG1 pin 3 test, then the coil resistance tests.
1 max.
Switch to (BK) (BK/WH)
STOP
Ignition Coil Input Voltage Test
MG1 pin 1 MG1 pin 2
Infinite (OL) Ensure ignition coil is properly powered as follows.
(BR) (YL)
MG2 pin 3 MG1 pin 3
Remove RH inner fender. Refer to the BODY sec-
Infinite (OL) tion.
Switch to (BK) (BK/WH)
RUN Disconnect the ignition coil input connector.
MG1 pin 1 MG1 pin 2
1 max.
(BR) (YL)

vmr2008-137-004_a

1. Ignition coil
vmr2008-137-003_a 2. Coil input connector

MG1 AND MG2 PIN OUT

Using a small screwdriver, remove the plastic con-
Replace multifunction switch assembly if engine nector pin lock for easy access to pins.
stop switch continuity test results are not as per
specification.

vmr2008-137 261
Section 06 ELECTRICAL SYSTEM
Subsection 01 (IGNITION SYSTEM)

Ignition Coil Ground Circuit

Continuity Test
Disconnect ignition coil input connector.
Disconnect ECM connector.

vmr2008-137-005_a

1. Remove plastic pin lock

Set the Fluke 111 multimeter (P/N 529 035 868)

to Vdc.
Measure battery voltage between the battery ter- vmr2008-139-008_a
minal on the starter solenoid and battery ground.
1. Press to release connector lock
Set engine stop switch to RUN. 2. Push to rotate connector lock upwards

Turn ignition switch to ON. Install the ECM connector onto the ECM adapter
Measure coil input voltage as follows. tool (P/N 529 036 085).

IGNITION COIL INPUT VOLTAGE TEST

IGNITION COIL
VOLTAGE
CONNECTOR
Pin 2 with chassis ground Battery voltage

vmr2008-139-016_a

1. ECM connector
2. Adapter tool

Measure for continuity through the coil ground

wire to the ECM as follows.

IGNITION COIL GROUND CIRCUIT

CONTINUITY TEST
vmr2008-137-006_a TEST PROBES RESISTANCE
IGNITION COIL INPUT VOLTAGE TEST Coil input
1. Pin 1 (VIOLET/BLUE) ECM pin M1 Close to 0
2. Pin 2 (BROWN/ORANGE) connector pin 1

If you did not read battery voltage, check continu-

ity of the ignition coil input circuit.
If battery voltage was read, disconnect the ECM
connector and check continuity of the ignition coil
ground circuit.

262 vmr2008-137
 Section 06 ELECTRICAL SYSTEM
Subsection 01 (IGNITION SYSTEM)

If it tests good, test the secondary winding resis-

tance.
Secondary Winding Resistance Test
A resistance test of the ignition coil secondary
winding is not possible due to internal circuitry.
Spark Plug Cable Resistance Test
Disconnect the spark plug cable from the spark
plug and the ignition coil.
Measure resistance through the cable.

RESISTANCE @
SPARK PLUG CABLE
20°C (68°F)
vmr2008-137-006_b

COIL GROUND CIRCUIT CONTINUITY TEST Spark plug

Coil side 5K ±1K
1. Pin 1 (BROWN/ORANGE) side

Ignition Coil Resistance Tests

NOTE: An ignition coil with good resistance mea-
surements can still be faulty. Voltage leak can oc-
cur at high voltage levels which is not detectable
with an ohmmeter. Replacing the ignition coil may
be necessary as a test.
Primary Winding Resistance Test
Disconnect the ignition coil input connector.
Set the Fluke 111 multimeter (P/N 529 035 868)
to and test the coil resistance as follows. vmr2008-137-011_a

SPARK PLUG CABLE RESISTANCE TEST

IGNITION COIL PRIMARY WINDING
RESISTANCE TEST If resistance value obtained is not close to value
IGNITION COIL INPUT RESISTANCE @ specified, or cable shows signs of deterioration,
CONNECTOR 20°C (68°F) replace spark plug cable.
Pin 1 Pin 2 0.63 ± 0.03
SPARK PLUG
Testing for Spark Occurrence
 WARNING
Never check for ignition spark from an open
coil and/or spark plug as spark may cause po-
tential fuel vapors to ignite.

Use an approved inductive type spark tester to

test for ignition. Follow spark tester manufacture
procedures.
Remove the LH side panel for access to the spark
vmr2008-137-007_a plug and spark plug cable.
COIL PRIMARY WINDING RESISTANCE TEST Turn ignition switch to ON.
Set engine stop switch to RUN.
If the primary coil resistance is not within specifi-
cation, replace the ignition coil. Press and hold the start button.

vmr2008-137 263
Section 06 ELECTRICAL SYSTEM
Subsection 01 (IGNITION SYSTEM)

If nothing happens when the start button is

pressed, refer to the STARTING SYSTEM section.
If the starter rotates the engine and there is no
spark indicated by the tester, follow the ignition
system troubleshooting sequence as indicated.
If the inductive spark tester indicates ignition to
the spark plug, install a new spark plug.
If a known good spark plug does not solve the
problem, continue testing the other system com-
ponents. The ignition spark may not be correct
due to other system components being out of tol-
erance. vmr2008-137-009_a

NOTE: Keep in mind that even if there is a spark CLEAN AREA AROUND SPARK PLUG
during this static test, the voltage requirement to
produce a spark in the combustion chamber is Using an approved spark plug socket, release the
higher when the engine is running. The ignition spark plug torque.
coil may not be functioning properly. Replacing
the ignition coil may be necessary as a test.

Spark Plug Removal

Remove the LH side panel, refer to the BODY sec-
tion.
1 2
Disconnect the spark plug cable.

A00E0BA

1. Proper socket
2. Improper socket

Remove wrench and socket from the spark plug

and unscrew it by hand.

Troubleshooting a Fouled Spark Plug

vmr2008-137-008_a
Fouling of the spark plug is indicated by irregular
1. Remove spark plug cable running or misfiring of the engine, decreased
engine speed due to misfiring, reduced perfor-
Clean the area around the spark plug with pressur- mance, and increased fuel consumption. This
ized air. may be due to a loss of compression.
Other possible causes are: a clogged air filter, in-
correct or bad fuel, defective ignition system, in-
correct spark plug gap, lubricating oil entering the
combustion chamber, or use of a spark plug with a
temperature rating too cold for the engine require-
ment.
The plug face of a fouled spark plug has either a
wet or dry black carbon deposit. Such coatings
form a conductive connection between the center
electrode and the ground electrode.

264 vmr2008-137
 Section 06 ELECTRICAL SYSTEM
Subsection 01 (IGNITION SYSTEM)

Spark Plug Analysis

A00E0AA 1 2 3
TYPICAL
1. Overheated (light grey, white)
2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, grey, melted coating)

The plug face reveals the condition of the engine,

operating condition, method of driving and fuel
mixture. For this reason it is advisable to inspect
the spark plug at prescribed intervals, examining
the plug face (i.e. the part of the plug projecting
into the combustion chamber).

Spark Plug Installation

Spark plug installation is the reverse of the re-
moval procedure. However, pay attention to the
following.
Prior to installation make sure that contact sur-
faces of the cylinder head and spark plug are free
of grime.
Using a wire type feeler gauge, set the electrode
gap to 0.7 – 0.8 mm (.028 – .032 in).
Apply a light coat of heat sink paste (P/N 420 897
186) over the spark plug threads and gasket.
Hand screw spark plug into cylinder head until it
bottoms out.
Torque spark plug to 20 N•m (15 lbf•ft) using an
approved spark plug socket and torque wrench.
Apply Super lube (P/N 293 550 030) to the elec-
trical contact inside the spark plug cap before in-
stalling it on the spark plug.

vmr2008-137 265
 Section 06 ELECTRICAL SYSTEM
Subsection 02 (CHARGING SYSTEM)

CHARGING SYSTEM
SERVICE TOOLS
Description Part Number Page
Fluke 111 multimeter ........................................................... 529 035 868 ................................. 269, 271

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
Extech inductive ammeter.................................................... 380941 ......................................... 270
Electro Specialties battery load tester .................................. 710 ......................................... 272

SERVICE PRODUCTS
Description Part Number Page
dielectric grease ................................................................... 293 550 004 ................................. 273–274

GENERAL
SYSTEM DESCRIPTION
The purpose of the charging system is to keep the
battery at a full state of charge.
NOTE: For an overview of the vehicle electrical
system, refer to ENGINE MANAGEMENT SYS-
TEM section.
Magneto
The magneto is the primary source of electrical
energy. It transforms a magnetic field into electric
current (AC).
vmr2006-017-001
The alternating current is regulated and trans-
TYPICAL
formed into direct current (DC) by the voltage
regulator, and normally powers all of the vehicle's
systems and accessories. Voltage Regulator
The magneto has a 3 phase delta wound stator. The regulator receives AC current from the mag-
neto and transforms it into direct current (DC).
The voltage regulator output voltage is distributed
as follows:
– 30 A main fuse
– 30 A Fan/Accessories fuse
– Battery.
The voltage regulator limits voltage to prevent any
damage to electrical components.

vmr2008-138 267
Section 06 ELECTRICAL SYSTEM
Subsection 02 (CHARGING SYSTEM)

MODEL VOLTAGE Vdc Remove the diagnostic connector from its storage
cap.
400 EFI 14.8

vmr2007-042-001_a

vmr2006-017-002 DIAGNOSTIC CONNECTOR

TYPICAL
Connect to the latest B.U.D.S. software, refer to
NOTE: If the battery will not stay charged, the COMMUNICATION TOOLS/B.U.D.S. SOFTWARE
problem can be any of the charging system com- section.
ponents. If these all test good, try a new voltage Start engine.
regulator.

Battery
 WARNING
Before starting engine, make sure parking
The battery supplies DC power to the electric brake is set and transmission is selected to
starter for cranking the engine. During engine park “P” or neutral “N”. Failure to comply
starting, it also supplies DC power to every elec- with this procedure may result in equipment
trical and electronic systems in the vehicle as well damage, severe injury and possibly loss of
as all accessories. At low engine RPM operation life.
and high current load conditions, it supplements
the magneto's output as required, and helps to In B.U.D.S., select Read Data.
maintain a steady system voltage.
Select the Monitoring tab.
PROCEDURES On the monitoring page, read the 12 Vdc system
voltage on the Battery Voltage meter and the en-
It is good practice to check for fault codes us- gine RPM on the Engine Speed indicator as per
ing the B.U.D.S. software as a first troubleshoot- following table.
ing step. Refer to MONITORING SYSTEM/FAULT
CODES section. TEST ENGINE SPEED VOLTAGE
NOTE: First, ensure the battery is in good condi- 4000 RPM 14.4 - 15.2 Vdc
tion prior to performing the following tests.

VOLTAGE REGULATOR
Voltage Regulator Continuity Test
Due to internal circuitry, there is no static test avail-
able.

Voltage Test Using B.U.D.S.

Remove the front storage cover, refer to BODY
section.

268 vmr2008-138
 Section 06 ELECTRICAL SYSTEM
Subsection 02 (CHARGING SYSTEM)

vmr2008-138-004_a
vmr2008-138-010_a
CHARGING SYSTEM VOLTAGE TEST
TYPICAL 1. Solenoid battery terminal
1. Voltage indication 2. Negative battery post
2. RPM indication

Start engine.
If voltage is below specification, test the follow-
ing: Read voltage as follows.
– Voltage regulator ground wire continuity
CHARGING SYSTEM VOLTAGE TEST
– Stator (refer to MAGNETO/STARTER)
– Wiring and connectors. TEST ENGINE SPEED VOLTAGE
If voltage is above specification, replace voltage 4000 RPM 14.4 - 15.2 Vdc
regulator.
Install all removed parts and connectors. If voltage is above specification, replace voltage
regulator.
Voltage Test with a Multimeter If voltage is below specification, test the follow-
Proceed as follows: ing:
Remove starter solenoid cover. – Battery cable from voltage regulator to starter
solenoid
– Voltage regulator ground wire continuity
– Stator (refer to MAGNETO/STARTER)
– Wiring and connections from stator to voltage
regulator.
Remove multimeter and install red rubber boot
over solenoid battery terminal.
Reinstall starter solenoid cover.

DC Current Test with an Inductive

Ammeter
Remove starter solenoid cover.

vmr2008-061-001_a

STARTER SOLENOID COVER REMOVAL

Pull back red rubber boot from starter solenoid

(battery terminal).
Set Fluke 111 multimeter (P/N 529 035 868) to Vdc
scale.
Connect the multimeter between the solenoid
battery terminal and the negative battery post.

vmr2008-138 269
Section 06 ELECTRICAL SYSTEM
Subsection 02 (CHARGING SYSTEM)

NOTE: If battery is in poor condition or is not at a

full state of charge, current reading will be above
specification. Refer to BATTERY in this section for
battery testing.

DC Current Test with a Multimeter

 WARNING
Be careful not to touch chassis with tool used
when disconnecting or connecting battery
wires. Battery positive post must not touch
chassis when moving battery. Pay particular
attention to the battery support mounting
bolt near the battery positive terminal in the
vmr2008-061-001_a forward end of the battery support.
STARTER SOLENOID COVER REMOVAL
Disconnect the BLACK (-) negative battery cable
Use an inductive ammeter such as theExtech in- from the battery.
ductive ammeter (P/N 380941) or equivalent. Disconnect the RED (+) battery cable and the RED
Turn on the ammeter and select Adc. voltage regulator wire from the starter solenoid.
Locate the RED wire of the voltage regulator (volt-
age output) and clamp the ammeter over it.

vmr2008-138-001_a

DC CURRENT TEST WITH INDUCTIVE AMMETER vmr2007-047-010_a

1. Output connector of voltage regulator
2. Ammeter clamped over RED wire TYPICAL
1. Remove battery cable
2. Remove this terminal lug with the RED voltage regulator wire
Start engine.
Read current. Reconnect battery cable to starter solenoid.

TEST ENGINE SPEED CURRENT

4000 RPM Approx. 8.5 A

NOTE: Current reading may be higher depending

on battery state of charge, and accessory loads
applied.
If current reading is far below specification, test
magneto (stator) output prior to concluding that
voltage regulator is faulty.

270 vmr2008-138
 Section 06 ELECTRICAL SYSTEM
Subsection 02 (CHARGING SYSTEM)

Connect multimeter probes between voltage reg-

ulator wire and the disconnected solenoid battery
terminal.

vmr2008-138-003_a

DC CURRENT TEST WITH MULTIMETER

vmr2006-017-002_a 1. Multimeter probes
2. Starter solenoid battery terminal
1. Battery cable installed 3. Voltage regulator wire
2. Voltage regulator wire disconnected

Reconnect the BLACK (-) negative battery cable to Read current as follows.
the battery.
TEST ENGINE SPEED CURRENT
Connect a jumper wire between the disconnect-
ed voltage regulator wire and the solenoid battery 4000 RPM Approx. 3 - 7 A
terminal.
If current is below specification, test magneto
(stator) output prior to concluding that regulator is
faulty.
NOTE: If battery is in poor condition or is not at a
full state of charge, current reading will be above
specification. Refer to BATTERY in this section for
battery testing.
Properly reconnect voltage regulator wire to
starter solenoid.

BATTERY
Battery Information
vmr2008-138-002_a
These vehicles are equipped with a VRLA battery
1. Jumper wire
2. Starter solenoid battery terminal
(Valve Regulated Lead Acid). It is a maintenance-
3. Voltage regulator wire free type battery.
CAUTION: During engine starting, current Refer to battery manufacturer's instructions for
draw is above the multimeter function capaci- proper filling, activation and routine charging pro-
ty (10 Adc). Connect multimeter after engine cedures.
is started, otherwise it would be in OVERLOAD
possibly resulting in equipment damage. Troubleshooting
Start engine. Weak or Discharged Battery
Remove the jumper wire. If you have a frequently weak or discharged bat-
Set Fluke 111 multimeter (P/N 529 035 868) to tery, check for the following:
Adc. – Battery posts or cable terminal loose or oxidized
– Faulty battery (does not keep a full charge)
– Loose or bad starter solenoid connections
vmr2008-138 271
Section 06 ELECTRICAL SYSTEM
Subsection 02 (CHARGING SYSTEM)

– Loose or bad engine and chassis ground con- Follow battery load tester instructions.
nections Apply a load of 3 times the ampere-hour rating of
– Faulty system wiring or connections the battery. At 14 seconds into the test, check
– Faulty voltage regulator battery voltage.
– Faulty stator.
BATTERY VOLTAGE TEST (LOAD APPLIED)
Rectify any problem identified, recharge battery
as per manufacturers instructions and carry out a TIME TO MEASURE
VOLTAGE
battery load test to confirm the condition of the INTO TEST
battery. 14 seconds Min. 10.5 Vdc
Battery Voltage Test (No Load) If battery voltage has dropped below 10.5 Vdc,
NOTE: A battery voltage test without a load ap- battery storage capacity has decreased apprecia-
plied is carried out on a battery without discharg- bly and battery should be replaced.
ing current. It is the simplest and most common-
ly used. However, be aware that the voltage test Battery Removal
can indicate that the battery is in good condition
even though the battery does not have enough  WARNING
power to crank the engine. A load test gives a Always disconnect BLACK (-) cable first. This
more accurate indication of the condition of the will open the battery circuit and remove the
battery. possibility of causing a spark, or a short cir-
Check the charge condition using a multimeter. cuit with the vehicle when disconnecting the
With a multimeter, voltage readings appear in- RED (+) battery cable. Electrolyte or fuel va-
stantly to show the state of charge. pors can be present and a spark may ignite
them, possibly causing an explosion which
If the battery has just received a charge, allow it to could result in severe personal injuries, or
rest for 1 - 2 hours before taking a voltage reading. death.
Set multimeter to Vdc and connect between the
battery negative terminal and the starter solenoid Remove battery holding strap.
battery terminal. Always respect polarity. Disconnect BLACK (-) cable.

vmr2008-138-004_a

BATTERY VOLTAGE TEST

1. Solenoid battery terminal vmr2008-138-008_a
2. Battery negative terminal
1. Remove battery holding strap
2. Disconnect BLACK (-) battery cable
FULLY CHARGED BATTERY VOLTAGE
12.5 Vdc minimum Pull back battery to reach the RED (+) cable battery
posts.
Battery Voltage Test (Load Applied)
This is the best test used to determine the con-
dition of the battery. Use a load testing device
such as the Electro Specialties battery load tester
(P/N 710). It has a 500 A carbon pile adjustable
load.
272 vmr2008-138
 Section 06 ELECTRICAL SYSTEM
Subsection 02 (CHARGING SYSTEM)

Inspect condition of battery posts, battery sup-

port, holding strap and strap attachment points
and wire terminal lugs.

Battery Storage
It is not necessary to remove the battery during
vehicle storage but it is recommended for long
term storage.
If the battery is left in the vehicle during storage or
used infrequently, disconnect the BLACK (-) nega-
tive battery cable to eliminate battery current drain
vmr2008-138-009_a
from the electrical equipment.
1. Pull back RED rubber boot Recharge the battery once a month with an ap-
2. Disconnect RED (+) battery cable proved battery charger as per manufacturer's rec-
ommendations.
Pull back the red rubber boot and disconnect the
RED (+) battery cable. Clean battery, battery support and connections as
required, refer to BATTERY CLEANING in this sec-
Remove battery from support. tion.
If replacing battery, remove the battery insulator For other recommendations during storage, refer
pad. to battery manufacturers instructions.

 WARNING
Ensure battery is stored in a safe place, out of
reach for children.

New Battery Activation

Refer to the instructions provided with the battery.

Battery Charging

vmr2008-138-011_a
 WARNING
Always wear safety glasses and charge in a
1. Battery insulator pad
well ventilated area. Never charge or boost a
battery while it is installed on vehicle. Do not
Battery Cleaning open the sealed cap during charging. Do not
place battery near open flame.
With the battery removed from vehicle, clean
the battery rack, insulator pad, cables and battery CAUTION: If battery becomes hot, stop charg-
posts using a solution of baking soda and water. ing and allow it to cool before continuing.
Remove corrosion (if present) from battery cable NOTE: Sealed VRLA batteries have an internal
terminals and battery posts using a firm wire safety valve. If battery pressure increases due to
brush. Rinse thoroughly with clear water and dry overcharging, the valve opens to release excess
using a clean cloth. pressure, preventing battery damage.
Apply a light coat of dielectric grease (P/N 293 550 Perform a BATTERY UNLOADED TEST.
004) on terminals.
An automatic charger is a fast and convenient way
Battery Inspection for error-proof charging.
Visually inspect battery casing for cracks or any Always follow the battery manufacturers charging
other damages. If casing is damaged, replace bat- instructions.
tery and thoroughly clean battery support with a Battery should be charged at a slow charge rate of
water and baking soda solution. 1/10 its given 10 hours. capacity.

vmr2008-138 273
Section 06 ELECTRICAL SYSTEM
Subsection 02 (CHARGING SYSTEM)

When using a constant current charger, charge With the left hand, lift the BLACK battery cable
battery according to the chart below. and holding strap as you insert the battery in the
battery support.
Battery Voltage Below 12.8 V and Above 11.5 V
Properly position battery with the positive post to-
STANDARD CHARGING wards the front and the negative post towards the
(RECOMMENDED) rear.
BATTERY
TIME CHARGE
TYPE
YTX20L-BS 4 - 9 hours 2 A

QUICK CHARGING
BATTERY
TIME CHARGE
TYPE
YTX20L-BS 50 minutes 10 A

Battery Installation

vbl2008-005-502_a

WARNING BATTERY CABLE ROUTING

Always connect RED (+) cable first then
BLACK (-) cable. Secure with battery holding strap.
Connect the BLACK (-) battery cable.
Install the battery insulator pad on the battery.
Insert the fasteners in the battery posts.
Place battery on a support behind vehicle with the
positive terminal to the left.
Route the RED (+) battery cable over and in line
with the battery lengthwise.
Connect the RED battery cable to the positive (+)
battery post.
Apply silicone dielectric grease (P/N 293 550 004)
on battery posts and connections.
Install the red rubber boot over the battery post.
vmr2008-138-008_a

1. Secure with battery holding strap

2. Connect the BLACK (-) battery cable

ELECTRICAL SYSTEM MAIN

GROUND
Remove starter solenoid cover.

vmr2008-138-009_b

BATTERY TERMINALS FACING VEHICLE

1. Connect RED (+) battery cable
2. Install red rubber boot over battery post

274 vmr2008-138
 Section 06 ELECTRICAL SYSTEM
Subsection 02 (CHARGING SYSTEM)

vmr2008-061-001_a

STARTER SOLENOID COVER REMOVAL

Ensure main ground connection is clean and tight.

vdd2007-001-086_a

ELECTRICAL SYSTEM MAIN GROUND

Reinstall starter solenoid cover.

vmr2008-138 275
 Section 06 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)

STARTING SYSTEM
SERVICE TOOLS
Description Part Number Page
Fluke 111 multimeter ........................................................... 529 035 868 ......................... 279, 281–283
ECM adapter tool.................................................................. 529 036 085 ......................................... 281

GENERAL If the engine can be started (pull start), check the

following in this order:
STARTING SYSTEM OPERATION – Battery (refer to CHARGING SYSTEM )
– Starter solenoid
When the START button is pressed, 12 Vdc is ap-
plied through the start switch to the starter so- – Start button switch
lenoid coil. If the engine cranking conditions are – Starter (refer to MAGNETO/STARTER)
met, the ECM completes the starter solenoid con- – Wiring and connections.
trol circuit by providing a ground. The starter so-
lenoid then closes its contacts and battery power PROCEDURES
is applied to the starter for cranking the engine.

Engine Cranking Conditions START BUTTON

The following conditions must be met to allow en- Start Button Quick Test
gine cranking.
Set transmission lever to the PARK position.
– Ignition switch turned ON
Set engine stop switch to RUN.
– Engine stop switch to RUN
– Transmission in Park or Neutral Turn ignition switch ON.
– Start button is pressed and held. Press and hold start button. The starter should
start to crank the engine immediately.
NOTE: The engine can be cranked by the starter
when the transmission is in High, Low, or Re- NOTE: If the engine does not crank, set trans-
verse if either the brake lever or brake pedal is mission to Neutral or apply the brakes using the
applied. brake lever or brake pedal, as you press the start
button. Also confirm the gear selection indicator
TROUBLESHOOTING in the multifunction gauge displays the selected
gearshift lever position.
NOTE: It is good practice to check for fault codes If the starter cranks over the engine with the
using B.U.D.S. software as a first troubleshoot- breaks applied, check the shifter adjustment and
ing step. Refer to MONITORING SYSTEM/FAULT the gearbox position sensor and wiring. Refer
CODES. to the SHIFTER and GEARBOX/OUTPUT SHAFT
sections.
Starter Will Not Crank Engine
If it still does not function, test the start button
No Multifunction Gauge and Taillight continuity.
If the multifunction gauge and taillight do not turn
ON (assuming bulb and gauge are good), refer to Start Button Continuity Test
IGNITION SYSTEM section. If engine does not crank when pressing the start
button, test the start button switch as follows.
Multifunction Gauge and Taillight Turn ON
Remove the front steering cover.
If the “Engine cranking conditions” are met and
the starter will not crank the engine, try a pull Disconnect the multifunction switch connector
start. (MG2).

vmr2008-139 277
Section 06 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)

vmr2008-139-002_a

vmr2008-139-004_b
MULTIFUNCTION SWITCH CONNECTOR (MG2)
FUSE F4
Test start button switch continuity as follows.
Test continuity of the following main vehicle har-
MULTI-FUNCTION ness wires:
START SWITCH – YL/RD wire from multifunction switch connec-
RESISTANCE
BUTTON CONNECTOR tor (MG2 contact 6) to starter solenoid
(MG2) – OR/GN wire from MG2 (contact 1) to fuse F4
Released Infinite (OL) (contact 6C fuse removed).
Pin 6 (RD/VI) and
Depressed Pin 1 (YL/RD) 0.6 max. MG2 (vehicle
and held TO RESISTANCE
harness side)
Starter solenoid
Pin 6 (YL/RD) Close to 0
YL/RD wire
Fuse F4
Pin 1 (OR/GN) Approx. 1.0
(contact 6C)

vmr2008-139-003_a

MG2 STEERING HARNESS CONNECTOR PIN-OUT

If start switch does not test as specified, replace

the multifunction switch assembly.
If start switch tests as specified, remove fuse F4. vmr2008-139-003_b

MG2 VEHICLE HARNESS CONNECTOR PIN-OUT

278 vmr2008-139
 Section 06 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)

vmr2008-139-001_a

vmr2008-139-004_a
1. Starter solenoid
FUSE BOX PIN-OUT 2. Voltage regulator/rectifier
3. Battery

Repair or replace wiring/connections.

Power Signal to Solenoid Coil Test
STARTER SOLENOID Set transmission to Park, or Neutral.
The starter solenoid is located to the right of the Set Fluke 111 multimeter (P/N 529 035 868) to
battery, forward of the voltage regulator/rectifier. Vdc.
To access the starter solenoid, remove the starter Measure battery voltage between solenoid bat-
solenoid cover. tery terminal and battery ground.

vmr2008-138-004_a

BATTERY VOLTAGE TEST

1. Solenoid battery terminal
2. Battery negative (–) terminal
vmr2008-061-001_a

STARTER SOLENOID COVER Disconnect the small wires from the solenoid.

vmr2008-139 279
Section 06 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)

vmr2008-139-005_a vmr2008-139-005_e

DISCONNECT SOLENOID COIL WIRES

1. Small solenoid coil wires
If voltage is as specified, test continuity of sole-
2. Small solenoid coil terminals noid ground control circuit.

Set engine stop switch to RUN. Solenoid Ground Control Circuit Test
Turn ignition switch to ON. Disconnect small terminal with OR/BR wire from
Press start button and measure the voltage at the solenoid.
small solenoid coil wires as follows.

vmr2008-139-006_b

vmr2008-139-005_b
Locate ECM secured to the front of the forward
SOLENOID COIL POWER SIGNAL TEST frame riser, just behind the radiator cooling fan.
START
WIRES VOLTAGE
BUTTON
Approx.
Released
0 Vdc
YL/RD and OR/BR
Depressed Battery
and held voltage

If voltage is as specified, carry out a SOLENOID

CONTINUITY TEST , see procedure in this section.
If voltage is not as specified, carry out the follow-
ing voltage check.
vmr2008-139-007_a

START
WIRES VOLTAGE 1. ECM
BUTTON 2. Radiator cooling fan

Released 0 Vdc
YL/RD and battery Disconnect ECM connector.
Depressed ground Battery
and held voltage
280 vmr2008-139
 Section 06 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)

vmr2008-139-006_a

SOLENOID GROUND CONTROL CIRCUIT TEST

vmr2008-139-008_a

1. Press to release connector lock If resistance is not as specified, repair or replace

2. Push to rotate connector lock upwards
wiring/connections.
Install the ECM connector onto the ECM adapter If solenoid input circuits and ground control cir-
tool (P/N 529 036 085). cuit continuity tested good, test ECM ground cir-
cuits. Refer to ELECTRONIC FUEL INJECTION
(EFI) section.

Solenoid Diode Test

Disconnect small terminals from solenoid.

vmr2008-139-016_a

1. ECM connector
2. ECM adapter tool

Set Fluke 111 multimeter (P/N 529 035 868) to .

Read resistance as follows.

SOLENOID GROUND CONTROL CIRCUIT vmr2008-139-005_a

TEST PROBES RESISTANCE 1. Small solenoid coil wires

2. Small solenoid coil terminals
Solenoid
ECM pin L3 Close to 0 Use the Fluke 111 multimeter (P/N 529 035 868)
OR/BR wire
and set it to the diode symbol as shown.

vmr2008-139 281
Section 06 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)

NOTE: Diode is located in main wiring harness

near solenoid. It is approximately 22 cm (8-3/4 in)
from the main fuse holder as shown in following
picture.

vmr2006-020-005
vmr2008-139-018_a

Probe wires while paying attention to the diode 1. D4 diode location

polarity. 2. Starter solenoid

Solenoid Continuity Test

Disconnect the black (-) negative battery cable.
Disconnect the small terminal wires from the so-
lenoid.

vmr2008-139-005_c

FORWARD POLARITY, MUST BE AROUND 0.5 V

vmr2008-139-005_a

1. Small solenoid coil wires

2. Small solenoid coil terminals

Set Fluke 111 multimeter (P/N 529 035 868) to .

Measure solenoid coil resistance as follows.

MEASUREMENT
SOLENOID TERMINALS RESISTANCE
@ 20°C (68°F)
vmr2008-139-005_d
A B Approx. 6
REVERSE POLARITY, MUST BE OPEN CIRCUIT

If test failed, replace diode.

282 vmr2008-139
 Section 06 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)

NOTE: Torque the large solenoid cable terminals

to 4 N•m (35 lbf•in).

Solenoid Dynamic Test

Remove fuse F3 to prevent engine from starting.
NOTE: Check engine will be displayed in multi-
function gauge, starter will crank engine but with
an initial delay of approximately 4 seconds.

vmr2008-139-005_f

SOLENOID COIL CONTINUITY TEST

Disconnect the battery cable at the solenoid ter-

minal.

vmr2008-139-004_c

FUSE F3

Set transmission to Park or Neutral.

Turn ignition switch to ON.
Set engine stop switch to RUN.
vmr2008-139-017_a Set Fluke 111 multimeter (P/N 529 035 868) to
1. Disconnect battery cable from solenoid Vdc.
Depress the start button.
Test for a stuck solenoid plunger by measuring
the resistance across the solenoid contacts as fol- As the engine is cranking, measure the voltage
lows. drop across the large solenoid terminals as fol-
lows.
SOLENOID POSTS MEASUREMENT
SOLENOID POST MEASUREMENT
Battery post Starter post Open circuit
Solenoid
Solenoid
battery 0.2 Vdc max.
starter terminal
terminal

vmr2008-139-017_b

If any measurement is out of specification, replace

solenoid.
vmr2008-139-010_a
Reconnect all wires and cables.
vmr2008-139 283
Section 06 ELECTRICAL SYSTEM
Subsection 03 (STARTING SYSTEM)

If voltage is above specification, replace solenoid.

284 vmr2008-139
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

LIGHTS, GAUGE AND ACCESSORIES

SERVICE TOOLS
Description Part Number Page
Fluke 115 multimeter ........................................................... 529 035 868 ........ 287, 293, 295, 297–300,
303–304, 307, 310, 313, 315

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
Fluke rigid back probes......................................................... TP88 ......................................... 295

SERVICE PRODUCTS
Description Part Number Page
dielectric grease ................................................................... 293 550 004 ......................................... 299
Super Lube ........................................................................... 293 550 030 ......................................... 297

GENERAL Diagnostic
NOTE: For a complete overview of the vehicle IMPORTANT: When solving an electrical system
electrical system, refer to ENGINE MANAGE- faults, the first thing to do is to check the battery
MENT. condition, cables, and connections.
It is highly recommended to disconnect the bat- Also ensure the ignition switch is turned ON and
tery when replacing any electric or electronic com- the engine run/stop switch is set to RUN.
ponent. Check the related-circuit fuse condition with an
ohmmeter (a visual inspection could lead to a
 WARNING wrong conclusion).
Always disconnect battery exactly in the IMPORTANT: In many electric circuits, the battery
specified order, BLACK (-) cable first. Do not supplies a switch which then supplies the elec-
place tools on battery. tric component. Therefore, the switch opens and
closes the positive side of the circuit.
Clean threads before applying a threadlocker. Re- In circuits controlled by the ECM, the battery sup-
fer to SELF-LOCKING FASTENERS and LOCTITE plies the electric component and the ECM works
APPLICATION at the beginning of this manual for as a switch to complete the circuit to ground. Take
complete procedure. this into account when troubleshooting electrical
During assembly/installation, use the torque val- systems.
ues and service products as in the exploded Pay close attention to ground wires. Their con-
views. nection to the frame or engine may become resis-
 WARNING tive due to corrosion. The resulting voltage drop
at the ground connection could cause certain sys-
Torque wrench tightening specifications tems to malfunction.
must be strictly adhered to. Locking de-
vices (e.g.: locking tabs, elastic stop nuts, Checking for Short Circuits Between 2 Wires
self-locking fasteners, etc.) must be replaced When checking continuity of a wire in a circuit,
with new ones. wires should be checked for a short circuit be-
tween them as follows.
vmr2008-140 285
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

Isolate the circuit by disconnecting its connectors.

Let’s suppose that the circuit to be checked is
composed of a RED and a BLACK wire. Using an
ohmmeter, measure the resistance between the
RED and the BLACK wire. The resistance should
be infinite (OL). Otherwise, a short circuit exists
between the two wires which must be identified
and corrected.

Electrical Connectors
Pay particular attention to ensure that pins are not
bent or pushed out of their connectors.
Ensure all wire terminals are properly crimped on vmr2008-139-004_k

wires, and connector housings are properly fas- FRONT FUSE BOX (PF1)
tened. 1. (F1) Engine control module (ECM)
2. (F2) Cooling fan
When replacing an electric or electronic com- 3. (F3) Fuel injector/ignition coil
4. (F4) Relays/speedo
ponent(s), always check electrical connections. 5. (F5) Fuel pump
Make sure they are tight, make good contact, 6. (F6) Accessories
and are corrosion-free. Dirty, loose or corroded
contacts are poor conductors and are often the NOTE: A shorted D5 or D6 diode will cause fuse
source of the problem. F6 to burn. Refer to D5 AND D6 DIODES (Winch
Relay) further in this section.
Check for signs of moisture, corrosion or dullness.
Clean pins properly and coat them with a silicon- CE Models
based dielectric grease or other appropriate lu- The CE modes have an additional fuse and two
bricant (except if otherwise specified) when re- diodes in the front fuse box. All other fuses and
assembling them. relays are the same.

PROCEDURES
FUSES
If a fuse is burnt, replace it with another fuse of
the same rating.
CAUTION: Do not use a higher rated fuse than
recommended. Use of a higher rated fuse can
lead to severe component or circuit damage,
an overheat condition, and possibly an electri-
cal fire.
vmr2008-140-011_a
Fuses are located in the front service compart-
FUSE BOX (2008 CE MODELS)
ment and at the rear of the vehicle near the bat- 1. Diode D2
tery. The rear fuse holder is attached to the back 2. Diode D3
3. Control Euro fuse (7.5 A)
of the voltage regulator/rectifier unit.
NOTE: The 2009 CE fuse box is similar, however,
Front Fuse Box (PF1) diodes D2 and D3 have been removed from the
The front fuse box contains the various system fuse box and are now integrated into the wiring
fuses, relays, and a fuse puller. harness. See TURN SIGNAL LIGHTS further in
An assortment of spare fuses is stored in the fuse this section.
box cover.

286 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

Rear Fuse Holder (PF2) The easiest way to check a relay is to remove it
and temporarily replace it with another relay not
essential for immediate engine operation (e.g. ac-
cessory relay or cooling fan relay). If the applicable
system then functions normally, replace the relay.
If the system does not function with the replace-
ment relay, reinstall the relay and test the applica-
ble system wiring/connectors.

Relay Continuity Test

Remove relay.
Using the Fluke 115 multimeter (P/N 529 035 868)
set to the position, probe relay as per following
vmr2008-139-015_a
table.
REAR FUSE HOLDER (PF2)
1. Main fuse 30 A (F8)
2. Spare fuse 30 A TERMINAL RESISTANCE
3. Fan/accessories fuse 30 A (F9)
30 87 Open circuit (OL)

ACCESSORY RELAY (R4)

Accessory Relay General Information
The accessory relay powers a variety of acces-
sories such as lights, a winch, 2WD/4WD actuator
and controls, as well as DC power outlets.
Whenever power is on the vehicle, the accessory
relay is closed. However, during engine starting,
from 60 to 800 RPM, the ECM opens the ground
circuit to the relay coil. The relay opens and re-
duces the electrical load on the battery and en- smr2007-027-050_a

sures maximum battery voltage is available to the

Connect battery as shown in following illustration
starter and engine circuits for proper starting.
and probe relay again as per following table.
NOTE: Relay may be inverted by 180° at installa-
tion and still function correctly. Ensure relay ter- TERMINAL RESISTANCE
minals are properly aligned with fuse holder at in-
stallation. 30 87 0.5 max. (continuity)

smr2007-027-060_a

vmr2008-139-004_g
If relay failed either test, replace it.
RELAY LOCATIONS
1. Main relay (R3)
2. Fuel pump relay (R2)
3. Accessories relay (R4)
4. Fan relay (R1)

vmr2008-140 287
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

MULTIFUNCTION GAUGE Display 2 (mode)

Gauge Operation

vmo2008-001-020_e

DISPLAY 2
vmo2008-001-020_q 1. Display 2 (mode)
2. Display 3 (mode/message)
1. Display 1 (speedometer) 3. Selector button
2. Display 2 (mode)
3. Display 3 (mode/message)
4. Display selector button By pressing the selector button, the following
5. Tachometer modes can be selected in display 3 and viewed in
6. Transmission position display
7. Fuel level display display 2:
8. Indicator lamps – Odometer (ODO)
Display 1 (Speedometer) – Trip meter (TRIP)
– Hour meter (TRIP TIME)
This display will show vehicle speed.
– Vehicle hour meter (ENGINE HOURS)
– Engine revolutions per minute (RPM).

vmo2008-001-020_g

DISPLAY 1
1. Indicated vehicle speed
2. Unit of display

288 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

Display 3 (mode/message) This display will show either an abbreviation of the

mode selected for viewing in display 2 or will com-
municate important messages to the operator if an
anomaly occurs.
Abbreviation Mode:
– ODO (odometer)
– TRIP (trip meter)
– TRIP TIME (hour meter)
– ENGINE HOURS (vehicle hour meter)
– RPM (engine revolutions per minute).

vmo2008-001-020_h

1. Display 3 (mode/message)
2. Display 2 (mode)

Message Mode:

MESSAGE PILOT LIGHT(S) ON DESCRIPTION

Is displayed when parking brake is applied for more than
PARK BRAKE Parking brake
15 seconds (while riding).
LO BATT Check engine Low battery voltage, check battery voltage and charging system.
HI BATT Check engine High battery voltage, check battery voltage and charging system.
LOW OIL (1) Check engine Engine low oil pressure, stop engine immediately.
HI TEMP (2) Check engine Engine is overheating, stop engine immediately.
Serious fault detected by the engine management that can
change the normal operation of the engine. Check engine
LIMP HOME Check engine
indicator light will also blink, refer to ENGINE MANAGEMENT for
more details.
Engine management fault. Check engine indicator light will also
CHECK ENGINE Check engine
be ON, refer to ENGINE MANAGEMENT for more details.
Periodic maintenance required.
MAINTENANCE
Check engine NOTE: To reset message, use B.U.D.S. software and click Reset
SOON
Service button in Vehicle tab.
NO ECM Communication error between multifunction gauge and engine
Check engine
COMMUNICATION control module (ECM). Refer to ENGINE MANAGEMENT.

CAUTION: (1) If the LOW OIL message and check engine light do not turn off right after engine
starting, stop engine. Check engine oil level. Refill if necessary. If the oil level is good, refer to the
LUBRICATION SYSTEM section.
CAUTION: (2) If the HIGH TEMP message and check engine light do not turn off right after engine
starting, stop engine. Refer to the COOLING SYSTEM section.

vmr2008-140 289
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

Display Selector Button

Button used to navigate between modes or to re-
set data depending on the feature selected.

vmo2008-001-020_p

1. Transmission position

DISPLAY FUNCTION
vmo2008-001-020_i P Park
1. Selector button
R Reverse
Tachometer N Neutral
Measures engine revolutions per minute (RPM).
Multiply by 1000 to obtain the actual revolutions. Fuel Level Display
Bar gauge that continuously indicates the amount
of fuel left in the fuel tank.
An indicator light will come on to indicate a low-
fuel condition when only one bar is displayed.

vmo2008-001-020_J

1. Tachometer
2. Operating range
3. Tachometer via display 2 (mode)

Transmission Position Display vmo2008-001-020_f

This display will show transmission gear position. 1. Fuel level display
2. Low fuel indicator light

290 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

Indicator Lights To change the unit of measurement, carry out the

Indicator lights (LEDs) are incorporated within the following procedure.
LCD display. These LEDs backlight an LCD dis- Connect vehicle to the latest applicable B.U.D.S.
play symbol which represents an operating condi- software, refer to the COMMUNICATION
tion that may require your immediate attention. TOOLS/B.U.D.S. SOFTWARE section.
Select the Read Data button.
Choose the Setting tab at the top of the page.
At the bottom RH side of the setting page, se-
lect the arrow to the right of page 1 and choose
page 2.
In the Cluster Scale field, choose the desired
unit of measurement, Imperial or Metric.

vmo2008-001-020_k vmr2008-140-001_a

1. Parking brake indicator light CHANGING UNITS OF MEASUREMENT

2. 4WD indicator light 1. Choose the Setting tab
3. Low fuel level indicator light 2. Choose page 2
4. Check engine indicator light 3. Choose the desired unit of measurement
5. High beam indicator light

Parking brake is activated.

4WD system is activated.

Low fuel level. Comes on when there

is approximately 25% of fuel left in fuel
tank, approximately 5 L (1.3 U.S. gal).

Check engine.

Headligh switch set to high beams.

Fault Codes Display

The multifunction gauge has the ability to display
recorded fault codes in the MODES/MESSAGES
display without connecting the vehicle to B.U.D.S.
Refer to the MONITORING SYSTEM/FAULT
vmo2008-001-020_b
CODES section for procedures.
1. Unit selection of speedometer
Cluster Unit Selection (MPH vs km/h)
The multifunction gauge is factory preset to indi- Cluster Country Selection
cate in Imperial units but can be set to indicate in
To change the cluster country selection, carry out
metric units.
the following procedure.
vmr2008-140 291
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

Connect vehicle to the latest applicable B.U.D.S. Connect vehicle to the latest applicable B.U.D.S.
software, refer to the COMMUNICATION software, refer to the COMMUNICATION
TOOLS/B.U.D.S. SOFTWARE section. TOOLS/B.U.D.S. SOFTWARE section.
Select the Read Data button. Set engine stop switch to RUN.
Choose the Setting tab at the top of the page. Set ignition switch to ON.
At the bottom RH side of the setting page, se- Select Read Data.
lect the arrow to the right of page 1 and choose Choose the Setting tab at the top of the page.
page 2.
At the bottom RH side of the setting page, se-
In the Cluster Scale field, choose the desired lect the arrow to the right of page 1 and choose
country setting, Outlander 400 or Outlander page 2.
400 CE (CE for European countries).
In the Activate field of page 2, select WOW
Test and observe gauge to ensure all indications
come on.

vmr2008-140-001_b

CHANGING UNITS OF MEASUREMENT

1. Choose the Setting tab
2. Choose page 2 vmr2008-140-002_a
3. Choose the desired country setting
MULTIFUNCTION GAUGE WOW TEST
1. Choose the Setting tab
2. Choose page 2
Multifunction Gauge Pin-Out 3. Select WOW test

FUNCTION PIN NOTE: The WOW test in B.U.D.S. tests the gauge
internal circuits and displays. It does not test the
Power 12 Vdc 17 gauge input circuits except for the CAN bus input.
Ground 20 The MODE button on the face of the gauge is an
input that is not tested during the WOW test.
CAN line 18
If a specific function does not come on during the
CAN line 19 WOW test, replace the multifunction gauge and
Fuel level gauge supply 4 repeat the WOW test.
Fuel level gauge ground 21 If all indications come on during the WOW test but
a specific function does not come on through nor-
2/4WD switch signal 7 mal gauge inputs, the multifunction gauge is func-
HI beam signal 5 tioning normally. Refer to the section applicable
to the specific function for testing procedures.
VSS signal 9
Speedometer Display
Multifunction Gauge Testing If the multifunction gauge tested good during the
NOTE: If the multifunction gauge does not come WOW test but there is no indication of vehicle
on when power is turned on, but the taillight speed or indicated speed is always zero, refer to
comes on, refer to MULTIFUNCTION GAUGE VEHICLE SPEED SENSOR (VSS) in this section.
VOLTAGE TEST.
Multifunction Gauge Testing with B.U.D.S.
Test multifunction gauge as per following proce-
dure:
292 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

If the speedometer always reads 144 km/h, or Disconnect the LH multifunction switch connec-
89 MPH, connect the vehicle to B.U.D.S. and fol- tor (MG2).
low the CLUSTER COUNTRY SELECTION proce-
dure in this section. You should find that neither
Cluster Country selection has been selected. Se-
lecting the appropriate country setting should fix
the problem.
NOTE: This problem will occur if the multifunction
gauge has been programmed to an ATV model
other than a 400 EFI. This is because the gauge
is looking for a speed signal from the CAN bus
instead of directly from a speed sensor. The
speedometer may also always read zero instead
of 144 km/h or 89 MPH for this same fault.
If applying a Cluster Country setting does not re- vmr2008-139-002_b
solve the zero speed indication, refer to VEHICLE
TYPICAL – MULTIFUNCTION SWITCH CONNECTORS
SPEED SENSOR (VSS) in this section. 1. Connector MG1
2. Connector MG2
Transmission Position Display
The transmission position display in the multifunc- Using a Fluke 115 multimeter (P/N 529 035 868)
tion gauge is capable of displaying the “N” for neu- set to , measure for continuity as per following
tral, “P” for park, or “R” for reverse transmission table.
positions. It can not display “H” for high or “L”
for low gear. MULTIFUNCTION
GAUGE SWITCH
If the transmission position display does not RESISTANCE
CONNECTOR CONNECTOR
match with the selected transmission lever posi- (MG2)
tion, check the gearbox switches. Refer to the
CRANKSHAFT/CRANKCASE section. Pin 5 Pin 5 Close to 0

If the letter “E” is displayed in the transmission

position display, the multifunction gauge has de-
tected an abnormal activation of multiple gearbox
switches. Refer to CRANKSHAFT/CRANKCASE
section for procedures.
2/4WD Indicator Light
This indicator light comes on when the vehicle is
in 4WD.
If the 2WD/4WD indicator light comes on during
the gauge WOW test with B.U.D.S., but will not
come on when the 2WD/4WD selector switch is
set to 4WD, refer to the 4X4 COUPLING UNIT
section.
HI Beam Indicator Light
vmr2006-020-055_a

If the HI beam indicator light comes on during TYPICAL

the gauge WOW test with B.U.D.S., but does
not come on when the high beams are on, check If you do not obtain close to 0 , repair or replace
wiring/connectors between multifunction gauge the faulty wiring/connector.
and the headlight switch as per following proce-
Reconnect connectors and install all removed
dure.
parts.
Remove the front steering cover, refer to BODY
section.
Disconnect the multifunction gauge connector.

vmr2008-140 293
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

Fuel Level Indication and Low Fuel

Level Indicator Light
The multifunction gauge receives a signal from the
fuel level sensor which it uses to produce an in-
dication of fuel level in the gauge, as well as for
activating the low fuel level indicator light.
If both come on during the gauge WOW test with
B.U.D.S., but do not function with the input from
the sensor, refer to the FUEL TANK/FUEL PUMP
section for fuel level sensor testing procedures.
If only one indication comes during the WOW test,
replace the gauge and repeat the test.

Multifunction Gauge Input Voltage Test

Disconnect multifunction gauge connector.
Turn ignition key ON.
Set engine run/stop switch to RUN. vmr2006-020-052_b

Read voltage from vehicle harness as per follow- If battery voltage is not read in both voltage tests,
ing table. repair or replace the 12 Vdc input circuit wiring
and/or connectors from the relays speedo fuse to
MULTIFUNCTION GAUGE INPUT VOLTAGE TEST the multifunction gauge (pin 17).
GAUGE CONNECTOR If battery voltage is measured to chassis ground
VOLTAGE
(HARNESS SIDE) but not to pin 20, carry out a continuity test of
Pin 17 Pin 20 the multifunction gauge ground circuit wiring/con-
Battery voltage nector (pin 20 to ground). Repair or replace
Pin 17 Chassis ground wiring/connectors as required.
If 12 Vdc input (pin 17) and ground circuit (pin 20)
tested good, replace multifunction gauge.

Multifunction Gauge Removal

Locate the locking tab on the gauge trim ring at
the 5 o'clock position.
Carefully insert a thin wooden tongue depressor
(or popsicle stick) between the rear steering cover
and the trim ring at the six oclock position.

vmr2006-020-052_a

vmr2008-140-007_a

1. Insert wooden tongue depressor here

2. Locking tab position

294 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

As you gently lift up on the tongue suppressor to

release ring locking tab, rotate gauge clockwise to
unlock and remove it from steering cover.

vmr2006-020-058_a

IMPORTANT: If a multifunction gauge from anoth-

er vehicle model is installed and is not registered
in the ECM through B.U.D.S., engine starting will
not be allowed until gauge is registered with
proper coding.

VEHICLE SPEED SENSOR (VSS)

VSS Input Voltage Test
vmr2008-140-008_a
Remove air filter housing. Refer to AIR INTAKE
Step 1: Lift up on tongue depressor SYSTEM.
Step 2: Look for release of locking tab
Step 3: Rotate trim ring clockwise Locate VSS connector in gearbox area.
Disconnect the multifunction gauge connector.

vmr2008-129-051_b

Turn ignition key ON.

vmr2008-140-009_a
Set engine stop switch to RUN.
Step 1: Press to release connector
Step 2: Pull connector off gauge Use Fluke rigid back probes (P/N TP88) or the
equivalent.
Multifunction Gauge Installation Insert the back probes onto the end of the stan-
dard probes of the Fluke 115 multimeter (P/N 529
For the installation, reverse the removal proce- 035 868).
dure.
Set multimeter to Vdc.
New Multifunction Gauge Registration Back-probe connector and read voltage as follows.
(Coding)
Whenever the multifunction gauge is replaced, SPEED SENSOR CONNECTOR
VOLTAGE
(HARNESS SIDE)
B.U.D.S. must be used to match the gauge (clus-
ter) coding with the ECM. Simply click Yes when VIOLET/BLUE BLACK/ORANGE Battery voltage
the following message appears.

vmr2008-140 295
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

vmr2008-129-051_c

If you read battery voltage, test the signal circuit.

If you do not read battery voltage, test for voltage
as follows.
mmr2009-023-027_a

SPEED SENSOR CONNECTOR Back-probe connector and read voltage as you

VOLTAGE
(HARNESS SIDE) slowly rotate the rear wheels with your hands.
VIOLET/BLUE Battery ground Battery voltage
SPEED SENSOR
CONNECTOR VOLTAGE
(HARNESS SIDE)
Alternate readings of:
approx. 11 Vdc,
VIOLET/BLUE PINK
then approx. 1 Vdc
and back to 11 Vdc

vmr2008-129-051_d

If you do not read battery voltage to ground,

check/repair input wiring/connectors.
If voltage is good, check ground circuit.

VSS Signal Circuit Test

Safely lift rear of vehicle so that rear wheels are vmr2008-129-051_c

off the ground. If voltage is as specified, sensor is good.

Set vehicle to 2WD mode and transmission to If voltage is not as specified, try a new sensor.
Neutral.
NOTE: Poor/faulty magnet in crankcase or dirty oil
Set multimeter to Vdc. can affect sensor operation.
Repeatedly press the multimeter RANGE button
until the display shows Manual Range 6 0. VSS Removal
NOTE: Engine removal is not necessary for access
to VSS sensor.
Clean sensor area.
Remove sensor retaining screw.
296 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

Pull out sensor. Headlight Switch Test

Remove front steering cover.
VSS Installation
Disconnect multifunction switch connector
Apply some Super Lube (P/N 293 550 030) grease (MG2).
on sensor O-ring.
Install sensor.
Torque retaining screw to 10 N•m (89 lbf•in).
Reinstall remaining removed parts.

HEADLIGHT SWITCH

1 vmr2008-139-002_a

TYPICAL – MULTIFUNCTION SWITCH CONNECTOR (MG2)

3 Using a Fluke 115 multimeter (P/N 529 035 868),

measure the headlight switch resistance as per
following table.
2
HEADLIGHT SWITCH CONTINUITY TEST
4 MULTIFUNCTION SWITCH RESISTANCE @
POSITION
CONNECTOR (MG2) 20°C (68°F)
vmo2007-015-009_a Pin 2 Pin 4
Switch to
(GREEN (RED/YELLOW
TYPICAL – (EXCEPT 2009 CE MODELS) LO
1. Headlights switch wire) wire)
2. Engine stop switch 0.2 max.
3. Start switch Pin 4
4. Override switch Switch to Pin 5
(RED/YELLOW
HI (BLUE wire)
wire)

vmo2008-018-023_a

TYPICAL – 2009 CE MODELS

1. Headlights switch
2. High beams
3. Low beams vmr2006-020-066_a
4. Lights selection index mark
TYPICAL – MG2 PIN-OUT

vmr2008-140 297
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

Replace multifunction switch if the headlight

switch is defective. Refer to STEERING SYSTEM
section.

OVERRIDE SWITCH
All Models except 2009 CE
See HEADLIGHT SWITCH above to locate the re-
verse override button (switch) on the multifunc-
tion switch.
2009 CE Models
On the 2009 models, the reverse override but- vmr2008-139-002_b

ton is located in the front of the LH multifunction TYPICAL – MULTIFUNCTION SWITCH CONNECTORS
switch. 1. Disconnect MG1
2. Disconnect MG2

Using a Fluke 115 multimeter (P/N 529 035

868) set to , measure the switch resistance
between the following wires.

OVERRIDE SWITCH CONTINUITY TEST

MULTIFUNCTION
SWITCH RESISTANCE @
SWITCH
POSITION 20°C (68°F)
CONNECTOR (MG1)

Released Pin 5 Pin 6 0.2 max.

(ORANGE (WHITE
Pushed wire) wire) Open (OL)

vmr2008-140-500_a

TYPICAL – 2009 MODELS

1. Reverse override button

Override Switch Test

The override switch provides a ground signal to
the ECM which cuts out the reverse speed limiting
function when driving in reverse gear.
To test the override switch, disconnect multi-
function switch connector MG1.

vmr2006-020-066_b

TYPICAL

Replace multifunction switch if override switch is

defective. Refer to STEERING SYSTEM section.

12-VOLT AUXILIARY POWER

CONNECTOR
The 12-volt auxiliary power outlet allows the instal-
lation of additional accessories.
298 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

12-Volt Auxiliary Power Connector Test If battery voltage is not read for both tests, check
NOTE: When the auxiliary power connector is to to see if headlights function.
be used on an accessory, be sure to apply a small If headlights do not function, test the following:
amount of dielectric grease (P/N 293 550 004) to – Accessories fuse (F6)
the connector contacts. – Accessories relay (R4)
Remove front steering cover, refer to the BODY – Wiring/connectors.
section.
If headlights function, test wiring/connections to
Turn ignition key to ON. accessories fuse (F6).
Set engine stop switch to RUN. If battery voltage is read to chassis ground but
Disconnect auxiliary power outlet connector (as not to the BLACK wire, test the wire to ground
applicable). continuity. Repair or replace wiring as required.

12-VOLT POWER OUTLET

12-Volt Power Outlet Test
Remove dashboard, refer to the BODY section.
Turn ignition key to ON.
Set engine run/stop switch to RUN.
Disconnect the power outlet connectors.
Using a Fluke 115 multimeter (P/N 529 035 868)
set to Vdc, measure the voltage as follows.

12-VOLT POWER OUTLET VOLTAGE TEST

vmr2006-020-063_a

TYPICAL – AUXILIARY POWER CONNECTOR WIRE COLOR VOLTAGE

RED/BLACK BLACK Battery voltage
Using a Fluke 115 multimeter (P/N 529 035 868)
set to Vdc, measure the voltage as per following
table.

AUXILIARY POWER CONNECTOR

VOLTAGE TEST
WIRE COLOR VOLTAGE
RED/BLACK BLACK
Battery voltage
RED/BLACK Chassis ground

vmr2006-020-064_a vmr2006-020-061_a

TYPICAL – AUXILIARY POWER CONNECTOR VOLTAGE TEST Ensure to reconnect RED/BLACK wire to positive
terminal.

vmr2008-140 299
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

vmr2006-020-062_aen

If battery voltage is not read for both test, check

to see if headlights function.
If headlights do not function, test the following: vmo2008-001-020_m

– Accessories fuse (F6) INDICATOR LIGHTS

– Accessories relay (R4) 1. Parking brake indicator light
2. 4WD indicator light
– Wiring/connectors. 3. Low fuel level indicator light
4. Check engine indicator light
If headlights function, test wiring/connections to 5. High beam indicator light
6. Turn signal/hazard signal indicator light
accessories fuse (F6).
If battery voltage is read to chassis ground but not
to BLACK wire, test the BLACK wire to ground Headlight Test
continuity. Repair or replace wiring as required. Disconnect headlight connector, refer to BULB
REPLACEMENT in this section.
12-Volt Power Outlet Removal
Set engine stop switch to RUN.
Remove dashboard, refer to the BODY section.
Set ignition switch to ON.
Disconnect the power outlet connectors.
Using a Fluke 115 multimeter (P/N 529 035 868)
Unscrew the retaining nut. set to Vdc, measure the voltage at headlight con-
nector as follows.
12-Volt Power Outlet Installation
Reverse the removal procedure.
Ensure to reconnect RED/BLACK wire to positive
terminal.

HEADLIGHTS
The headlights come on when the ignition switch
is set to ON with the engine stop switch to RUN.
If the high beams are selected, a high beam indi-
cator light will come on in the multifunction gauge.

vmr2006-020-065_a

TYPICAL

300 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

HEADLIGHT INPUT VOLTAGE TEST

SWITCH
WIRE COLOR VOLTAGE
POSITION
BLACK
LO beam GREEN Chassis Battery voltage
ground
BLACK
HI beam BLUE Chassis Battery voltage
ground

If battery voltage is read as specified in table, re- vmo2006-005-040_a

place headlight bulb.
1. Rubber protector
If battery voltage is not read as specified, or not at 2. Headlight housing
all, refer to HEADLIGHT SWITCH in this section.
Disconnect the headlight connector.
If battery voltage is read to chassis ground but
not to BLACK wire, test BLACK wire continuity. NOTE: Press inwards on small locking tabs to un-
Repair or replace wiring/connectors as required. lock connector then pull on connector.

Headlight Bulb Replacement

CAUTION: Never touch glass portion of a halo-
gen bulb with bare fingers, it shortens its oper-
ating life. If glass is touched, clean it with iso-
propyl alcohol which will not leave a film on the
bulb.
Remove cover screws.

vmo2006-005-041_a

PRESS ON LOCKING TABS TO UNLOCK CONNECTOR

Press spindle inwards towards bulb contacts, then

outwards and to the side to unlock headlight bulb.

vmo2006-005-043_a

1. Screws
2. Cover

Remove rubber protector covering headlight hous-

ing.

V06G0RA

TYPICAL

vmr2008-140 301
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

Lift and hold the spindle then remove the bulb.

90°
A
B

vmr2006-020-002_a

1. Light beam center

A. 5 m (17 ft)
B. 131 mm (5 in)

Headlight Beam Adjustment

Turn adjustment screws to adjust beam height and
side orientation as described below. Adjust both
headlights evenly.

V06G0SA

TYPICAL

Install removed parts in the reverse order of their

removal.
Validate headlight operation.

Headlight Beam Aiming

Select high intensity.
Beam aiming is correct when center of high beam
is 131 mm (5 in) below the headlight horizontal
center line, scribed on a test surface, 5 m (17 ft) vmo2006-005-040_b
away.
TYPICAL
NOTE: Have the driver sit on or place an equiva- 1. Headlight cover
2. Adjustment screws
lent weight on the vehicle.
Measure headlight center distance from ground.
Scribe a line at this height on test surface (wall FRONT POSITION LIGHTS
or screen). Light beam center should be 131 mm
(5 in) below scribed line. CE Models Only
Two front position lights, one in each headlight,
come on as soon as the vehicle is powered. They
receive battery power through the relays/speedo
90° fuse when the main relay closes its contacts.

Front Position Light Bulb Replacement

1 2 To replace a front position light, proceed as fol-
lows.
Locate the position light bulb holder under the
90° headlight housing.
Rotate bulb holder counterclockwise to release it
vmr2006-020-001_a from the headlight housing.
1. Headlight center lines
2. Light beam center

302 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

The brake light comes on when either the brake

lever or brake pedal is depressed.
NOTE: When testing the brake light, always test it
using both controls to make ensure both switches
can turn on the brake light.

Taillight/Brake Light Circuit Test

No Taillight or Brake Light
If neither taillight or brake light come on, discon-
nect the taillight/brake light connector located be-
hind the taillight assembly

vmo2006-006-008_a

1. Position light socket

2. Headlight housing

Carefully pull bulb straight out of bulb holder con-

tacts to remove it.
Install the new bulb by pushing it into the bulb
holder contacts.
Insert the bulb holder into the headlight housing
and turn it clockwise to lock it into the headlight
housing.

Position Light Testing vmr2008-140-005_a

The position lights receive power from the ac- 1. Taillight/brake light connector
cessories fuse when the vehicle electric power is 2. Taillight assembly
turned ON.
Set engine stop switch to RUN.
To test the lights, first test or replace light bulb.
Set ignition switch to ON.
If bulb is not the cause, carry out the following
procedure: Using a Fluke 115 multimeter (P/N 529 035
868) set to Vdc, test for input voltage at the
Remove position light connector. taillight/brake light connector between pin 3 (OR-
Set engine stop switch to RUN. ANGE/GREEN wire) and chassis ground.
Set ignition switch to ON.
TAILLIGHT/BRAKE LIGHT INPUT VOLTAGE TEST
Test for battery power at RED/YELLOW wire.
VOLTAGE
PROBE
POSITION LIGHT INPUT VOLTAGE TEST READING

BLACK wire Taillight connector pin 3 Chassis Battery

RED/YELLOW (ORANGE/GREEN wire) ground voltage
Battery voltage
wire Chassis ground

If there is no input voltage to light, repair or replace

wire from accessories relay fuse to light.
If there is voltage to chassis ground but not to
BLACK wire, repair or replace the BLACK wire.

TAILLIGHT/BRAKE LIGHT
Taillight/Brake Light Operation
The taillight automatically comes on when the ig-
nition switch is turned ON with the engine stop
switch set to RUN.
vmr2008-140 303
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

vmr2008-140-006_a vmr2008-140-006_b

TAILLIGHT/BRAKE LIGHT INPUT VOLTAGE TEST CONTINUITY TEST OF TAILLIGHT/BRAKE LIGHT WIRING

If battery voltage is not read, repair or replace If you do not obtain close to 0 through the tail-
wiring/connectors from light assembly to re- light circuit, repair or replace wiring.
lays/speedo fuse. If you do not obtain close to 0 through one of the
If voltage is read, test the light assembly continu- brake light circuits, refer to the BRAKES section
ity. for brake lever and brake pedal switch testing and
Replace bulb or light assembly as required. replacement.

Only one Filament Functions Taillight/Brake Light Bulb Replacement

If only one filament functions and replacing the Pull lens out at both outside corners to release it
bulb does not solve the problem, test the light from the grommets that secure it in the rear fascia
ground circuits as follows. panel.
Turn ignition switch to the OFF position. NOTE: If lens is difficult to pull out of grommets,
Using a Fluke 115 multimeter (P/N 529 035 868) reach in behind light assembly and push on the
set to , measure continuity to ground at light lens retaining pins protruding through the grom-
connector as per following table. mets. Do not pry lens out of fascia panel using a
tool such as a screwdriver or component damage
CONTINUITY TEST may occur.
TAILLIGHT/BRAKE LIGHT GROUND CIRCUIT
TAILLIGHT/
CONTROL TO RESISTANCE @
BRAKE LIGHT
ACTUATE 20°C (68°F)
CONNECTOR
Pin 2
None (taillight)
(BLACK wire)
Brake lever Pin 1 Close to 0
(BLACK/GREY
Brake pedal wire)

vmr2008-140-003_a

TYPICAL – TAILLIGHT LENS REMOVAL

1. Lens
2. Fascia panel

Rotate bulb holder counterclockwise to release it

from the light assembly.

304 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

vmr2008-140-004_a

1. Lens retaining pin (x2)

2. Retaining grommet (x2)
vmo2007-005-001_b

TYPICAL – 2008 CE MODEL

1. Turn signal lights switch

vmo2008-001-006

Push bulb in and hold while turning counterclock-

wise to release from bulb holder.
Install the new bulb by first pushing in then turning vmo2008-018-021_b
clockwise.
TYPICAL – 2009 CE MODELS
Install remaining parts in the reverse order of re- 1. Turn signal lights switch
moval.
To activate the turn signal lights, move the switch
Turn on vehicle electrical power and test tail- button to the right or left side, depending on the
light/brake light operation. direction of the intended turn. Reposition the
switch to the center position when the maneuver
TURN SIGNAL LIGHTS is completed.
CE Models Only
Turn Signal Lights Operation
A turn signal switch is located on the left side of
handlebar.

vmr2008-140 305
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

2009 CE Models
The flasher diodes (D2 and D3) are integrated in
the vehicle harness near the electronic flasher unit
located in the steering cover.
Diode D2 is approximately 48 cm (19 in) from the
flasher module connector (3-MC1).

vmo2008-001-020_m

1. Parking brake indicator light

2. 4WD indicator light
3. Low fuel level indicator light
4. Check engine indicator light vmr2008-140-502_a
5. High beam indicator light
6. Turn signal/hazard signal indicator light APPROXIMATE D2 DIODE LOCATION
A. 48 cm (19 in) from the front harness connector

Flasher diodes allow a voltage signal from either

LH or RH turn signals, or the hazard warning lights,
to turn ON the turn signal/hazard warning indicator
light in the multifunction gauge, and at the same
time isolating the circuits from each other.
If all the turn signals come on when only one side
is selected, a flasher diode may be shorted.
If the turn signal/hazard warning indicator light in
the multifunction gauge does not come on when
a turn signal is selected, that diode may be open
circuit.
2008 CE Models
The flasher diodes (D2 and D3) are located in the
front fuse box. vmr2008-140-503_a

APPROXIMATE D3 DIODE LOCATION

A. 50 cm (20 in) from the flasher module connector

Diode D3 is approximately 50 cm (20 in) from the

front harness connector (3-CAKX).

Turn Signal Lights Testing

2008 CE Models
Remove the front steering cover.
Disconnect the turn signal switch connector.

vmr2008-140-011_b

FUSE BOX (2008 CE MODELS)

1. Diode D2
2. Diode D3

306 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

vmr2008-140-010_a

REAR VIEW – BOTH STEERING COVERS REMOVED vmr2008-140-501_a

1. Turn signal switch connector
2. Flasher module 1. Connector 3-MG1
3. Multifunction gauge connector 2. Connector 3-MG2
3. Connector 3-MG3 (green)
4. Flasher unit
Measure the switch resistance as follows. 5. Flasher unit connector 3-MC1

TURN SIGNAL SWITCH CONTINUITY TEST Set the Fluke 115 multimeter (P/N 529 035 868)
to setting.
SWITCH RESISTANCE @
CONNECTOR PINS Test for continuity of the flasher unit ground at
POSITION 20°C (68°F)
connector 3-MC1 pin 9 (BLACK wire) to chassis
Pin 3 ground.
Pin 4
(GREY/
Left (BLACK/ Set engine RUN/STOP switch to RUN and turn
BLACK
RED wire) ignition key to ON.
wire)
Close to 0
Pin 4 Set multimeter to Vdc.
Pin 4
(WHITE/ Test for 12 Vdc at connector 3-MC1 pin 8
Right (BLACK/
BLACK (RED/BLACK wire), accessories power to flasher
RED wire)
wire)
unit.
If switch does not test as specified, replace Test for 12 Vdc at connector 3-MG3 pin 3
switch. (RED/BLACK wire), accessories power to sig-
nal lights control switch.
2009 CE Models If you have a good ground at 3-MC1 pin 9, 12 Vdc
NOTE: Refer to the WIRING DIAGRAM for circuit at 3-MC1 pin , and 3-MG3 pin 3, carry out a conti-
details when carrying out the following checks. nuity test of the signal lights control switch.
Remove the front steering cover. Also test continuity of wire harness between
Disconnect the GREEN multifunction switch con- flasher unit and the signal lights control switch
nector (3-MG3). connector. Refer to WIRING DIAGRAM for circuit
details.
Disconnect the flasher unit connector (3-MC1).
If wiring circuits test good, replace the flasher unit.

Flasher Diodes Test

2008 CE Models
Remove the front storage cover and the fuse box
cover.
Remove each diode separately from the fuse
box.
NOTE: Pay attention to diode orientation (polarity)
for installation.
Use the Fluke 115 multimeter (P/N 529 035 868)
and set it to the diode symbol as shown.

vmr2008-140 307
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

2009 CE Models
The flasher diodes are integrated in the wiring har-
ness. To test them, you must first isolate them
from the rest of the circuits by disconnecting the
following connectors.
– Multifunction gauge connector
– Flasher unit connector
– All four signal lights connectors.
Set multimeter to the diode test function and test
the diodes between the multifunction gauge con-
nector (1-C1 pin 8) and the flasher unit connector,
3-MC1 pin 10 for diode D3, and 3-MC1 pin 11 for
diode D2. Refer to the wiring diagram for details.
NOTE: Pay attention to diode polarity when carry-
ing out the test. See previous 2008 model proce-
vmr2006-020-005
dure for details.
Probe diodes in each direction while paying at-
tention to the diode polarity. HAZARD WARNING LIGHTS
CE Models Only

Hazard Warning Lights Operation

2008 CE Models
The hazard warning lights button is located on the
left side of the console.

vmr2006-020-006_a

MUST BE OPEN CIRCUIT

vmo2008-017-004_a

TYPICAL – 2008 MODEL ILLUSTRATED

1. Hazard warning button

When the button is pushed in, it activates the four

turn signal lights (hazard warning function) which
takes precedence over the turn signal function.
When the hazard warning lights button is pressed
in, it completes a circuit through the flasher mod-
ule to the turn signal lights causing simultaneous
vmr2006-020-006_b
flashing of all four turn signal lights as well as
MUST BE APPROXIMATELY 0.5 V the turn signal indicator light in the multifunction
gauge.

308 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

The switch has a mechanical detent which, locks The hazard warning lights button on 2009 models
the switch in the activation position. Press the is not internally lit. However, a red indicator light
hazard warning lights button once to activate, on top of the LH multifunction switch will flash
press once again to deactivate. when the hazard warning lights are selected ON.
The hazard warning lights can be activated even This light receives the same 12 Vdc as the sig-
when the vehicle electrical system is shut down. nal/hazard warning lights. The ground for the
They receive battery power through the fan/acces- hazard indicator light is supplied by the electronic
sories fuse and the control Euro fuse directly to flasher unit only when the “Hazard lights” func-
the hazard lights control switch. tion is activated.
When electrical power is applied to the vehicle,
power is applied to the hazard warning lights but- Hazard Warning Switch Testing
ton for internal lighting (dim lighting) to make lo- 2008 CE Models
cating the button easier in the dark. If the lights will not flash in turn signal or hazard
2009 CE Models warning functions, try a known good flasher mod-
ule. If it still does not function, carry out the fol-
The hazard warning lights control button is located lowing tests.
in the front of the LH multifunction switch.
Remove the console panel, refer to the BODY
section.
Disconnect the hazard warning switch connec-
tor.

vmr2008-140-500_b

1. Hazard warning lights button

It is a momentary contact type and must be held

in for approximately half a second to ensure ac- vmr2008-140-012

tivation or deactivation of the circuits in the elec- HAZARD WARNING SWITCH CONTACTS
tronic flasher unit.
The hazard warning lights cannot be activated on Test hazard warning switch as per following ta-
battery power only. Vehicle electrical power must bles.
be turned ON. This will energize the accessories
relay which will power the FLASHER, HAZARD
and HORN control switches through the acces-
sories fuse.
Once the HAZARD lights are activated, the vehicle
power may be turned OFF. The hazard lights will
remain active until electrical power is turned ON
again, and the hazard warning lights are selected
OFF.
NOTE: The flasher unit requires electrical power
from both the accessories and the control Euro
fuses for hazard warning lights operation, but only
from the accessories fuse for flasher operation.

vmr2008-140 309
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

HAZARD WARNING SWITCH TESTING HAZARD WARNING SWITCH INPUT VOLTAGE

WITCH WITCH RESISTANCE @ SWITCH VOLTAGE
CONTACTS CONTACTS
POSITION FUNCTION 20°C (68°F) FUNCTION READING
Light (dim) Pin 31 Pin 58 Turn signal Chassis
Close to 0 Pin 49
Out power ground
Turn signal (Continuity)
Pin 15 Pin 49
power Pin 58 Pin 31 Battery
(ORANGE/ (BLACK) voltage
Light (dim) Pin 31 Pin 58 Light (dim)
GREEN Chassis
Hazard Close to 0
Pin wire) ground
signal Pin 30 (Continuity)
30b
power
If you do not measure battery voltage in either
Turn signal of the above tests, repair or replace applicable
In Pin 15 Pin 49 OL (open)
power wiring/connectors.
LH lights
power
Pin 49a Pin L 2009 CE Models
Close to 0
(Continuity) NOTE: Refer to the WIRING DIAGRAM for circuit
RH lights
Pin 49a Pin R details when carrying out the following checks.
power
Remove the front steering cover.
If switch does not test as specified, replace Disconnect the GREEN multifunction switch con-
switch. nector (3-MG3).
If switch tested good, carry out the following haz- Disconnect the flasher unit connector (3-MC1).
ard warning switch input voltage test at the switch
connector (harness side).
Do not turn on the ignition switch at this time.
Test for hazard warning signal power as per fol-
lowing table.

HAZARD WARNING SWITCH INPUT VOLTAGE

SWITCH VOLTAGE
CONTACTS
FUNCTION READING
Hazard Pin 30
Chassis Battery
signal (RED/WHITE
ground voltage
power wire)
vmr2008-140-501_a
If you do not have battery power, test the control
1. Connector 3-MG1
Euro fuse, wiring and connectors. 2. Connector 3-MG2
3. Connector 3-MG3 (green)
NOTE: If the control Euro fuse is burnt, the horn 4. Flasher unit
will not function either. 5. Flasher unit connector 3-MC1

If hazard switch input voltage and hazard switch Set the Fluke 115 multimeter (P/N 529 035 868)
tested good, and a replacement flasher module to setting.
did not function, test continuity of wiring/connec-
tors. Test for continuity of the flasher unit ground at
connector 3-MC1 pin 9 (BLACK wire) to chassis
Also test the following. ground.
Set engine stop switch to RUN. Set engine RUN/STOP switch to RUN and turn
Set ignition switch to ON. ignition key to ON.
Carry out the following test as per table. Set multimeter to Vdc.
Test for 12 Vdc at connector 3-MC1 pin 8
(RED/BLACK wire), accessories power to flasher
unit.

310 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

Test for 12 Vdc at connector 3-MC1 pin 6

(RED/BLACK wire), battery power to flasher
unit.
Test for 12 Vdc at connector 3-MG3 pin 3
(RED/BLACK wire), accessories power to haz-
ard lights control switch.
If you have a good ground at 3-MC1 pin 9, 12 Vdc
at 3-MC1 pins 8 and 6, and 12 Vdc at 3-MG3 pin
3, carry out a continuity test of the hazard warning
lights control switch.
Also test continuity of wire harness between the
flasher unit and warning lights switch connector.
Refer to WIRING DIAGRAM for circuit details.
If wiring circuits test good, replace the flasher unit.
vmo2008-018-021_c

HORN TYPICAL – 2009 MODEL ILLUSTRATED

1. Horn button
2008 CE Models Only
The horn activation button is located on the left The horn cannot be activated without power be-
side of handlebar. ing applied to the vehicle on 2009 models.
It receives 12 Vdc power from the accessories
fuse (F7), through the horn button.

Horn Testing
2008 CE Models
If the horn does not function, disconnect horn
connectors and test for input voltage at the
RED/WHITE wire terminal. You should mea-
sure battery voltage.

vmo2007-005-001_c

TYPICAL – 2008 CE MODELS

1. Horn button

The horn can be activated without power being

applied to the vehicle on 2008 models.
It receives battery power through the fan/acces- vmr2008-140-013_a

sories fuse (F9) and the control Euro fuse (F10) 1. Horn location
directly to the horn. The horn button supplies the 2. Horn connectors
ground to the horn when pressed in.
If horn input voltage is good, reconnect the
NOTE: If the control Euro fuse is burnt, the hazard
RED/WHITE wire to the horn and momentarily
warning lights will not function either.
ground the other horn terminal to the chassis
2009 CE Models with a jumper.
The horn activation button is located on the LH If the horn does not function with the jumper, re-
multifunction switch assembly. place it.
If the horn functioned with a jumper to ground,
set multimeter to and connect between chas-
sis ground and the BEIGE/BLACK horn wire ter-
minal.
vmr2008-140 311
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

Press the horn button, you should obtain close WINCH

to 0 (continuity).
XT Models Only
If you do not obtain continuity through the switch
from the horn terminal, carry out the following. Test winch using the control switch on the LH han-
dle bar and the remote control in the front service
Remove the front steering cover, refer to BODY compartment.
section.
Carry out a continuity test of the horn switch and
wiring, refer to the wiring diagram for details.
Repair or replace switch, wiring or connectors as
applicable.
2009 CE Models
If the horn does not function, disconnect horn con-
nectors.
Test for continuity to ground at the black wire ter-
minal (3-KX1).
Turn on the vehicle power.
While depressing the horn button, test for 12 Vdc vmo2008-019-046_a

between the horn BEIGE/BLACK wire and chassis TYPICAL

ground. 1. Reel winch cable IN
2. Let winch cable OUT
If you measure a good ground and a good 12 Vdc,
replace the horn.
If you do not measure 12 Vdc, Turn OFF vehicle
power.
Remove the front steering cover.
Disconnect the green multifunction switch con-
nector 3-MG3.

vmo2008-001-001_a

FRONT SERVICE COMPARTMENT PANEL

1. Winch remote control

vmr2008-140-501_b

1. Multifunction switch connector 3-MG3 (GREEN)

As you press the horn button, test for continuity

through the horn switch, pins 3 and 4.
Also test for continuity of the harness wiring be-
tween the horn connector and the multifunction
switch connector. Refer to the WIRING DIA-
GRAM for details.
Repair or replace wiring/connectors, or horn as re-
quired.

312 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

Winch Control Switch Input Voltage Test

Remove the front steering cover. Refer to BODY.
Disconnect the winch control switch connector.

vmo2008-019-045_a

FRONT SERVICE COMPARTMENT

1. Winch remote control connector

Winch Test vmr2008-140-014_a

TYPICAL
Winch Motor 1. Winch control switch connector

Using booster cables, connect one end of the Set engine stop switch to RUN.
red cable to the (-) battery post and touch the
other end to the out post on the winch motor. Set ignition switch to ON.
The winch should run to let out the cable. Using a Fluke 115 multimeter (P/N 529 035 868)
Repeat the test touching the cable to the IN post set to Vdc, measure the resistance as follows.
on the winch motor. The winch should run to
reel in its cable. WINCH CONTROL SWITCH INPUT
VOLTAGE TEST
WINCH SWITCH CONNECTOR
VOLTAGE
(HARNESS SIDE)
Pin A Battery ground Battery voltage

If there is no voltage, check fuses F9, F6, relay R4

(accessories relay) and wiring condition.
If there is voltage, test switch as follows.
Winch Relay Control Signal Voltage
Turn OFF vehicle electrical power and wait for it to
vmr2006-020-072_a
shut off.
Disconnect terminals at winch relay.
Measure control signal voltage from switch as fol-
lows.

WINCH RELAY CONTROL SIGNAL VOLTAGE

WIRE
SWITCH
TERMINALS AT VOLTAGE
POSITION
RELAY
Switch pressed GREEN/ Chassis Battery
to IN and held BLUE ground voltage
vmr2006-020-072_b

If motor does not turn in either test, replace motor.

If it works, continue testing.

vmr2008-140 313
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

vmr2006-020-071_b

vmr2006-020-074_b

SWITCH WIRE TERMINAL

VOLTAGE VOLTAGE
POSITION AT RELAY POSITION RELAY TERMINAL
DROP
Switch pressed BLUE/ Chassis Battery
to OUT and held GREEN ground voltage Battery OUT cable
Switch pressed 0.2 Vdc
post (RED to winch
to OUT and held max.
cable) motor

vmr2006-020-071_c

If voltage is not read in either test, carry out a

continuity test of the winch control switch further vmr2006-020-074_a

in this section.
If voltage drop is higher than specification in ei-
If voltage is read in both tests, test winch relay as ther test, check wiring/connectors. If wiring/con-
follows. nectors are good, replace winch relay.
Winch Relay Voltage Drop If voltage read is battery voltage, the relay does
Reconnect terminals at winch relay. not close. Replace winch relay.
Measure voltage drop across relay contacts as fol- D5 and D6 Diode Test
lows.
NOTE: Refer to WIRING DIAGRAM.
WINCH RELAY VOLTAGE DROP Remove the front steering cover. Refer to the
BODY section.
SWITCH VOLTAGE
RELAY TERMINALS Disconnect winch switch connector, see previous
POSITION DROP
illustration.
Battery IN cable
Switch pressed 0.2 Vdc Disconnect the GREEN/BLUE wire going to winch
post (RED to winch
to IN and held max. relay (GREEN on relay).
cable) motor
Disconnect the BLUE/GREEN wire going to winch
relay (BLACK on relay).

314 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

vmr2007-043-011_b
vmr2007-043-010_a

REVERSE POLARITY (MUST BE OPEN CIRCUIT)

Use the Fluke 115 multimeter (P/N 529 035 868)
and set it to the diode symbol as shown.

vmr2007-043-011_a

vmr2006-020-005
FORWARD POLARITY (MUST BE AROUND 0.5 V)
Probe wires while paying attention to the diode
polarity. If a diode fails the test, replace the diode.
NOTE: Diodes are located in wiring harness ap-
WIRES TO PROBE (HARNESS SIDE) proximately where shown in following illustration.
DIODE WINCH SWITCH WINCH RELAY
CONNECTOR POST
D5 GREEN/BLUE
Ground
D6 BLUE/GREEN

Probe diodes in both forward and backwards po-

larity for proper testing. See illustrations.

vmr2008-140 315
Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

1 2

vmr2007-043-012_a V07A2GB

DIODE LOCATION 1. Cotter pin

2. Hook retaining pin
Properly reinstall removed parts.
Remove the winch retaining screws, and winch.
Winch Removal
Disconnect, the BLACK (-) battery cable, then the 1
RED (+) cable.

 WARNING
Always disconnect BLACK (-) battery cable
first. Electrolyte or fuel vapors can be present
in engine compartment and a spark may ig-
nite them possibly causing severe injuries.

Disconnect winch power cables.

1

V07A2HA 1
1. Winch retaining screws

Winch Installation
For the installation, reverse the removal proce-
dure.

WINCH CONTROL SWITCH

Winch Control Switch Continuity Test
V07A2FA Disconnect winch control switch connector.
1. Winch power cable connections

NOTE: Note the position of the power cables for

reinstallation.
Remove the cotter pin from the winch hook retain-
ing pin.
Remove the hook retaining pin, and hook.
316 vmr2008-140
 Section 06 ELECTRICAL SYSTEM
Subsection 04 (LIGHTS, GAUGE AND ACCESSORIES)

vmr2008-140-014_a

TYPICAL
1. Winch control switch connector

Set multimeter to and test switch as per fol-

lowing table.

WINCH CONTROL SWITCH CONTINUITY TEST

SWITCH
SWITCH CONNECTOR PINS
POSITION
Out Pin A Pin B
In Pin A Pin C

If switch does not pass continuity test, replace

winch control switch.
If all readings were good, test wiring/connectors
between switch and winch relay. Repair or re-
place as required.

Winch Control Switch Removal

Remove screws retaining winch control switch to
handlebar.
Remove front steering cover, refer to BODY.
Disconnect the winch control switch connector.

Winch Control Switch Installation

For the installation, reverse the removal proce-
dure.

vmr2008-140 317
 Section 07 DRIVE SYSTEM
Subsection 01 (4X4 COUPLING UNIT)

4X4 COUPLING UNIT

SERVICE TOOLS
Description Part Number Page
Fluke 115 multimeter ........................................................... 529 035 868 ................................. 321, 323
blind hole bearing puller set.................................................. 529 036 117 ......................................... 326

SERVICE PRODUCTS
Description Part Number Page
XP-S synthetic grease........................................................... 293 550 010 ......................................... 329
Loctite 243 (blue).................................................................. 293 800 060 ......................... 323, 328–329

vmr2008-141 319
Section 07 DRIVE SYSTEM
Subsection 01 (4X4 COUPLING UNIT)

20 N•m
(15 lbf•ft)

Loctite Engine oil

243

16 N•m
(142 lbf•in)

Loctite
243

XP-S
synthetic
grease NEW
20 N•m
(15 lbf•ft)

NEW

NEW

25 N•m
(18 lbf•ft)
Loctite
243

XP-S
synthetic
grease

vmr2008-141-001_a

320 vmr2008-141
 Section 07 DRIVE SYSTEM
Subsection 01 (4X4 COUPLING UNIT)

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

 WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pins, 529035868_a
etc.) must be replaced with new ones.
Turn ignition key ON.
Hoses or cables removed or disconnected must Select 2WD position.
be installed and routed at the same place. Install the RED probe to the WHITE wire connec-
CAUTION: Locking ties removed during a pro- tor and the BLACK probe to the WHITE/BLACK
cedure must be replaced and installed at the wire connector.
same location. The obtained value should be 12 Vdc.

PROCEDURES
2WD/4WD SELECTOR
2WD/4WD Selector Test
Remove LH footrest. Refer to BODY section.
Unplug connector from coupling unit.

vmr2008-141-003_a

Select 4WD position.

Install the RED probe to the WHITE/BLUE wire
connector and the BLACK probe to the WHITE
wire connector.
The obtained value should be 12 Vdc.

vmr2008-141-002_a

1. CVT air inlet duct

2. Connector

Using the Fluke 115 multimeter (P/N 529 035

868), check if the 2WD/4WD selector at handle-
bar works properly.

vmr2008-141-003_b

vmr2008-141 321
Section 07 DRIVE SYSTEM
Subsection 01 (4X4 COUPLING UNIT)

If voltage is not as specified, check wires and con-

nectors. If good, replace the 2WD/4WD selector
at handlebar.

2WD/4WD Selector Replacement

To replace the 2WD/4WD selector, refer to
THROTTLE LEVER in STEERING SYSTEM sec-
tion.

ACTUATOR
Actuator Removal vmr2008-141-006_a

Remove the LH and RH footrests. 1. Coupling unit screws

Remove CVT air inlet duct from CVT housing.
Rotate the coupling unit to reach actuator screws.
Remove actuator screws.

vmr2008-141-004_a

1. CVT housing
2. CVT air inlet duct
vmr2008-141-007_a

Unplug actuator connector. 1. Actuator screws

When all actuator screws are removed, pull the

actuator out of housing.

Actuator Installation
Apply a small amount of engine oil on actuator
O-ring.

vmr2008-141-005_a

1. Actuator connector

Unscrew coupling unit from engine.

vmr2008-141-008_a

1. Actuator O-ring

322 vmr2008-141
 Section 07 DRIVE SYSTEM
Subsection 01 (4X4 COUPLING UNIT)

Verify if sliding sleeve is in 2WD position. The slid- Apply Loctite 243 (blue) (P/N 293 800 060) on
ing sleeve should be pointed toward the front of threads of actuator screws.
vehicle. Tighten actuator screws.
Apply Loctite 243 (blue) (P/N 293 800 060) on
threads of coupling unit screws.
Tighten coupling unit screws.
Connect actuator.
Lift the front of vehicle until front wheels turn
freely.
Try to turn the front propeller shaft. The shaft
should turn easily.
Place ignition switch to ON position and select the
4WD position.
vmr2008-141-009_a
The front propeller shaft should not turn (the PARK
1. Sliding sleeve
2. Coupling unit housing position must be selected).
If the front propeller shaft turns, the actuator is not
Turn the actuator 37 degrees clockwise from the installed correctly. Remove actuator and reinstall
mounting position. it.
Install all other removed parts.

2WD/4WD SWITCH
Switch Removal
Remove RH footrest.
Unplug the 2WD/4WD switch connector.
Unscrew the switch from coupling unit housing.
Discard the sealing washer.
vmr2008-141-010_a

FROM RH SIDE — ACTUATOR POSITIONS AT 37 DEGREES

Align the actuator fork with the dog on sliding

sleeve then push the actuator in the housing.

V07H0KA 1
1. Sealing washer

Switch Test
Using the Fluke 115 multimeter (P/N 529 035 868),
do the following to check the switch.
vmr2008-141-011_a
Place the multimeter selector on .
1. Actuator fork
2. Sliding sleeve dog

Rotate the actuator counterclockwise until it ori-

ents itself to mounting position.
CAUTION: Do not cut or break the actuator
O-ring.
vmr2008-141 323
Section 07 DRIVE SYSTEM
Subsection 01 (4X4 COUPLING UNIT)

COUPLING UNIT
Coupling Unit Removal
Remove front propeller shaft. Refer to FRONT
DRIVE section.
Unplug coupling unit connector and 2WD/4WD
switch connector.
Remove screws retaining the coupling unit hous-
ing to the engine.

vmr2008-141-012

Using an alligator clip, place the BLACK probe on

the external pin.

vmr2008-141-013_a

vmr2006-035-005 1. Coupling unit housing screws

Touch the contact pin with the RED probe. The

Pull out the coupling unit.
multimeter should indicate ± 1 .
Coupling Unit Disassembly
Remove the actuator from the coupling unit by
removing the three retaining screws.

vmr2006-035-006

Apply the RED probe on switch body. The mea-

sure should be OL.

vmr2008-141-014_a

vmr2006-035-007 1. Actuator screws

If switch is out of specifications, replace it. Remove the oil seal.

Switch Installation
The installation is the reverse of the removal pro-
cedure.
Use a NEW sealing washer when installing the
switch.

324 vmr2008-141
 Section 07 DRIVE SYSTEM
Subsection 01 (4X4 COUPLING UNIT)

vmr2008-141-015_a

1. Oil seal vmr2008-141-018_a

1. Sliding sleeve
Remove the Allen set screw.
Remove the shifter fork.

vmr2008-141-016_a
vmr2008-141-019_a

1. Allen set screw

1. Shifter fork

Pull out the sliding sleeve pin. Pull out the coupling sleeve.

vmr2008-141-017_a

1. Sliding sleeve pin vmr2008-141-020_a

1. Coupling sleeve
Remove sliding sleeve.
Remove the inner circlip.

vmr2008-141 325
Section 07 DRIVE SYSTEM
Subsection 01 (4X4 COUPLING UNIT)

vmr2008-141-021_a

1. Inner circlilp

Turn the coupling unit housing and remove the out- 529036117

er circlip.
NOTE: Remove the ball bearing only if it does not
turn freely and smoothly.

Coupling Unit Inspection

Check disconnect unit housing and actuator for
cracks or other damages. Replace defective
part(s) if necessary.
Check if the actuator O-ring and the coupling unit
housing O-ring are brittle, hard or damaged.
Check splines of coupling sleeve for wear or other
damages. Replace if splines are damaged.

vmr2008-141-022_a

1. Outer circlip

Remove coupling unit shaft.

V07H0TA
vmr2008-141-023_a

1. Coupling unit shaft Measure the coupling sleeve groove. If the width
of groove is out of specification replace the cou-
Using the blind hole bearing puller set (P/N 529 pling sleeve.
036 117), remove the ball bearing.
COUPLING SLEEVE GROOVE WIDTH
SERVICE LIMIT 5.00 mm (.197 in)

326 vmr2008-141
 Section 07 DRIVE SYSTEM
Subsection 01 (4X4 COUPLING UNIT)

A SHIFTER FORK CLAWS THICKNESS

SERVICE LIMIT 2.93 mm (.115 in)

V07H0XA

A. Shifter fork claw thickness

V07H0UA

A. Groove width Check inner and outer shaft splines for wear or
other damages. Replace shaft if necessary.
Check sliding sleeve dog for bend and measure it. Measure the coupling unit shaft for wear limit.
SLIDING SLEEVE DOG THICKNESS COUPLING UNIT SHAFT
SERVICE LIMIT 4.80 mm (.189 in) SERVICE LIMIT 29.995 mm (1.181 in)

Measure the sliding sleeve groove.

SLIDING SLEEVE GROOVE WIDTH

SERVICE LIMIT 3.60 mm (.142 in)

A A
V07H0YA

A. Shaft diameter in the area of bearing

Coupling Unit Assembly

The assembly is the reverse of the disassembly
procedure. Pay attention to the following details.
Apply engine oil on moving parts.
Install the shifter fork and coupling sleeve as per
the following illustrations.

V07H0WA B
A. Sliding sleeve dog thickness
B. Sliding sleeve groove width

Check shifter fork for visible damage, wear or bent

claws.
Measure the shifter fork claw thicknesses.

vmr2008-141 327
Section 07 DRIVE SYSTEM
Subsection 01 (4X4 COUPLING UNIT)

V07H0ZA

V07H12A
Insert pin and install Allen set screw.
Apply Loctite 243 (blue) (P/N 293 800 060) on Move the sliding sleeve on right side and check if
threads of Allen set screw. the coupling sleeve is flush with the end of shaft.
Install and tighten the Allen set screw.
Check if the shifter plate and the coupling sleeve
are installed properly.
When the sliding sleeve is positioned on left side,
the coupling sleeve is equal with the end of the
shaft splines.

V07H15A

Install the actuator onto the coupling unit. Refer

to ACTUATOR INSTALLATION in this section.
328 vmr2008-141
 Section 07 DRIVE SYSTEM
Subsection 01 (4X4 COUPLING UNIT)

Coupling Unit Installation

The installation is the reverse of removal proce-
dure. However, pay attention to the following.
Apply XP-S synthetic grease (P/N 293 550 010) on
coupling unit housing O-ring.
Apply Loctite 243 (blue) (P/N 293 800 060) on
threads of coupling unit screws.
Install all other removed parts and check if the ac-
tuator is operational. See the procedure in ACTU-
ATOR INSTALLATION in this section.

vmr2008-141 329
 Section 07 DRIVE SYSTEM
Subsection 02 (FRONT DRIVE)

FRONT DRIVE
SERVICE TOOLS
Description Part Number Page
pliers Oetiker 1099 ............................................................... 295 000 070 ......................................... 334
differential spanner socket ................................................... 529 035 649 ......................................... 337
backlash measurement tool ................................................. 529 035 665 ......................................... 338
joint extractor tool................................................................. 529 036 005 ......................................... 335
CV boot clamp pliers............................................................. 529 036 120 ......................................... 334

SERVICE PRODUCTS
Description Part Number Page
XP-S synthetic grease........................................................... 293 550 010 ................................. 335, 339
BRP differential oil ................................................................ 293 600 043 ......................................... 333
Loctite 277............................................................................ 293 800 073 ......................................... 339
pulley flange cleaner............................................................. 413 711 809 ......................................... 333

vmr2008-142 331
Section 07 DRIVE SYSTEM
Subsection 02 (FRONT DRIVE)

NEW

XP-S
synthetic
grease

32 N•m
(24 lbf•ft)

NEW
22 N•m
(16 lbf•ft)

NEW
180 N•m
(133 lbf•ft) 7.5 N•m
(66 lbf•in) XP-S
XP-S synthetic
synthetic XP-S grease
grease synthetic
grease
Loctite
NEW 277

70 N•m NEW
(52 lbf•ft)
Loctite
243
42 N•m
(31 lbf•ft) NEW

NEW

NEW
vmr2008-142-001_a

332 vmr2008-142
 Section 07 DRIVE SYSTEM
Subsection 02 (FRONT DRIVE)

GENERAL Remove the filler plug. Oil must reach the lower
edge.
The procedure explains below is the same for the
RH and LH sides unless otherwise instructed. Add recommended oil if necessary.
During assembly/installation, use torque values Oil Change
and service products as in the exploded view.
Place vehicle on a level surface. Set transmission
Clean threads before applying threadlocker. Re- in park position.
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for Clean drain plug and filler plug areas.
complete procedure. 2

 WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pins,
etc.) must be replaced with new ones.

MAINTENANCE
DIFFERENTIAL OIL
Recommended Oil
The BRP differential oil (P/N 293 600 043) is highly V07H0DB 1
recommended.
1. Drain plug
If the BRP differential oil is not available, use a 2. Filler plug
75W90 synthetic oil (API GL-5).
Place a drain pan under differential drain plug area.
Oil Level Verification Remove drain plug.
Place the vehicle on a level surface and set trans- Lift LH side of vehicle to drain the lower portion of
mission in park position. the differential.
Clean filler plug area. Allow enough time for oil to flow out.
1 Lower the vehicle on the ground.
Clean drain plug area then reinstall plug.
Unscrew filler plug.
Use a funnel and refill front differential with 500 ml
(17 oz. US) of recommended oil
Reinstall filler plug.
Ensure there are no leaks.
Using pulley flange cleaner (P/N 413 711 809),
clean brake disc before using the vehicle.
Dispose oil as per your local environmental regu-
lations.

V07H0DA

1. Filler plug

vmr2008-142 333
Section 07 DRIVE SYSTEM
Subsection 02 (FRONT DRIVE)

PROCEDURES Extract CV joint from the knuckle.

Move the knuckle and the tie-rod aside to make
DRIVE SHAFT room.
Remove caliper. Refer to BRAKES section.
Pull drive shaft out of differential.
NOTE: Pull drive shaft strongly.

Drive Shaft Inspection

Inspect the condition of drive shaft boots. If there
is any damage or evidence of leaking lubricant, re-
vmr2008-142-003_a
place them. Refer to DRIVE SHAFT DISASSEM-
1. Plunging Joint BLY further in this section.
2. CV joint
3. Stop ring Check splines for excessive wear. Replace if nec-
4. Drive shaft boots
5. Oetiker clamps essary.
6. Wear ring
NOTE: If the splines on plunging joint are worn, a
check of differential inner splines should be done.
Drive Shaft Removal Check the stop ring at the end of drive shaft. If
Remove the appropriate wheel hub. Refer to wear is apparent, replace the wear ring located on
WHEELS/TIRES section. the plunging joint.
Unscrew bolts holding strut to knuckle. Check if the wheel bearing in knuckle move freely
and smoothly. If not, replace it. Refer to STEER-
ING SYSTEM section.

Drive Shaft Disassembly

Remove and discard Oetiker clamps securing
drive shaft boots. Use the CV boot clamp pli-
ers (P/N 529 036 120) and pliers Oetiker 1099
(P/N 295 000 070).

vmr2008-142-002_a

1. Strut bolts
2. Knuckle 529036120

CV BOOT CLAMP PLIERS

Remove ball joint retaining bolt.

295000070

PLIERS OETIKER 1099

V07H09A 2 1
Remove the large end of the drive shaft boot from
1. Ball joint retaining bolt the joint (plunging joint or CV joint).
2. Lower suspension arm
Two procedures can be used to separate joint from
Separate knuckle from lower suspension arm. shaft.
334 vmr2008-142
 Section 07 DRIVE SYSTEM
Subsection 02 (FRONT DRIVE)

Without the Joint Extractor Tool Pack bearing area with the grease included in the
Clamp joint housing in a vise. new boot kit.
Align shaft with joint. NOTE: Do not use or add other grease.
Pull hard on shaft to remove from joint. Drive Shaft Installation
Remove boot from drive shaft. NOTE: LH and RH drive shafts are not the same
Remove and discard the circlip. A new one is in- length. The LH drive shaft is shorter than the RH.
cluded in the boot kit. Apply XP-S synthetic grease (P/N 293 550 010) to
With the Joint Extractor Tool the splines.
Place drive shaft in vice with the joint downward. Insert the end of drive shaft in differential.
Install the joint extractor tool (P/N 529 036 005) on Pull to make sure that the stop ring is locked in
bearing. differential side gear groove.
1

529036005

V07H0AA

1. Stop ring

The wear ring should be close to the differential

when drive shaft is well inserted.

vmr2007-053-010_a

TYPICAL — CV JOINT SHOWN

1. Joint extractor tool

With an hammer, hit on the tool to separate joint

from shaft.
Remove boot from drive shaft.
Remove and discard the circlip. A new one is in-
cluded in the boot kit.
Check bearing in plunging joint or CV joint. If bear-
ing is hard to move, change plunging joint or CV
joint.

Drive Shaft Assembly V07H0BA

Insert the small clamp and the small end of boot TYPICAL
on shaft.
Insert the other end of drive shaft in the knuckle.
Install the NEW circlip included in the new boot
kit. Install the knuckle to the lower suspension arm.
Clamp joint in a vise with joint facing up. Install and torque the ball joint retaining bolt to
48 N•m (35 lbf•ft).
Center circlip on shaft.
Install all other removed parts.
Carefully insert shaft into joint.
Push hard to engage clip.

vmr2008-142 335
Section 07 DRIVE SYSTEM
Subsection 02 (FRONT DRIVE)

DIFFERENTIAL Differential Inspection

Check backlash and preload, see DIFFERENTIAL
Differential Removal ADJUSTMENT further in this section.
Drain the differential. See DIFFERENTIAL OIL at Check if oil seals are brittle, hard or damaged. Re-
the beginning of this section. place if necessary.
Loosen lug nuts.
Raise front of vehicle. Differential Disassembly
Support the vehicle securely using jack stands. Ring Gear Carrier/Ring Gear
Remove front wheels. Remove differential housing screws.
On both sides, remove the DRIVE SHAFTS. See
procedure above in this section.
Remove and discard the propeller shaft boot
clamp located near differential.

vmr2008-142-005_a

1. Differential housing screws

Separate half housings.

NOTE: Be careful to keep track of shims on each
end of ring gear carrier.
Remove ring gear carrier with ring gear out of half
housing.
V07H0FA
Pinion Gear
Unscrew the both differential mounting bolts. Remove screw retaining the propeller shaft adap-
tor.

vmr2008-142-004_a
V07H0HA 1
1. Propeller shaft adaptor
1. Differential mounting bolts 2. Propeller shaft adaptor screw

Move the differential forward to disconnect the Remove and discard oil seal.
propeller shaft.
Remove the differential from the RH side.

336 vmr2008-142
 Section 07 DRIVE SYSTEM
Subsection 02 (FRONT DRIVE)

vmr2008-142-007_a vmr2008-142-009_a

1. Oil seal 1. Pinion gear

2. Bearing
Unscrew the pinion nut. Use the differential span-
ner socket (P/N 529 035 649). NOTE: The pinion gear and bearing can be easily
removed using the following suggested tool:
529 035 649 – Pipe 3-1/2 in diameter x 5 in (1)
– Screwed rod M10 x 1.25, 7 in length (1)
– Nut M10 x 1.25 (3)
– Flat bar (1).
Remove and discard the O-ring retaining the bear-
ing.

vmr2008-142-010_a

1. O-ring
2. Pinion gear
vmr2008-142-008_a
3. Bearing

1. Pinion nut
Remove bearing from pinion gear.
Remove the bearing at the same time as the pin-
ion gear. Be careful to keep track of shims.
Differential Adjustment
A shimming procedure must be done when one
of these components is changed.
– Ring gear carrier
– Pinion gear
– Ring gear
– Housing.
Measure the old pinion shim stack. If the shims
measure over 1.00 mm (.039 in), install shim
stacks on the differential components as per
CHART A.

vmr2008-142 337
Section 07 DRIVE SYSTEM
Subsection 02 (FRONT DRIVE)

If the old pinion shim stack measurement is under

1.00 mm (.039 in), install a 0.5 mm (.02 in) shim
on the differential components as per CHART B.

CHART A CHART B
1.85 mm
PINION PINION
(.073 in)
0.5 mm
BACKLASH 1.00 mm BACKLASH (.02 in)
PRELOAD (.039 in) PRELOAD

NOTE: The procedure above sets the pinion shim

thickness and should not be modified thereafter.
Any changes should be done on the preload and/or
backlash side(s). vmr2006-023-015_a

1. Tab of backlash measurement tool

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

Position the dial indicator tip against the tab at

a 90° angle and right on the previously scribed
mark.
2 1
Gently, move the tab back and forth. Note the
result.

vmr2006-023-009_a

1. Backlash side
2. Preload side

Assemble the differential and check backlash as

well as preload.
Backlash
Using a dial indicator and the backlash measure-
ment tool (P/N 529 035 665), measure the back-
lash. Place the backlash measurement tool at
vmr2006-023-016
the end of pinion gear.
From center of bolt, measure 25.4 mm (1 in) and Rotate pinion gear 1/2 turn and check backlash
scribe a mark on the tab. again. Note the result.
Rotate pinion gear 1 turn and check backlash
again.
If backlash is below 0.05 mm (.002 in), increase
backlash shim by 0.05 mm (.002 in) and check the
backlash again.
If backlash is greater than 0.356 mm (.014 in), de-
crease backlash shim by 0.05 mm (.002 in) and
check the backlash again.
Measure preload.
Preload
Screw the propeller shaft adaptor screw in pinion
gear.

338 vmr2008-142
 Section 07 DRIVE SYSTEM
Subsection 02 (FRONT DRIVE)

vmr2008-142-011_a
vmr2006-023-011_a
1. Half housing seal
TYPICAL
Check all bearings and all oil seals. Change them
Using a needle torque wrench, measure the drag if necessary.
torque.
Pinion Gear
To install, reverse the removal procedure. Pay at-
tention to the following details.
Install the shim(s) then the ball bearing.
Install a NEW O-ring.
Apply Loctite 277 (P/N 293 800 073) on threads of
pinion nut.
Install pinion nut then torque it to 180 N•m
(133 lbf•ft).
Apply XP-S synthetic grease (P/N 293 550 010) in
vmr2006-023-012
the lips of the NEW oil seal and install it.
TYPICAL
Differential Installation
If the drag torque is greater than 0.7 N•m
(6 lbf•in), reduce preload shim by 0.05 mm The installation is the reverse of the removal pro-
(.002 in) and check drag torque again. cedure.
If the drag torque is less than 0.06 N•m (.5 lbf•in),
increase preload shim by 0.05 mm (.002 in) and
PROPELLER SHAFT
check drag torque again. Propeller Shaft Removal
Differential Assembly Refer to BODY section to remove the following
parts:
Ring Gear Carrier/Ring Gear – RH footrest
To assemble, reverse the removal procedure. Pay – RH inner fender.
attention to the following details.
On RH side of vehicle, remove the DRIVE SHAFT.
Verify condition of half housing seal. Change seal See procedure above in this section.
if necessary.
Remove and discard both large Oetiker clamps se-
curing propeller shaft boots.

vmr2008-142 339
Section 07 DRIVE SYSTEM
Subsection 02 (FRONT DRIVE)

V07H0IA 1
1. Remove these clamps

Remove the differential mounting bolts.

V07H0HA 1
1. Differential mounting bolts

Move differential forward to separate propeller

shaft from differential and disconnect unit.

Propeller Shaft Inspection

Check propeller shaft splines for wear or other
damages.
Check propeller shaft boots for holes or brittle-
ness.

Propeller Shaft Installation

Installation is the reverse of removal procedure.

340 vmr2008-142
 Section 07 DRIVE SYSTEM
Subsection 03 (REAR DRIVE)

REAR DRIVE
SERVICE TOOLS
Description Part Number Page
differential spanner socket ................................................... 529 035 649 ......................................... 349
backlash measurement tool ................................................. 529 035 665 ......................................... 350
CV boot clamp pliers............................................................. 529 036 120 ................................. 344–345

SERVICE PRODUCTS
Description Part Number Page
XP-S synthetic grease........................................................... 293 550 010 ......................... 347–348, 351
BRP differential oil ................................................................ 293 600 043 ......................................... 343
Loctite 243 (blue).................................................................. 293 800 060 ......................................... 347
Loctite 277............................................................................ 293 800 073 ......................................... 351

smr2008-143 341
Section 07 DRIVE SYSTEM
Subsection 03 (REAR DRIVE)

NEW

XP-S
synthetic
grease
32 N•m
(24 lbf•ft)
22 N•m
(16 lbf•ft)
NEW

XP-S synthetic
grease

180 N•m
(133 lbf•ft) 7.5 N•m
(66 lbf•in)
XP-S synthetic NEW
grease
NEW NEW NEW

Loctite
277 NEW
XP-S
synthetic
grease

90 N•m
(66 lbf•ft)

XP-S XP-S
synthetic synthetic
grease grease

Loctite
NEW 42 N•m 243
(31 lbf•ft)

42 N•m
(31 lbf•ft)
Loctite 2.5 N•m
243 (22 lbf•in)
vmr2008-143_001_a

342 smr2008-143
 Section 07 DRIVE SYSTEM
Subsection 03 (REAR DRIVE)

GENERAL The rear differential oil is not level with the filler
plug threads. It is possible to verify the oil level
During assembly/installation, use torque values by inserting a wire with a 90° bend through the oil
and service products as in the exploded view. filler hole.
Clean threads before applying a threadlocker. Re- Oil level is between 25 to 32 mm (1 to 1-1/4 in)
fer to SELF-LOCKING FASTENERS and LOCTITE from the bottom of filler plug threads when the
APPLICATION at the beginning of this manual for vehicle is level on ground.
complete procedure.
Using a funnel, add recommended oil if necessary.
 WARNING
Oil Replacement
Torque wrench tightening specifications
must be strictly adhered to. Place the vehicle on a level surface and set trans-
Locking devices (e.g.: locking tabs, elastic mission in park position.
stop nuts, self-locking fasteners, cotter pins, Remove the DIFFERENTIAL PROTECTOR, see
etc.) must be replaced with new ones. procedure further in this section.
Clean drain plug area.
Place a drain pan under rear differential drain plug
MAINTENANCE area.
Remove drain plug.
DIFFERENTIAL OIL
Remove filler plug to help oil flowing out of differ-
Recommended Oil ential.
The BRP differential oil (P/N 293 600 043) is highly 2
recommended.
If the BRP differential oil is not available, use a
75W90 synthetic oil (API GL-5).

Oil Level Verification

Place the vehicle on a level surface and set trans-
mission in park position.
Place bottom of frame horizontally.
Clean filler plug area.
Remove filler plug.
1
1
V07H26B

1. Drain plug
2. Filler plug

Clean drain plug area then reinstall drain plug.

Use a funnel and refill differential at the proper
level with recommended oil.

REAR DIFFERENTIAL OIL CAPACITY

250 ml (8.5 U.S. oz)

Reinstall filler plug.

V07H26A
Ensure there are no leaks.
1. Filler plug Dispose oil as per your local environmental regu-
lations.

smr2008-143 343
Section 07 DRIVE SYSTEM
Subsection 03 (REAR DRIVE)

PROCEDURES Drive Shaft Inspection

Inspect the condition of drive shaft boots. If there
DIFFERENTIAL PROTECTOR is any damage or evidence of leaking lubricant, re-
place them. Refer to DRIVE SHAFT DISASSEM-
Differential Protector Removal BLY further in this section.
Remove bolts retaining the protector to the frame. Check shaft splines. Replace drive shaft if neces-
sary.
NOTE: If the splines on plunging joint are worn, a
check of differential inner splines should be done.
Check wear ring located on the plunging joint. Re-
place if necessary.

Drive Shaft Disassembly

Remove and discard Oetiker clamps securing
drive shaft boots. Use the CV boot clamp pliers
(P/N 529 036 120).

vmr2008-143-002_a

1. Protector bolts
2. Differential protector
3. Hitch

529036120

Differential Protector Installation CV BOOT CLAMP PLIERS

The installation is the reverse of removal proce-
dure. Remove the large end of the drive shaft boot from
the joint (plunging joint or CV joint).
DRIVE SHAFT Install drive shaft in a vise.

vmr2008-142-003_a

1. Plunging Joint
2. CV joint
3. Stop ring vmr2008-143-010
4. Drive shaft boots
5. Oetiker clamps Using an aluminum or a brass tube, hit against the
6. Wear ring
inner race forcefully to separate the joint from the
shaft.
Drive Shaft Removal
Remove the appropriate trailing arm. Refer to
REAR SUSPENSION section.
Pull drive shaft out of differential.
NOTE: Pull drive shaft strongly.

344 smr2008-143
 Section 07 DRIVE SYSTEM
Subsection 03 (REAR DRIVE)

vmr2008-143-013

CV JOINT PROPERLY SEATED

vmr2008-143-011_a

1. Aluminum tube
2. Inner race

NOTE: In some case, you may have to hit one

side, then move the drive shaft 180 degrees in the
vise and hit the other side until joint is off.
Remove boot from drive shaft.
Check bearing in plunging joint or CV joint. If bear-
ing is hard to move, change plunging joint or CV
joint.
Check circlip for damage, change as necessary.
vmr2008-143-014
Drive Shaft Assembly PLUNGING JOINT PROPERLY SEATED
Insert the small clamp and the small end of boot
on shaft. If the joint doesn't slide on, there is a good chance
With the circlip in place, align the inner race that the circlip came out of its groove. Check and
squarely with the shaft splines. try again with a new circlip.
Using a plastic hammer, hit the end of the joint.
The joint should slip over the shaft until it bottom
out.

vmr2008-143-015_a

1. Circlip out of groove

Pack bearing area with grease included in the new

vmr2008-143-012
boot kit.
NOTE: Do not use any other grease.
Fit the boot in place and install the clamps on the
boot using the CV boot clamp pliers (P/N 529 036
120).

smr2008-143 345
Section 07 DRIVE SYSTEM
Subsection 03 (REAR DRIVE)

Support the vehicle securely using jack stands.

Remove rear wheels.
Remove caliper screws then suspend the caliper
aside.
529036120

CV BOOT CLAMP PLIERS

vmr2007-054-004_a

CAUTION: Do not let caliper hang by the hose

and do not stretch or twist hose.
Remove screw securing propeller shaft to engine.
vmr2008-143-016

Drive Shaft Installation

Insert the end of drive shaft in differential and
pull joint a little to make sure that the stop ring
is locked in differential gear groove.

vmr2007-054-005_a

Remove screw securing propeller shaft to differ-

ential.

V01H0FA 1
1. Stop ring

NOTE: Make sure do not interchange LH and RH

drive shafts. The shafts are different lengths.
Install the other parts in the reverse order of re-
moval procedure. Refer to the appropriate sec- vmr2007-054-006_a

tions to apply the proper torque.

Remove DIFFERENTIAL PROTECTOR, see proce-
dure above in this section.
PROPELLER SHAFT
Propeller Shaft Removal
Place the vehicle on a level surface and set trans-
mission in park position.
Loosen rear wheel lug nuts.
Raise rear of vehicle.
346 smr2008-143
 Section 07 DRIVE SYSTEM
Subsection 03 (REAR DRIVE)

Apply XP-S synthetic grease (P/N 293 550 010)

on splines of engine drive shaft and differential
pinion.
Apply Loctite 243 (blue) (P/N 293 800 060) on the
threads of both propeller shaft screws.
Install screws and washers.
Tighten screws to 42 N•m (31 lbf•ft).
vmr2007-054-007_a
Reinstall all other removed parts.
1. Differential protector
Grease U-joints from rear propeller shaft. Use a
Unscrew lower and upper differential bolts. grease gun with XP-S synthetic grease (P/N 293
550 010).

REAR PROPELLER
SHAFTU-JOINT
Remove the brake disc before working on differ-
ential side of propeller shaft.

U-joint Removal
Remove internal snap ring from bearing caps.

vmr2007-054-008_a

1. Differential bolts

Loosen hitch plate bolts.

V01H0YA 1
vmr2007-054-009_a 1. Snap ring

Move the differential backward.

Support inner yoke in vice and drive other yoke
Unplug the propeller shaft from the differential down with a soft hammer.
then remove it from vehicle.

Propeller Shaft Inspection

Check yokes and U-joints for wear, backlash or
axial play, replace if necessary.
Inspect engine seal for damage or leaks. Replace
if necessary.
Inspect brake disc (refer to BRAKES section).

Propeller Shaft Installation

Installation is essentially the reverse of removal
procedure. Pay attention to the following details.
V01H0ZA

smr2008-143 347
Section 07 DRIVE SYSTEM
Subsection 03 (REAR DRIVE)

Support U-joint in vice and drive inner yoke down

to remove remaining bearing caps.
Remove U-joint cross.

U-joint Installation
Install new U-joint cross in inner yoke.
Install new bearing cap by hand.
NOTE: Carefully install U-joint cross with grease
fitting properly positioned.

V01H12A

Install snap ring.

Repeat procedure for other sides.
Grease U-joint, using a grease gun with XP-S syn-
thetic grease (P/N 293 550 010).

DIFFERENTIAL
V01H10A
Differential Removal
Tighten vise to force bearing caps in. Install a jack stand under differential to support the
vehicle during the following procedure.
Remove both trailing arms. Refer to REAR SUS-
PENSION section.
Remove both drive shafts.
Remove the DIFFERENTIAL PROTECTOR, see
procedure above in this section.
Unscrew the screw securing propeller shaft to dif-
ferential.
Remove bolts securing the differential.

V01H11A

Using a suitable tappet, fully seat bearing cap in

one side. Continually, check for free movement
of bearing cross as bearing caps are assembled.

vmr2008-143-003_a

1. Differential bolts

Remove the differential from vehicle.

Differential Inspection
Turn differential gear with a finger; it should turn
smoothly. Replace if necessary.

348 smr2008-143
 Section 07 DRIVE SYSTEM
Subsection 03 (REAR DRIVE)

Check backlash and drag torque, see DIFFEREN- Remove and discard the O-ring retaining the bear-
TIAL ADJUSTMENT further in this section. ing.
Check if oil seals are brittle, hard or damaged. Re-
place if necessary.

Differential Disassembly
Ring Gear
Remove differential housing screws.

vmr2008-142-010_a

1. O-ring
2. Pinion gear
3. Bearing

Remove bearing from pinion gear. Be careful to

keep track of shims.

Differential Adjustment
vmr2008-143-004_a
A shimming procedure must be done when one
1. Differential housing screws of these components is changed.
Separate half housings. – Pinion gear
– Ring gear
NOTE: Be careful to keep track of shims on each
end of ring gear carrier. – Housing.
Remove ring gear from half housing. Measure the old pinion shim stack. If the shims
measure over 1.00 mm (.039 in), install shim
Pinion Gear stacks on the differential components as per
Remove and discard oil seal. CHART A.
Using the differential spanner socket (P/N 529 035 If the old pinion shim stack measurement is under
649), unscrew the pinion nut by turning it CLOCK- 1.00 mm (.039 in), install a 0.5 mm (.02 in) shim
WISE. on the differential components as per CHART B.

529 035 649 CHART A CHART B

2.18 mm
PINION PINION
(.086 in)
0.94 mm 0.5 mm
BACKLASH BACKLASH
(.037 in) (.02 in)
1.37 mm
PRELOAD PRELOAD
(.054 in)
CAUTION: The pinion nut is left hand threaded.
Unscrew by turning clockwise. NOTE: The procedure above sets the pinion shim
Remove the bearing at the same time as the pin- thickness and should not be modified thereafter.
ion gear. Any changes should be done on preload and/or
backlash side(s).
NOTE: The pinion gear and bearing can be easily
removed using the following suggested tool:
– Pipe 3-1/2 in diameter x 5 in (1)
– Screwed rod M10 x 1.25, 7 in length (1)
– Nut M10 x 1.25 (3)
– Flat bar (1).

smr2008-143 349
Section 07 DRIVE SYSTEM
Subsection 03 (REAR DRIVE)

vmr2006-023-016

vmr2006-024-010_a Rotate pinion gear 1/2 turn and check backlash

1. Backlash side again. Note the result.
2. Preload side
Rotate pinion gear 1 turn and check backlash
again.
Assemble the differential.
If backlash is below 0.05 mm (.002 in), increase
Backlash backlash shim by 0.05 mm (.002 in) and check the
Measure the backlash using a dial indicator and backlash again.
the backlash measurement tool (P/N 529 035 665). If backlash is greater than 0.356 mm (.014 in), de-
Place the backlash measurement tool at the end crease backlash shim by 0.05 mm (.002 in) and
of pinion gear. check the backlash again.
From center of bolt, measure 25.4 mm (1 in) and Measure preload.
scribe a mark on the tab.
Preload
Screw the propeller shaft adaptor screw in pinion
gear.

vmr2006-023-011_a
vmr2006-023-015_a
TYPICAL — FRONT DIFFERENTIAL SHOWN
1. Tab of backlash measurement tool
2. Mark on tab
A. 25.4 mm (1 in) Using a needle torque wrench, measure the drag
torque.
Position the dial indicator tip against the tab at
a 90° angle and right on the previously scribed
mark.
Gently, move the tab back and forth. Note the
result.

350 smr2008-143
 Section 07 DRIVE SYSTEM
Subsection 03 (REAR DRIVE)

Apply XP-S synthetic grease (P/N 293 550 010) in

the lips of the NEW oil seal and install it.

Differential Installation
The installation is the reverse of the removal pro-
cedure.

vmr2006-023-012

TYPICAL — FRONT DIFFERENTIAL SHOWN

If the drag torque is greater than 0.7 N•m

(6 lbf•in), reduce preload shim by 0.05 mm
(.002 in) and check drag torque again.
If the drag torque is less than 0.06 N•m (.5 lbf•in),
increase preload shim by 0.05 mm (.002 in) and
check drag torque again.

Differential Assembly
Ring Gear
To assemble, reverse the removal procedure. Pay
attention to the following details.
Verify condition of half housing seal. Change seal
if necessary.

vmr2008-143-005_a

1. Half housing seal

Check all bearings and all oil seals. Change them

if necessary.
Pinion Gear
To install, reverse the removal procedure. Pay at-
tention to the following details.
Install shim(s) then the ball bearing.
Install a NEW O-ring.
Apply Loctite 277 (P/N 293 800 073) on threads of
pinion nut.
Install pinion nut then torque it to 180 N•m
(133 lbf•ft).

smr2008-143 351
 Section 08 CHASSIS
Subsection 01 (WHEELS/TIRES)

WHEELS/TIRES
SERVICE PRODUCTS
Description Part Number Page
Loctite 767 (antiseize lubricant) ............................................ 293 800 070 ......................................... 355

Outlander 400 EFI

Outlander MAX 400 EFI

Loctite 767
(antiseize lubricant) NEW

205 N•m
(151 lbf•ft)

70 N•m
(52 lbf•ft)

Loctite 767
(antiseize lubricant)

NEW

205 N•m
(151 lbf•ft)
Outlander 400 EFI XT
Outlander MAX 400 EFI XT

100 N•m
(74 lbf•ft)
vmr2008-144-001_a

vmr2008-144 353
Section 08 CHASSIS
Subsection 01 (WHEELS/TIRES)

GENERAL TIRE PRESSURE

 WARNING OUTLANDER 400 EFI and

OUTLANDER MAX 400 EFI
Severe injury or death can result if these in-
structions are not followed. FRONT REAR
– When the tires are replaced, never install a 34.5 kPa 34.5 kPa
UP to MAX.
bias tire with a radial tire. Such a combina- (5 PSI) (5 PSI)
tion could create handling and/or stability 227 kg
(500 lb) 31 kPa 31 kPa
problems. MIN.
(4.5 PSI) (4.5 PSI)
– Do not rotate tires. The front and rear tires
are of different sizes. OUTLANDER 400 EFI XT and
OUTLANDER MAX 400 EFI XT
– Do not mix tires of different size and/or de-
sign on the same axle. FRONT REAR
– Front and rear tire pairs must be of identical 34.5 kPa 34.5 kPa
UP to MAX.
model and manufacturer. (5 PSI) (5 PSI)
235 kg
– For unidirectional tread pattern, ensure 31 kPa 31 kPa
(517 lb) MIN.
that the tires are installed in the correct (4.5 PSI) (4.5 PSI)
direction of rotation.
– The radial tires must be installed as a com-
plete set. PROCEDURES
WHEEL
MAINTENANCE Wheel Removal
Place the vehicle on a level surface.
TIRE PRESSURE
Apply parking brake.
 WARNING Loosen wheel lug nuts.
Tire pressure greatly affects vehicle handling
Lift the front of vehicle.
and stability. Underpressure may cause
tire to deflate and rotate on wheel. Over- Secure vehicle on jack stands. Position jack
pressure may burst the tire. Always follow stands under lower suspension arms.
recommended pressure. Since tires are Remove wheel.
low-pressure types, a manual pump should
be used. Wheel Installation
The installation is the reverse of the removal pro-
Check pressure when tires are COLD before using cedure.
the vehicle. Tire pressure changes with tempera-
ture and altitude. The tires are directional and their rotation must be
kept in a specific direction for proper operation.
Recheck pressure if one of these conditions has
changed. Using the next table, torque wheel lug nuts in ac-
cordance with the following illustration.

354 vmr2008-144
 Section 08 CHASSIS
Subsection 01 (WHEELS/TIRES)

– Inside edge.
It is normal to see uneven wear on tires depending
on how the vehicle is driven and road conditions.
The front tires external or internal edges tread will
wear unevenly depending on if the vehicle is driv-
en smoothly or aggressively.

Tire Replacement
To replace a tire, do the following:
Remove WHEEL from vehicle, see procedure in
this section.
vmr2008-144-006_a Using an automotive tire changer (rim clamp
CAUTION: Always use the recommended type), remove the old tire.
wheel lug nuts. Using a different nut could NOTE: Refer to manufacturer's instructions for
cause damages to the rim. tire changer operation.
Install the new tire.
WHEEL TORQUE
Remove the old balancing masses from rim.
TORQUE
MODELS Clean inner side of wheel with alcohol to remove
FRONT REAR grease and dust.
Outlander 400 EFI
70 N•m (52 lbf•ft)
Balance wheel using a wheel balancer.
Outlander MAX 400 EFI
NOTE: Refer to manufacturer's instructions for
Outlander 400 EFI XT wheel balancer operation.
100 N•m (74 lbf•ft)
Outlander MAX 400 EFI XT Install new balancing masses inside wheel. Po-
sition them in the center of the flat inner surface
NOTE: Occasionally, wheel lug nuts should be re- of the rim.
moved to apply Loctite 767 (antiseize lubricant)
(P/N 293 800 070) on studs to ease future removal. Reinstall wheel.
This is particularly important when vehicle is used
in salt water environment or in mud. Remove one WHEEL HUB
nut at a time, lubricate then retorque.
Wheel Hub Removal
TIRE Place the vehicle on a level surface.
Apply parking brake or select 4WD position and
Tire Inspection place transmission lever on P.
Check for air leaks (hissing sound) caused by an Loosen wheel lug nuts.
ill-fitting rim or a faulty tire valve.
Raise the front or the rear of vehicle.
Check tire for:
Support it securely on jack stands.
– Cuts
– Slits Remove wheel.
– Cracks. Remove the hub cap.
Check sides of tire for: Remove and discard the cotter pin.
– Bumps
– Bulges
– Nails
– Other foreign objects.
Check minimum tread depth by using a tread
depth gauge. Check in three locations across the
tire's tread:
– Outer edge
– Center
vmr2008-144 355
Section 08 CHASSIS
Subsection 01 (WHEELS/TIRES)

Check wear ring. If damage is apparent, replace

the wear ring.

vmr2008-144-002_a

1. Cotter pin
vmr2008-144-005_a

Unscrew the castellated nut. 1. Wheel hub

2. Wheel hub splines
3. Wear ring

Wheel Hub Installation

The installation is the reverse of removal proce-
dure.
Install Belleville washer so that the inside diameter
protrudes outward and contacts the nut.
Tighten the castellated nut on the drive shaft end
to 205 N•m (151 lbf•ft) and further tighten until
one of its grooves is aligned with a cotter pin hole.
vmr2008-144-003_a NOTE: Do not unscrew the castellated nut to
1. Castellated nut reach a cotter pin hole.
Install a NEW cotter pin. Fold one pin of cotter pin
Remove the Belleville washer. over drive shaft end.

vmr2008-144-004_a

1. Belleville washer

Pull wheel hub to remove it.

V07H0CA

Wheel Hub Inspection

Check wheel hub for cracks or other damages. Install the hub cap.
Check inner splines for wear or other damages. Install WHEEL, see procedure above in this sec-
tion for proper torque.
If any damage is detected on wheel hub, replace
it with a new one.
356 vmr2008-144
 Section 08 CHASSIS
Subsection 02 (STEERING SYSTEM)

STEERING SYSTEM
SERVICE TOOLS
Description Part Number Page
steering alignment tool......................................................... 529 036 059 ......................................... 359

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
Smoothflow™ tapered tip .................................................... 16 ga #511 ......................................... 360
rtt-b

SERVICE PRODUCTS
Description Part Number Page
Loctite 243 (blue).................................................................. 293 800 060 ......................................... 365
Loctite 406 (glue).................................................................. 293 800 100 ......................................... 360
pulley flange cleaner............................................................. 413 711 809 ......................................... 360
XP-S synthetic grease........................................................... 529 550 010 ......................................... 366

vmr2008-145 357
Section 08 CHASSIS
Subsection 02 (STEERING SYSTEM)

Outlander 400 EFI 1 N•m Outlander 400 EFI XT 1 N•m

Outlander MAX 400 EFI (9 lbf•in) Outlander MAX 400 EFI XT (9 lbf•in)

2 N•m
(18 lbf•in)

2 N•m
(18 lbf•in)

Loctite 406

31 N•m
(23 lbf•ft) 25 N•m
(18 lbf•ft)

37 N•m
(27 lbf•ft)
XP-S synthetic grease
NEW
72 N•m
(53 lbf•ft)

10 N•m
(89 lbf•in)

Loctite 243

NEW

NEW
72 N•m 72 N•m
(53 lbf•ft) (53 lbf•ft)
NEW
NEW
vmr2008-145-001_a

358 vmr2008-145
 Section 08 CHASSIS
Subsection 02 (STEERING SYSTEM)

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

 WARNING vmr2007-055-010

Torque wrench tightening specifications

Move the vehicle to place the tool on a level with
must strictly be adhered to.
the ground.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pins,
etc.) must be replaced with new ones.

Hoses or cables removed or disconnected must

be installed and routed at the same place.
CAUTION: Locking ties removed during a pro-
cedure must be replaced and installed at the
same location.

ADJUSTMENT
STEERING ALIGNMENT vmr2007-055-011_a

Place vehicle on level surface. Place a rope around the vehicle and using an elas-
Position handlebar so that it is in straight ahead tic, link both ends together.
position by measuring from the extremities of the The rope must be place at the center of the
handlebar to a rear fixed point. wheels.
From the front of vehicle, near the front of rim,
move rope so that it does not touch the first spacer
of tool.

vmr2008-145-002_a

A. Same length

NOTE: The reference point must be the same to vmr2007-055-012_a

each side. TYPICAL

Tie handlebar to prevent movements during align-
ment. Then, bring the rope back until it touches the spac-
er.
Check pressure in each tires. Always follow rec-
ommended pressure.
Remove two wheel nuts and install the steering
alignment tool (P/N 529 036 059).

vmr2008-145 359
Section 08 CHASSIS
Subsection 02 (STEERING SYSTEM)

PROCEDURES
HANDLEBAR GRIP
Handlebar Grip Removal
Loosen (2–3 turns only) the screw at the end of
handlebar grip.
NOTE: If the screw is removed completely, the
vmr2007-055-013_a
threaded insert will stay inside handlebar and its
TYPICAL removal could be difficult.
Keep this position and measure the distance be-
tween the rope and the rim, to the front and to
the rear of wheel.

vmr2008-145-003_a

1. Handlebar grip
vmr2007-055-014 2. Handlebar end weight
3. Handlebar end weight screw
TYPICAL — FRONT OF WHEEL
Slide the handlebar end weight with its threaded
insert out of handlebar.

vmr2008-145-004_a
vmr2007-055-015

TYPICAL — REAR OF WHEEL 1. Threaded insert

2. Handlebar end weight
3. Handlebar end weight screw
Refer to the following chart to know the difference
between the rear and the front measurement. Cut and remove the handlebar grip.

MODELS TOE-OUT Handlebar Grip Installation

0 mm ± 4 mm Remove all rubber residues of the old grip before
All Outlander 400 EFI
(0 in ± .157 in) installing the new.
Clean the handlebar with pulley flange cleaner
Set alignment of wheel by adjusting tie-rod. (P/N 413 711 809) or alcohol to remove any greasy
Recheck the measurement after torquing tie-rod matter on it.
lock nuts. Install handlebar grip by blowing compressed air
Repeat the procedure for the other side of vehicle. between handle grip and handlebar.
Install a Smoothflow™ tapered tip (P/N 16 ga #511
rtt-b) from EFD Inc on a bottle of Loctite 406 (glue)
(P/N 293 800 100).

360 vmr2008-145
 Section 08 CHASSIS
Subsection 02 (STEERING SYSTEM)

Lift a part of the grip using a small screwdriver and

inject glue (about 4 spots per side).
NOTE: The glue dries quickly. Do not apply it be-
fore installing grip.
Apply pressure on the grip for approximately
30 seconds to set the glue.
Install the handlebar end weight and torque screw
to 25 N•m (18 lbf•ft).

HANDLEBAR COVERS vmr2008-145-007_a

Handlebar Covers Removal 1. Rear handlebar cover screws

Front Handlebar Cover Unplug the speedometer.

Remove handlebar cover screws.

vmr2008-145-008_a

1. Speedometer connector
vmr2008-145-005_a

1. Handlebar cover screws Remove rear handlebar cover from vehicle.

Remove the front handlebar cover. Handlebar Covers Inspection
Check covers for cracks or other damages. Re-
place if necessary.

Handlebar Covers Installation

The installation is the reverse of removal proce-
dure.

MULTIFUNCTION SWITCH
Multifunction Switch Removal
Remove the front handlebar cover. See HANDLE-
vmr2008-145-006_a BAR COVERS above in this section.
1. Front handlebar cover Unplug multifunction switch connectors.
2. Rear handlebar cover

Rear Handlebar Cover

Remove the FRONT HANDLEBAR COVER, see
procedure above.
Remove screws securing the rear handlebar cover
to handlebar.

vmr2008-145 361
Section 08 CHASSIS
Subsection 02 (STEERING SYSTEM)

Slide rubber protector back to expose throttle ca-

ble adjuster.

vmr2008-145-013_a

1. Multifunction switch connectors

Remove screws securing multifunction switch.

V07I0GA 1 2 3 4
1. Cable protector
2. Throttle cable adjuster
3. Lock nut
4. Throttle lever housing

Loosen lock nut and fully tighten the throttle cable

adjuster.
Underneath throttle lever housing, remove
screws securing the housing clamp.
vmr2008-145-012_a

1. Multifunction switch screws

Separate multifunction switch from handlebar.

Multifunction Switch Installation

The installation is the reverse of the removal pro-
cedure.

THROTTLE LEVER
vmr2008-145-016_a

Throttle Lever Removal 1. Throttle lever housing screws

Remove the front handlebar cover. See HANDLE-
BAR COVERS above in this section. Separate throttle handle from handlebar.
Unplug 2/4WD switch connector. Remove inner housing protector.

vmr2008-145-015_a

1. 2/4WD switch connector

362 vmr2008-145
 Section 08 CHASSIS
Subsection 02 (STEERING SYSTEM)

– Multifunction switch (see procedure in this sec-

tion)
– Brake lever (see procedure in BRAKES section).
Remove both HANDLEBAR COVERS, see proce-
dure above in this section.
Unscrew 4 bolts securing handlebar to steering
column.

V07I0HA 1
1. Inner housing protector

Slide cable in clip slot and remove the end of the

cable from clip.
vmr2008-145-009_a

1. RH handlebar bolts

Move the connector plate with connectors aside.

vmr2008-145-010_a
V07I0IA
1. Connector plate
Remove throttle cable from housing.
Remove the handlebar clamps.
Throttle Lever Installation
For installation, reverse the removal procedure.
Adjust throttle cable. Refer to ELECTRONIC FU-
EL INJECTION section.

HANDLEBAR
Handlebar Removal
If the handlebar must be changed, remove all fol-
lowing components before removing it from vehi-
cle.
– Handlebar end weights vmr2008-145-011_a

– Throttle lever (see procedure in this section) 1. Handlebar clamps

2. Handlebar

vmr2008-145 363
Section 08 CHASSIS
Subsection 02 (STEERING SYSTEM)

Remove the handlebar.

Handlebar Inspection
Check handlebar for:
– Wear
– Cracks
– Bending.
Replace handlebar if any of these problems is de-
tected.
 WARNING vmr2008-145-021_a

Never try to weld or modify the handlebar. 1. RH handlebar screws

Always replace the handlebar with a new one.
Move handlebar with wires aside to make room.
Unscrew bolts securing the steering half supports.
Handlebar Installation
For the installation, reverse the removal proce-
dure.

STEERING COLUMN
Steering Column Removal
Remove the front fender. Refer to BODY section
for procedure.
Remove HANDLEBAR COVERS, see procedure in
this section. vmr2008-145-022_a

Cut the locking tie securing wires on the top of 1. Steering half supports bolts
2. Stopper plate
steering column. 3. Steering half supports
4. Bushings

At the bottom of steering column, remove and

discard the cotter pin.

vmr2008-145-020_a

1. Cut this locking tie

Remove bolts securing handlebar to steering col-

umn.
vmr2008-145-023_a

1. Cotter pin
2. Steering column

Remove the elastic stop nut and the washer. Dis-

card nut.

364 vmr2008-145
 Section 08 CHASSIS
Subsection 02 (STEERING SYSTEM)

vmr2008-145-024_a vmr2008-145-025_a

1. Elastic nut 1. Bearing flange bolts

2. Washer 2. Upper bearing flange

Separate steering column and tie-rods. Refer to Remove bearing.

TIE-ROD, further in this section.
Pull out steering column.

Steering Column Inspection

Check steering column for:
– Wear
– Cracks
– Bending.
Replace if any of these problems is detected. vmr2008-145-026_a

 WARNING 1. Steering column bearing

Never try to weld or modify the steering col- Check bearing flanges condition. Replace them if
umn. Always replace the column with a new wear is find.
one. Install the first bearing flange with the collar into
frame opening.
Check if steering column O-rings are:
Install the bearing.
– Brittle
– Hard Place the second bearing flange with the collar
upward.
– Otherwise damaged.
Replace them if necessary.
At the same time, check steering column bearing
condition. It must turn smoothly and freely. If not,
replace it.

Steering Column Bearing Replacement

While steering column is raised, unscrew bolts se-
curing bearing flanges to frame.

vmr2008-145-027_a

1. First bearing flange (collar downward)

2. Steering column bearing
3. Second bearing flange (collar upward)

Apply Loctite 243 (blue) (P/N 293 800 060) on

threads of bearing flange bolts.
Tighten them to 10 N•m (89 lbf•in).

vmr2008-145 365
Section 08 CHASSIS
Subsection 02 (STEERING SYSTEM)

Install steering column.

Steering Column Installation

For the installation, reverse the removal proce-
dure. Pay attention to the following.
Apply XP-S synthetic grease (P/N 529 550 010) on
steering column O-rings and on bushings.
Install a NEW steering column nut.
Install NEW cotter pins (steering column and tie vmr2008-145-029_a
rods). Both ends of cotter pins must be folded.
FROM STEERING COLUMN
1. Steering column lever
TIE-ROD 2. Cotter pin
3. Tie-rod nut
4. Hardened washers
Tie-Rod Removal
Place vehicle on a level surface. Remove tie-rod from vehicle.
Apply parking brake. Tie-Rod Inspection
Loosen wheel lug nuts. Inspect tie-rod ends for wear or looseness, if ex-
Lift the front of vehicle. cessive, replace.
Remove wheel. Tie-Rod Installation
From steering column and knuckle, remove: For the installation, reverse the removal proce-
– Cotter pins (discard) dure. However, pay attention to the following.
– Tie-rod end nuts Adjust the tie-rod length to 354 mm (13-15/16 in).
– Hardened washers.
Check the both unengaged threaded portion of tie-
rod.

vmr2008-145-030_a

A. Preliminary adjustment
B. Unengaged threads

TIE-ROD
vmr2008-145-028_a
Preliminary length
FROM KNUCKLE adjustment — dimension 354 mm (13–15/16 in)
1. Cotter pin “A”
2. Tie-rod end nut
3. Hardened washer Maximum unengaged
4. Knuckle 17.5 ± 5 mm
threads — dimension
(11/16 ± 3/16 in)
“B” *
* Dimension “B” to be approximately equal upon
assembly.

Tighten tie-rod lock nuts.

Install NEW cotter pins. Both ends of cotter pins
must be folded.
Perform steering alignment. Refer to ADJUST-
MENT at the beginning of this section.

366 vmr2008-145
 Section 08 CHASSIS
Subsection 02 (STEERING SYSTEM)

KNUCKLE
Knuckle Removal
Place vehicle on a level surface.
Loosen wheel lug nuts.
Lift the front of vehicle.
Remove wheel.
Remove wheel hub. Refer to WHEELS/TIRES
section.
Detach tie-rod end from knuckle. vmr2008-145-032_a

1. Knuckle
2. Lower ball joint bolt
3. Lower suspension arm

Remove the knuckle.

Knuckle Inspection
Check knuckle for cracks or other damages. Re-
place if necessary.
Check if wheel bearing turns freely and smoothly.
See WHEEL BEARING below if the replacement
is necessary.
vmr2008-145-031_a

1. Tie-rod end Knuckle Installation

2. Knuckle
The installation is the reverse of the removal pro-
Unscrew bolts holding strut to knuckle. cedure. However, pay attention to the following.
Install NEW cotter pins. Both ends of cotter pins
must be folded.
Verify steering alignment. Refer to ADJUST-
MENT at the beginning of this section.

WHEEL BEARING
Wheel Bearing Inspection
Raise the front of vehicle.
Hold the wheel by the top and the bottom and
move it. Check for lateral play.
vmr2008-142-002_a

1. Strut bolts
If there is any loose, replace the wheel bearing.
2. Knuckle NOTE: First, check if ball joint is loose. If neces-
sary repair all defective parts before checking the
Remove bolt that attaches lower ball joint to
wheel bearing condition. Be careful not to mis-
knuckle.
judge loose in the ball joint and loose in the wheel
bearing.

Wheel Bearing Removal

Remove the KNUCKLE, see procedure in this sec-
tion.
Using a flat screwdriver, remove and discard the
wheel bearing seal.

vmr2008-145 367
Section 08 CHASSIS
Subsection 02 (STEERING SYSTEM)

When knuckle is cold, install the circlip.

Install a NEW seal.
Install the other parts in the reverse order of re-
moval procedure.

V07I0RA

Remove the circlip securing the bearing into the

knuckle.
1

V07I0SA

1. Circlip

Using a press machine, push the bearing out of

knuckle.
NOTE: It may be necessary to heat the knuckle to
remove the bearing.

 WARNING
Clean all grease, outside and inside, from
knuckle before heating it.

Wheel Bearing Installation

Place the bearing in a freezer for 10 minutes be-
fore installing.
Place the knuckle in oven to 100°C (212°F) for
30 minutes maximum to ease bearing installation.

368 vmr2008-145
 Section 08 CHASSIS
Subsection 03 (FRONT SUSPENSION)

FRONT SUSPENSION
SERVICE TOOLS
Description Part Number Page
spring remover ..................................................................... 529 036 007 ......................................... 371

SERVICE PRODUCTS
Description Part Number Page
suspension grease................................................................ 293 550 033 ......................................... 374
Loctite 243 (blue).................................................................. 293 800 060 ......................................... 372

vmr2008-146 369
Section 08 CHASSIS
Subsection 03 (FRONT SUSPENSION)

Loctite 243
55 N•m
(41 lbf•ft)

105 N•m
61 N•m Suspension (77 lbf•ft)
(45 lbf•ft) grease
2.5 N•m
(22 lbf•in)

48 N•m
25 N•m (35 lbf•ft)
(18 lbf•ft)
61 N•m
(45 lbf•ft)

vmr2008-069-002_a

370 vmr2008-146
 Section 08 CHASSIS
Subsection 03 (FRONT SUSPENSION)

GENERAL
The procedure explained below is the same for the
RH and LH sides unless otherwise noted.
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for vmr2008-069-004_a

complete procedure. 1. Strut bolts

2. Strut
 WARNING 3. Knuckle

Torque wrench tightening specifications Remove the circlip and unscrew the strut nut.
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, cotter pins, etc.) must be replaced
with new ones.

Hoses or cables removed or disconnected must

be installed and routed at the same place.
CAUTION: Locking ties removed during a pro-
cedure must be replaced and installed at the
same location.

PROCEDURES vmr2008-146-003_a

1. Circlip
STRUT 2. Strut nut

Strut Removal Remove strut from vehicle.

Remove the front rack. Refer to BODY section.
Strut Disassembly
Remove the appropriate strut nut cap on the top
of the front fender. To remove spring from the strut, use the spring
remover (P/N 529 036 007).

529036007

Place the tool in a vise.

vmr2008-146-002_a

1. Strut nut caps

vmr2006-026-004
Loosen wheel lug nuts of the appropriate wheel.
Position the top of the strut in the tool.
Lift front of vehicle until front struts are fully ex-
tended.
Install a jack stand under the frame to support the
vehicle off the ground.
Remove wheel.
Unscrew bolts retaining strut to the knuckle.
vmr2008-146 371
Section 08 CHASSIS
Subsection 03 (FRONT SUSPENSION)

Strut Inspection
Inspect the spring for damage. Replace if neces-
sary.
Inspect strut as following:
Examine the strut for leaks.
Extend and compress the strut shaft several
times over its entire stroke.
Check that the strut shaft moves smoothly and
with uniform resistance with rod up.
Any of the following conditions will denote a de-
fective strut:
– A skip or hang up when reversing stroke at mid
vbs2006-004-006 travel.
The bottom extremity cannot be locked in place; – Seizing or binding conditions except at extreme
simply sit the bottom of strut as shown. end of either stroke.
– A gurgling noise after completing one full com-
pression and extension stroke.
Replace strut if any of these conditions are found.

Strut Assembly
For assembly, reverse the disassembly proce-
dures.

Strut Installation
For installation, reverse the removal procedures.
However, pay attention to the following.
Apply Loctite 243 (blue) (P/N 293 800 060) on
vbs2006-004-008 threads of strut nut.
Install the spring compressor pins to retain the Tighten strut nut to 55 N•m (41 lbf•ft).
strut spring. Install circlip. If the circlip appears loose, replace
Tighten the spring remover screw until the spring it with a new one.
is sufficiently compressed to remove spring lock- Install all other removed parts.
ing devices.
Remove spring stopper and its cap then loosen SUSPENSION ARM PROTECTOR
the spring remover screw.
Protector Inspection
Check protector for cracks or other damages. Re-
place if necessary.

Protector Removal
Remove bolts then the protector.

vmr2006-026-011

372 vmr2008-146
 Section 08 CHASSIS
Subsection 03 (FRONT SUSPENSION)

Check ball joint bellows on suspension arm for

cracks or any other damage. Inspect ball joint end
for damage. Ensure it's moving freely. Replace
ball joints as required, see below for procedure.

Suspension Arm Removal

Loosen wheel lug nuts of the appropriate wheel.
Lift front of vehicle until front struts are fully ex-
tended.
Install a jack stand under the frame to support the
vmr2008-146-004_a vehicle off the ground.
1. Bolts Remove wheel.
2. Protector
Remove bolt retaining ball joint to the knuckle.
Remove the protector.

Protector Installation
The installation is the reverse of removal proce-
dure.

SUSPENSION ARM
Suspension Arm Inspection
Check suspension arms for distortion or damage.
Replace suspension arms if necessary.
Move suspension arm from side to side. There
should be no noticeable loose. Replace bushings vmr2008-146-006_a

if necessary. 1. Suspension arm

2. Ball joint bolt
Move suspension arm up and down. There 3. Ball joint
should be no noticeable loose. Replace bushings 4. Knuckle

if necessary.
Separate suspension arm from knuckle.
The following items are performed when the sus-
Remove bolts retaining suspension arm to frame.
pension arm is removed.
Inspect pivot bushings and cushions for wear or
damages. Replace bushings and/or cushions if
necessary.

vmr2008-146-007_a

1. LH suspension arm bolts

Remove suspension arm from vehicle.

vmr2008-146-005_a

1. Pivot bushing Suspension Arm Installation

2. Cushions
For assembly, reverse the disassembly procedure.
However, pay attention to the following.
Install suspension arm to frame.

vmr2008-146 373
Section 08 CHASSIS
Subsection 03 (FRONT SUSPENSION)

Install suspension arm bolts as per following illus-

tration.

vmr2008-146-008_a

Torque suspension arm bolts to 61 N•m (45 lbf•ft).

Use suspension grease (P/N 293 550 033) to lubri-
cate both suspension arms. There are two grease
fitting on each arm.
Attach suspension arm to knuckle.
Install wheel. Refer to STEERING SYSTEM for
proper torque.

BALL JOINT
Ball Joint Inspection
Check ball joint for damage, pitting, looseness and
roughness. If so, replace it.
Check ball joint bellows for cracks. Change if nec-
essary.

Ball Joint Removal

Remove appropriate wheel.
Remove bolt securing ball joint to knuckle.
Unscrew bolts retaining ball joint to suspension
arm.
Extract the ball joint by pulling it out of suspension
arm.

vmr2008-069-013_a

1. Bolts securing ball joint

2. Ball joint

Ball Joint Installation

The installation is the reverse of removal proce-
dure.
374 vmr2008-146
 Section 08 CHASSIS
Subsection 04 (REAR SUSPENSION)

REAR SUSPENSION
SERVICE TOOLS
Description Part Number Page
Bearing extractor/installer..................................................... 529 035 918 ......................................... 383
Bearing extractor/installer..................................................... 529 035 920 ......................................... 383
trailing arm support............................................................... 529 035 922 ......................................... 382
trailing arm nut socket .......................................................... 529 035 925 ................................. 381, 384
spring remover ..................................................................... 529 036 007 ......................................... 378

SERVICE PRODUCTS
Description Part Number Page
Loctite 271 (red) ................................................................... 293 800 005 ................................. 380, 384

vmr2008-147 375
Section 08 CHASSIS
Subsection 04 (REAR SUSPENSION)

190 N•m
(140 lbf•ft)

Loctite 271

See
Loctite 271 procedure
inside

NEW

53 N•m
(39 lbf•ft)

NEW

53 N•m
(39 lbf•ft)

NEW

vmr2008-147-001_a

376 vmr2008-147
 Section 08 CHASSIS
Subsection 04 (REAR SUSPENSION)

GENERAL
The procedure described below is the same for
the RH and LH sides, unless otherwise instructed.
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.


vmr2008-147-002_a
WARNING 1. Adjusting cams
Torque wrench tightening specifications 2. Smooth adjustment
3. Hard adjustment
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pins,
etc.) must be replaced with new ones. PROCEDURES

Hoses or cables removed or disconnected must SHOCK ABSORBER

be installed and routed at the same place.
Shock Absorber Removal
CAUTION: Locking ties removed during a pro-
cedure must be replaced and installed at the Lift rear of vehicle until rear shock absorbers are
same location. fully extended.
Install jack stands or blocks under the frame to
ADJUSTMENT support the vehicle.
Remove the shock absorber lower bolt.
SPRING PRELOAD
 WARNING
Left and right adjustment cams must always
be set to the same position. Never adjust
one adjusting cam only. Uneven adjustment
can cause poor handling and loss of stability,
which could lead to an accident.

Adjust spring preload by turning adjusting cam ac-

cordingly, with the adjusting wrench in vehicle tool
kit.
Turn the adjusting cams clockwise for a firmer ride vmr2008-147-003_a

and rough road condition or when carrying cargo 1. Shock absorber lower bolt
or pulling a trailer. 2. RH shock absorber

Turn the adjusting cams counterclockwise for a Remove the shock absorber after removing the
light load and a smooth road condition. shock absorber upper bolt.

vmr2008-147 377
Section 08 CHASSIS
Subsection 04 (REAR SUSPENSION)

vmr2008-147-004_a vmr2006-026-011

1. Shock absorber upper bolt

Remove spring from shock.

Shock Absorber Disassembly Shock Absorber Inspection

Inspect the spring for damage. Replace if neces-
Use the spring remover (P/N 529 036 007).
sary.
Secure the end of shock body in a vise with its rod
upward.
1
529036007

Place the tool in a vise.

Position the shock absorber in the tool and install
the spring compressor pins. A14F0BA

TYPICAL
1. Clamp here

CAUTION: Do not clamp directly on shock

body.
Inspect shock absorber as following:
Examine the shock absorber for leaks.
Extend and compress the shock absorber shaft
several times over its entire stroke.
vmr2006-026-010 Check that the shock absorber shaft moves
smoothly and with uniform resistance with its
Tighten the spring remover screw until the spring rod upward.
is sufficiently compressed to remove spring lock-
ing devices. Any of the following conditions will denote a de-
fective shock absorber:
Remove spring stopper and its cap then loosen
the spring remover screw. – A skip or a hang back when reversing stroke at
mid travel.
– Seizing or binding condition except at extreme
end of either stroke.
– A gurgling noise, after completing one full com-
pression and extension stroke.
Replace shock absorber if any faults are present.

Shock Absorber Assembly and

Installation
Assembly and installation are essentially the re-
verse of disassembly and removal procedures.
378 vmr2008-147
 Section 08 CHASSIS
Subsection 04 (REAR SUSPENSION)

NOTE: Install cap opening at 180° from spring

stopper opening.

TORSION BAR
Torsion Bar Removal
Apply parking brake and lift rear of vehicle until rear
shock absorbers are fully extended.
Install a jack stand or blocks under the frame to
safely support the vehicle.
vmr2008-147-007_a

Remove both footrests. Refer to BODY section. 1. Torsion bar nut

Remove and discard Oetiker clamps securing pro-
tective covers. Remove the flat washer.

vmr2008-147-005_a vmr2008-147-008_a

1. Protective cover clamp 1. Flat washer

Remove protective covers. Heat the torsion bar lever to break the threadlock-
er. Pull and remove the torsion bar lever.

vmr2008-147-006_a
vmr2008-147-009_a
1. Protective cover
1. Torsion bar lever
Unscrew and discard a torsion bar nut.
From the other side of vehicle, remove the torsion
CAUTION: Unscrew nut slowly to avoid dam- bar.
aging threads and jamming nut on torsion bar.

vmr2008-147 379
Section 08 CHASSIS
Subsection 04 (REAR SUSPENSION)

vmr2008-147-010_a

Remove torsion bar nut, washer and torsion bar vmr2008-147-011_a

lever. 1. Torsion bar lever tab

2. Trailing arm slot
Discard torsion bar nut. 3. Arrow upward

Torsion Bar Inspection Install the flat washer and a NEW elastic nut.
Check torsion bar for: Tighten first the RH elastic nut of torsion bar lever
– Cracks to 55 N•m (41 lbf•ft).
– Bending Tighten the LH elastic nut of torsion bar lever to
– Other damages. 120 N•m (89 lbf•ft).
Check torsion bar splines for damages. Reinstall both protective covers with NEW
clamps.
Verify torsion bar lever tabs for:
– Racking TRAILING ARM
– Cracks
– Other damages. Trailing Arm Removal
NOTE: If a tab is damaged, check the trailing arm Apply parking brake and lift rear of vehicle until rear
for damages. shock absorbers are fully extended.
Replace all damaged parts. Install a jack stands or a blocks under the frame to
safely support the vehicle.
Torsion Bar Installation Remove wheel hub. Refer to WHEELS/TIRES
Insert the torsion bar into the frame. section.
Apply a line of Loctite 271 (red) (P/N 293 800 005) Remove and discard Oetiker clamps securing pro-
all around torsion bar splines and on splines of tor- tective covers.
sion bar lever.

vmr2008-147-005_a
vmr2008-147-017_a
1. Protective cover clamp
1. Apply Loctite 271 here

Remove protective covers.

Install both torsion bar levers with the arrows up-
ward. Align lever tabs with trailing arm slots.

380 vmr2008-147
 Section 08 CHASSIS
Subsection 04 (REAR SUSPENSION)

vmr2008-147-006_a vmr2008-147-009_a

1. Protective cover 1. Torsion bar lever

Unscrew and discard a torsion bar nut. Remove the circlip retaining the trailing arm nut.
CAUTION: Unscrew nut slowly to avoid dam-
aging threads and jamming nut on torsion bar.

vmr2008-147-012_a
vmr2008-147-007_a
1. Circlip
1. Torsion bar nut
Heat the trailing arm nut to break the threadlocker.
Remove the flat washer.
Using the trailing arm nut socket (P/N 529 035
925), unscrew the trailing arm nut.

vmr2008-147-008_a

1. Flat washer

Heat the torsion bar lever to break the threadlock- 529035925

er. Pull and remove the torsion bar lever.

vmr2008-147 381
Section 08 CHASSIS
Subsection 04 (REAR SUSPENSION)

vmr2008-147-013_a

vmr2008-147-015_a
1. Trailing arm nut
WHEEL SIDE
Unscrew lower bolt of shock absorber. 1. Circlip

Remove trailing arm.

Trailing Arm Inspection

Verify trailing arm for:
– Cracks
– Bending
– Other damages.
Replace trailing arm if necessary.
Check inner race of each bearing with a finger.
The bearings should turn smoothly and quietly.
Remove and discard bearings if race does not turn
smoothly or quietly. vmr2008-147-016_a

FRAME SIDE
Trailing Arm Bearing Replacement 1. Circlip

The same procedure can be used for both bear- Place the trailing arm support (P/N 529 035 922)
ings. on the end of trailing arm.
Before extracting the bearing on wheel side, re-
move the trailing arm protector by drilling the pop
rivets with a 3/16” drill.

vmr2008-147-014_a

1. Trailing arm protector

V07H1NA
2. Rivets
WHEEL SIDE
Remove the circlip.

382 vmr2008-147
 Section 08 CHASSIS
Subsection 04 (REAR SUSPENSION)

V07H1OA

FRAME SIDE

Using a press and the proper bearing extractor/in- V07H1QA

staller, remove the bearing.

FRAME SIDE

LOCATION TOOL Clean the bearing housing.

Bearing To install the bearing in its location, use the same
Wheel side extractor/installer tool as per removal procedure.
(P/N 529 035 918)
Bearing
Frame side extractor/installer
(P/N 529 035 920)

V07H1RA

WHEEL SIDE

V07H1PA

WHEEL SIDE

vmr2008-147 383
Section 08 CHASSIS
Subsection 04 (REAR SUSPENSION)

vmr2008-147-012_a

1. Circlip

Finalize the torsion bar installation. Refer to TOR-

SION BAR in this section.
Tighten shock absorber lower bolt.
Wheel Side
V07H1HA
Install wheel hub. Refer to WHEELS/TIRES sec-
tion for complete procedure.
FRAME SIDE

Install the circlip. If the circlip is slacked, replace

it with a new.
Install all other removed parts.

Trailing Arm Installation

Insert drive shaft end into trailing arm.
Install the trailing arm on frame.
Install the shock absorber lower bolt to support
the trailing arm. Do not torque yet.
Frame Side
Apply Loctite 271 (red) (P/N 293 800 005) on
threads of frame extensions.
Install the trailing arm nut and torque it to 190 N•m
(140 lbf•ft) using the trailing arm nut socket
(P/N 529 035 925).
Install the circlip retaining the trailing arm nut.

384 vmr2008-147
 Section 08 CHASSIS
Subsection 05 (BRAKES)

BRAKES
SERVICE TOOLS
Description Part Number Page
vacuum/pressure pump........................................................ 529 021 800 ......................................... 390

SERVICE PRODUCTS
Description Part Number Page
dielectric grease ................................................................... 293 550 004 ......................................... 393
XP-S synthetic grease........................................................... 293 550 010 ................................. 395, 399
brake fluid GTLMA (DOT 4) .................................................. 293 600 062 ......................................... 389
Loctite 243 (blue).................................................................. 293 800 060 ......................................... 400

vmr2008-148 385
Section 08 CHASSIS
Subsection 05 (BRAKES)

FRONT BRAKE CIRCUIT (EXCEPT 2009 CE MODELS)

1 N•m
6 N•m (9 lbf•in)
(53 lbf•in)

9 N•m
(80 lbf•in)

NEW 28 N•m
(21 lbf•ft)

17 N•m
(150 lbf•in) 5 N•m
(44 lbf•in)
6 N•m
34 N•m (53 lbf•in)
(25 lbf•ft)

38 N•m
(28 lbf•ft)
NEW
NEW
28 N•m
(21 lbf•ft)
NEW
34 N•m
20 N•m (25 lbf•ft)
(15 lbf•ft)

38 N•m
(28 lbf•ft)
NEW
vmr2008-148-001_a

386 vmr2008-148
 Section 08 CHASSIS
Subsection 05 (BRAKES)

FRONT BRAKE CIRCUIT (2009 CE MODELS)

1 N•m
(9 lbf•in)

6 N•m 28 N•m
(53 lbf•in) NEW (21 lbf•ft)

6 N•m
(53 lbf•in)

9 N•m
(80 lbf•in)
28 N•m
17 N•m (21 lbf•ft)
(150 lbf•in)
5 N•m
(44 lbf•in) 10 N•m NEW
(89 lbf•in)

NEW NEW
28 N•m
(21 lbf•ft)

10 N•m
(89 lbf•in)

34 N•m
(25 lbf•ft) Loctite
243
38 N•m
(28 lbf•ft) NEW
NEW NEW 28 N•m
(21 lbf•ft)
28 N•m
(21 lbf•ft)

NEW

20 N•m 34 N•m
(15 lbf•ft) (25 lbf•ft)

38 N•m
(28 lbf•ft)
NEW
vmr2008-148-015_a

vmr2008-148 387
Section 08 CHASSIS
Subsection 05 (BRAKES)

REAR BRAKE CIRCUIT

25 N•m
(18 lbf•ft)
20 N•m NEW
NEW
(15 lbf•ft)

28 N•m 5 N•m
(21 lbf•ft) (44 lbf•in)
XP-S synthetic
grease
48 N•m
(35 lbf•ft)

NEW

25 N•m
(18 lbf•ft)

NEW
34 N•m
(25 lbf•ft) 2.5 N•m
(22 lbf•in)

5 N•m 17 N•m
(44 lbf•in) (150 lbf•in)

vmr2008-148-021_a

388 vmr2008-148
 Section 08 CHASSIS
Subsection 05 (BRAKES)

GENERAL  WARNING
During assembly/installation, use the torque val- Periodically check the brake hoses for dam-
ues and service products as in the exploded ages or leaks. Repair any damage before op-
views. erating the vehicle.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for Parking Brake
complete procedure. To engage mechanism: Squeeze the brake
lever and maintain while moving locking lever.
 WARNING The brake lever is now compressed and applying
Torque wrench tightening specifications all brakes.
must be strictly adhered to. NOTE: The locking lever can be adjusted in several
Locking devices (e.g.: locking tabs, elastic positions.
stop nuts, self-locking fasteners, cotter pins,
etc.) must be replaced with new ones. 2 1

Hoses or cables removed or disconnected must

be installed and routed at the same place.
CAUTION: Locking ties removed during a pro-
cedure must be replaced and installed at the
same location.

 WARNING
Never apply anything to brake fittings, The
use of threads sealant or Teflon tape could
cause brake system failure. Severe injury or
death can occur.

CAUTION: Avoid spilling brake fluid on plas-

tic, rubber or painted parts. Protect these parts V07K02A

with a rag when servicing brake system. 1. Parking brake lever

2. Press to apply parking brake
CAUTION: To avoid serious damage to the
brake system, use only DOT 4 brake fluid from
To release mechanism: Squeeze brake lever.
a sealed container. Do not use brake fluid
taken from old or already opened containers, Locking lever and brake lever should automatically
nor mix different fluids for topping off. returns to their original position.
CAUTION: Sealing washers must be discarded CAUTION: Always release parking brake before
and replaced with new ones every time a Banjo riding.
fitting is loosen.
CAUTION: Before opening or working near MAINTENANCE
bleeders, reservoirs or fittings, clean the part
and its area to avoid system contamination. BRAKE FLUID
Dispose brake fluid as per your local environmen-
tal regulation. Recommended Brake Fluid
Always use brake fluid meeting the specification
SYSTEM DESCRIPTION DOT 4 only such as brake fluid GTLMA (DOT 4)
(P/N 293 600 062).
The brake system consists of two circuits. Each
system has its own master cylinder and reservoir. Brake Fluid Level Verification
Both front and rear brakes are disc type. With vehicle on a level surface, check brake fluid
in reservoirs for proper level.
Clean reservoir cover before removing.
Add fluid as required. Do not overfill.
vmr2008-148 389
Section 08 CHASSIS
Subsection 05 (BRAKES)

NOTE: A low level may indicate leaks or worn Brake Fluid Replacement
brake pads. To replace brake fluid, follow the brake bleeding
Brake Lever Fluid Reservoir procedure and replenish system with new brake
fluid.
Turn steering in the straight-ahead position to en-
sure reservoir is level. Brake Fluid Draining
Squeeze and release the brake lever. Clean and remove reservoir cover.
Check the fluid level. The reservoir is full when Remove the diaphragm.
the fluid reaches the top of windows.
Connect a clear hose to bleeder.
Loosen bleeder and pump brake lever or brake
pedal until no more fluid flows out through the
clear hose.

Brake Bleeding
General Recommendations
Fill reservoirs to recommended level using recom-
mended brake fluid only.
Check brake fluid level regularly during the bleed-
ing procedure to prevent air from being pumped
V07K0AA
into the system.
Visually inspect lever boot condition. Check for For the front brakes bleed alternately the LH and
cracks, tears, etc. Replace if damaged. RH calipers. Turn handlebar to full RH side when
bleeding right caliper and turn to the LH side for
Brake Pedal Fluid Reservoir the left caliper. This helps to bleed the air.
Place the vehicle on a level surface.
Preparation
Check brake fluid in reservoir. The brake fluid
Place vehicle on a level surface.
must be above the MIN. mark.
Loosen front wheel lug nuts.
Secure front of vehicle on jack stands.
Remove front wheels.
NOTICE Never use any type of impact wrench
for lug nut removal and installation. The use
of impact wrench could damage the wheel stud
threads or lug nuts.
Bleed system as per one of the following proce-
dures.
Bleeding Procedure Using a Vacuum Pump
Install the vacuum/pressure pump (P/N 529 021
800) on a bleeder.

vmo2006-007-017_a 529 021 800

INSIDE SERVICE COMPARTMENT

390 vmr2008-148
 Section 08 CHASSIS
Subsection 05 (BRAKES)

Pump vacuum pump then loosen bleeder.

Pump until no more air bubbles appear in clear
hose.
Close bleeder.
Operate brake lever or brake pedal (except for CE
models, continue bleeding procedure. Refer to
BRAKE BLEEDING (ADDITIONAL STEPS FOR CE
MODELS)). If it still feels spongy, bleed system
again.
If necessary, repeat the previous procedures un- vmr2008-148-017_a

til air bubbles do not appear in hose and lever or 1. Splitter bleeder
pedal is stiff. 2. LH front shock absorber

Top up reservoirs to the appropriate level. Pump vacuum pump then loosen bleeder.
Install diaphragms and covers on reservoirs. Repeat the procedure until no more air bubbles
Wipe any brake fluid spillage. appear in hose and lever is stiff.
Check brakes operation before riding the vehicle. Close bleeder.
Manual Bleeding Procedure NOTE: Do not release brake lever until bleeder has
been closed.
Install a clear hose on a bleeder.
Check brakes operation before riding the vehicle.
Place the other end of hose in a small container
partially filled with clean brake fluid. Manual Bleeding Procedure
Carefully pump the brake lever or the brake pedal Pump the brake lever again and hold it while open-
few times and hold it while opening the bleeder. ing the bleeder on the brake circuit splitter.
NOTE: When bleeder is opened, brake fluid flows
out of caliper and the brake lever moves toward
the handlebar or the brake pedal moves down.
Retighten the bleeder, then release brake lever or
brake pedal gradually.
Repeat the procedure until no more air bubbles
appear in hose and lever or pedal is stiff (except for
CE models, continue bleeding procedure. Refer
to BRAKE BLEEDING (ADDITIONAL STEPS FOR
CE MODELS)).
Top up reservoirs to the appropriate level. vmr2008-148-017_a

Install diaphragm and cover on reservoirs. 1. Splitter bleeder

2. LH front shock absorber
Wipe any brake fluid spillage.
Check brakes operation carefully before riding the When lever is down, close the bleeder and release
vehicle. the brake lever gradually.
Repeat the procedure until no more air bubbles
Brake Bleeding appear in hose and lever is stiff.
(Additional Steps for CE Models) Close bleeder.
Procedure Using a Vacuum Pump NOTE: Do not release brake lever until bleeder has
Install the vacuum/pressure pump on the bleeder been closed.
of the brake circuit splitter. Top up reservoirs to the appropriate level.
Install diaphragm and cover on reservoirs.
Wipe any brake fluid spillage.
Check brakes operation before riding the vehicle.

vmr2008-148 391
Section 08 CHASSIS
Subsection 05 (BRAKES)

PROCEDURES
BRAKE LIGHT SWITCH
Brake Light Switch Test
NOTE: First, ensure brake light is good.
Remove the LH inner fender. Refer to BODY sec-
tion.
Disconnect brake light switch connector.
vmr2008-071-006_a

1. Brake light switch

Remove LH and RH footwells. Refer to BODY

section.
Cut locking ties securing brake light switch wires.

vmr2008-148-004_a

1. Brake light switch connector

Check switch operation as follows.

BRAKE SWITCH
PIN RESISTANCE
POSITION
vmr2008-148-005_a
Firmly pushed 0.2 max.
1 2 Disconnect brake light switch connector.
Released Infinite (OL)
Place a container under brake light switch area to
If switch is defective, replace with a new one. catch brake fluid.
If the switch test good, verify wire continuity be- Unscrew brake light switch from master cylinder.
tween brake switch and ECM. CAUTION: When brake light switch is removed,
cleanliness must be observed. Clean area be-
ECM fore disassembly.
BRAKE
CONNECTOR RESISTANCE Discard the sealing washers.
SWITCH PIN
PIN
B-23 RED Close to 0 Brake Light Switch Installation
For installation, reverse the removal procedure.
Brake Light Switch Removal However, pay attention to the following.
The brake switch is located on the rear master Install the brake light switch using two NEW seal-
cylinder and cannot be adjusted. ing washers.
Fill and bleed the brake system. Refer to BRAKE
BLEEDING in this section.
Check for leaks and make sure the brakes operate
normally before driving.

392 vmr2008-148
 Section 08 CHASSIS
Subsection 05 (BRAKES)

PARKING BRAKE MECHANISM

Parking Brake Mechanism Removal
Unscrew the nut underneath the brake lever.
Remove the parking lever lock pivot and the
spring.
Remove the parking lever lock.
3
vmr2008-148-002_a

1. Brake lever
2. Brake lever pivot
3. Brake lever pivot nut
4. Parking brake lever

Brake Lever Inspection

Check brake lever for bending, cracks or other
damages. Replace if necessary.

Brake Lever Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
V07K07A 4 2 1 Apply dielectric grease (P/N 293 550 004) to the
brake lever contacting surface of the piston.
1. Parking lever lock
2. Spring Apply dielectric grease (P/N 293 550 004) on brake
3. Parking lever lock pivot
4. Nut lever pivot.

MASTER CYLINDERS
Parking Brake Mechanism Installation
For installation, reverse the removal procedure. Front Master Cylinder Removal
See the following illustration to install the spring NOTE: If the master cylinder is not replaced, omit
properly. the next steps concerning the brake fluid draining
as well as brake hose and brake lever removal.
CAUTION: When hoses are disconnected,
cleanliness must be observed. Clean all parts
before disassembly.
Drain brake fluid, see BRAKE FLUID DRAINING at
the beginning of this section.
Remove Banjo fitting and sealing washers retain-
ing brake hose to front master cylinder. Discard
sealing washers.

V07K08A

BRAKE LEVER
Brake Lever Removal
Unscrew nut securing the brake lever pivot.
Unscrew the brake lever pivot.
vmr2008-148 393
Section 08 CHASSIS
Subsection 05 (BRAKES)

vmr2008-148-009_a
vmr2008-071-007_a
1. Banjo fitting
2. Sealing washers 1. Brake light switch
3. Brake hose 2. Brake pedal fluid reservoir hose
4. Front master cylinder reservoir 3. Rear brake hose

Remove BRAKE LEVER from master cylinder, see Unscrew the front brake hose.
procedure above in this section. NOTE: At this time, check hoses and fittings for
Remove screws securing master cylinder to han- damages or leaks.
dlebar. Unhook push rod from brake pedal.
Remove and discard screws securing master
cylinder to frame.

2
3

vmr2008-148-003_a

1. Master cylinder screws 1

V07K0XA

Remove the master cylinder.

1. Front hose
2. Push rod lock
Rear Master Cylinder Removal 3. Master cylinder screws

NOTE: If the master cylinder is not replaced, omit

Remove master cylinder.
the next steps concerning the brake fluid draining
as well as brake light switch and brake hoses re- Front Master Cylinder Disassembly
moval.
No internal parts of master cylinder are available.
CAUTION: When hoses are disconnected, Replace master cylinder as an assembly.
cleanliness must be observed. Clean all parts
before disassembly. Rear Master Cylinder Disassembly
Remove the LH and RH footwells. Refer to BODY Remove hook from master cylinder rod.
section.
Drain brake fluid, see BRAKE FLUID DRAINING at
the beginning of this section.
Remove BRAKE LIGHT SWITCH , see procedure
above in this section.
Disconnect the brake pedal fluid reservoir hose
from the top of master cylinder.

394 vmr2008-148
 Section 08 CHASSIS
Subsection 05 (BRAKES)

With the handlebar in straight ahead position,

position master cylinder reservoir parallel to the
ground. Tighten upper screw first.

vmr2008-033-035_a

1. Hook
2. Locking nut
3. Master cylinder rod

Remove boot, snap ring and push rod.

Master Cylinder Inspection

(Front and Rear)
Check boot for crack.
V07K0KA
Check spring for damage.
Check push rod for wear or bending. Connect brake hose to master cylinder with Banjo
fitting and two NEW sealing washers.
Change part(s) if necessary.
Fill and bleed brake system. Refer to BRAKE
NOTE: If master cylinder housing is damaged or BLEEDING in this section.
leaking, replace as an assembly.
Check for leaks and make sure the brakes operate
Rear Master Cylinder Assembly normally before driving.
The assembly is the reverse of the disassembly Rear Master Cylinder Installation
procedure. However, pay attention to the follow-
ing. For the installation, reverse the removal proce-
dure, pay attention to the following details.
Apply XP-S synthetic grease (P/N 293 550 010) on
both end of push rod. Secure master cylinder to frame using NEW
screws.
Install the push rod then adjust push rod length.
Hook push rod on brake pedal.
Connect front brake hoses on master cylinder.
Connect brake pedal fluid reservoir hose on the
top of master cylinder.
Fill up reservoir with clean brake fluid.
Bleed brake system, see procedure in BRAKE
BLEEDING at the beginning of this section.
vmr2008-148-007_a Check for leaks and make sure the brakes operate
A. 44 ± 1 mm (1.732 ± .039 in) normally before driving.

CALIPERS
Front Master Cylinder Installation
For the installation, reverse the removal proce- Caliper Removal (Front and Rear)
dure, pay attention to the following details. Park vehicle on a firm level surface.
Place the brake lever assembly on the handlebar. Loosen wheel lug nuts.
Position master cylinder bracket with the UP mark Raise vehicle and support it securely.
upward.
Remove appropriate wheel.
Install master cylinder screws and tighten loosely.
NOTE: If the caliper is not replaced, omit the next
steps concerning the brake system draining and
brake hose removal.
vmr2008-148 395
Section 08 CHASSIS
Subsection 05 (BRAKES)

CAUTION: Do not let caliper hangs by the hose Caliper Installation (Front and Rear)
and do not stretch or twist the hose. Simply For the installation, reverse the removal proce-
hang it with a piece of wire to take the weight
off the brake hose. dure, pay attention to the following details.
Drain brake system. Refer to BRAKE FLUID Use two NEW sealing washers when installing
DRAINING in this section. Banjo fitting retaining brake hose to caliper.
Remove the Banjo fitting securing brake hose to Install caliper in its original position.
caliper. Torque screws in accordance with the following
table.
CAUTION: When hoses are disconnected,
cleanliness must be observed. Clean all parts
before disassembly. CALIPER SCREWS TORQUE

Discard sealing washers. Front caliper 34 N•m (25 lbf•ft)

Remove caliper screws. Rear caliper 25 N•m (18 lbf•ft)

Fill and bleed the brake system. Refer to BRAKE

BLEEDING at the beginning of this section.
Check for leaks and make sure the brakes operate
normally before driving.

BRAKE PADS
Brake Pad Removal
Place vehicle on a firm level surface.
vmr2008-148-006_a
Loosen wheel lug nuts.
FRONT CALIPER Raise vehicle and support it securely.
1. Caliper screw
Remove appropriate wheel.
Loosen pad pins.

1
2
V07K0ZA vmr2008-148-008_a

REAR CALIPER 1. Pad pins

1. Banjo fitting and sealing washers 2. Caliper
2. Caliper screws 3. Pad

Catch spilled fluid with a rag. Remove CALIPER, see procedure above in this
section.
Caliper Inspection (Front and Rear) Unscrew pad pins then remove pads.
Check piston for: CAUTION: Do not let the caliper hang by the
– Rust hose and do not stretch or twist the hose.
– Scratches
– Leaks.
Replace caliper if necessary.

396 vmr2008-148
 Section 08 CHASSIS
Subsection 05 (BRAKES)

Brake Pad Inspection

CAUTION: Do not clean brake pads in petrole-
um based solvent. Use brake system cleaner
only. Soiled brake pads must be replaced with
new ones.
Measure brake pad lining thickness or look at the
hollow places on both sides on the pad lining.

SERVICE LIMIT
Brake pad thickness 1 mm (1/32 in)

There are four hollow places on one set of brake V02K0BA 1 2

pads. When the pad wear reaches one of the hol-
1. Pad spring
low places, the pad must be changed even if the 2. Piston
pad wear does not reach another hollow place.
Install new brake pads.
Install pad pins by pushing in the pads against pad
1
spring to align pad slots in the pads and caliper
body.
Install brake caliper so the disc is positioned be-
tween pads.
V02K0FA NOTE: Be careful not to damage pads and make
1. Hollow place sure pads are correctly inserted in their location.
Check fluid level in master cylinder reservoirs and
 WARNING top up if necessary.
Avoid getting oil or grease on brake pads. After the job is completed, firmly depress the
Contaminated brake pads can affect stopping brake lever a few times to bring the pads in con-
capacities. tact with the disc.
Check for leaks and make sure the brakes operate
CAUTION: Brake pads must always be replaced normally before driving. The pads must rest flat
in pairs. on the disk.
Brake Pad Installation
BRAKE DISCS
Clean the visible portion of piston with clean brake
fluid. Brake Disc Inspection (Front and Rear)
Push caliper pistons inward before installing brake Brake discs can be inspected without removing
pads. them from the vehicle.
NOTE: Use a C-clamp or another suitable tool. To Raise vehicle and support it securely. Remove
avoid damaging the piston, use an old pad to push wheels and visually inspect disc surfaces for
it into the caliper. scratches or grooves. Make sure to check both
Make sure that pad spring is in position. sides of disc.
Measure thickness of the disc.

DISC MINIMUM THICKNESS

Front 3.5 mm (.138 in)
Rear 4.3 mm (.170 in)

Replace disc if not within specifications.

CAUTION: Brake discs should never be ma-
chined.
Turn the disc by hand and check warpage.
vmr2008-148 397
Section 08 CHASSIS
Subsection 05 (BRAKES)

MAXIMUM DISC WARPAGE Front Brake Disc Installation

Front The installation is the reverse of removal proce-
0.2 mm (.01 in) dure. However, pay attention to the following de-
Rear tails.
The Belleville washers must be installed with
Front Brake Disc Removal theirs concave side toward the brake disc.
Apply parking brake and raise the front of the ve- Install NEW brake disc screws.
hicle.
Remove the appropriate knuckle. Refer to STEER-  WARNING
ING SYSTEM section. Never substitute Belleville washer with an-
Remove the inner fender. Refer to BODY section. other type of washer (flat, lock, etc.).
Unscrew and discard brake disc screws.
Keep the Belleville washers. Rear Brake Disc Installation
Secure brake disc on propeller shaft using NEW
screws.
Brake disc screws must be tighten in a crisscross
sequence.

BRAKE PEDAL
Brake Pedal Removal
Remove RH footwell. Refer to BODY section.
Remove the return spring.
vmr2008-148-010_a

1. Brake disc screw

Remove the push rod hook.
2. Belleville washer
3. Brake disc

Release parking brake and remove CALIPER. See

procedure above in this section.
Remove brake disc. Pay attention not to cut the
CV boot.

Rear Brake Disc Removal

Remove the rear propeller shaft. Refer to REAR
DRIVE section.
Unscrew and discard brake disc screws. Heat up
brake disc around screws to facilitate removal. vmr2008-148-012_a

1. Return spring
2. Push rod hook
3. Brake pedal

Remove bolt retaining the brake pedal to frame.

vmr2008-148-011_a

1. Brake disc screws

398 vmr2008-148
 Section 08 CHASSIS
Subsection 05 (BRAKES)

Drain brake fluid. Refer to BRAKE FLUID DRAIN-

ING at the beginning of this section.
Disconnect brake light switch connector.

vmr2008-148-013_a

1. Retaining bolt
2. Brake pedal

Brake Pedal Inspection

vmr2008-148-004_a
Check brake pedal for: 1. Brake light switch connector
– Cracks
– Distortion. Remove all brake hoses from the splitter and dis-
Check if O-rings are: brittle, hard or otherwise card the sealing washers.
damaged.
– Brittle
– Hard
– Otherwise damaged.
Check inner bushing for wear.
Replace any defective parts.

Brake Pedal Installation

For installation, reverse the removal procedure.
Apply XP-S synthetic grease (P/N 293 550 010) on
both O-rings and on external diameter of bushing. vmr2008-148-018_a

1. Brake hoses
2. Splitter

CAUTION: When hoses are disconnected,

cleanliness must be observed. Clean all parts
before disassembly.
Unscrew splitter retaining screws. Do not remove
screws yet.

vmr2008-148-014_a

1. Apply grease here

BRAKE CIRCUIT SPLITTER

2009 CE Models
Brake Circuit Splitter Removal
Remove the LH inner fender. Refer to BODY sec-
tion.
vmr2008-148 399
Section 08 CHASSIS
Subsection 05 (BRAKES)

Connect the brake light switch.

Install the inner fender.

BRAKE HOSES
Brake Hose Inspection
Brake hoses should be inspected frequently for
leaks and damages.
Check if the hoses are crushed or damaged. Any
deformation can restrict the proper flow of fluid
and cause braking problems.
vmr2008-148-019_a

1. Splitter
Check hoses for cracking or scrapes. This dam-
2. Retaining screws age can cause hose failure under pressure.
Replace any defective parts.
Before pulling the splitter, place your hand under it
to catch both shims. Shims are located between Brake Hose Removal
splitter and frame.
CAUTION: When hoses are removed or discon-
Pull the splitter to remove it. nected, cleanliness must be observed. Clean
Wipe brake fluid spillages. all joints and connections before disassembly.
NOTE: Before removing any hoses, drain brake
Brake Circuit Splitter Installation system.
The installation is the reverse of the removal pro- Remove all necessary parts to reach the hoses.
cedure. However, pay attention to the following.
Thoroughly clean the area around the joints that
Install shims behind splitter. will be disconnected.
Apply Loctite 243 (blue) (P/N 293 800 060) on Place a drain pan under the joint that will be dis-
threads of splitter screws. connected.
Install splitter and tighten screws to 10 N•m Disconnect any retaining clips or brackets holding
(89 lbf•in). the hose and remove the defective part(s).
Using NEW sealing washers, connect brake
hoses. Use the next illustration to position hoses Brake Hose Installation
correctly. Install the hose.
CAUTION: New hoses should be cleaned with
brake fluid before installation to remove any
contamination.
Make sure the hose will not rub against any other
part.
When there is a Banjo fitting securing the hose
to the caliper or to the master cylinder, always re-
place the sealing washers with NEW ones.

vmr2008-148-020_a

1. From front master cylinder

2. From front brakes
3. Toward RH front caliper
4. Toward LH front caliper
5. Toward front master cylinder
6. Toward front brakes

Tighten all Banjo fittings to 28 N•m (21 lbf•ft).

Refill and bleed the system. Refer to BRAKE
BLEEDING at the beginning of this section.
400 vmr2008-148
 Section 08 CHASSIS
Subsection 05 (BRAKES)

V07K0PA 1
FRONT MASTER CYLINDER SHOWN
1. Banjo fitting
2. Sealing washers

Install any retaining clips or brackets.

Refill and bleed the system. Refer to BRAKE
BLEEDING at the beginning of this section.

vmr2008-148 401
 Section 08 CHASSIS
Subsection 06 (BODY)

BODY
SERVICE TOOLS
Description Part Number Page
pliers Oetiker 1099 ............................................................... 295 000 070 ......................................... 409

vmr2008-149 403
Section 08 CHASSIS
Subsection 06 (BODY)

BODY PARTS (FRONT)

4.5 N•m
(40 lbf•in)

20 N•m 5 N•m
(15 lbf•ft) (44 lbf•in)

1 N•m
(9 lbf•in)

25 N•m
(18 lbf•ft)
20 N•m
2.5 N•m (15 lbf•ft)
(22 lbf•in)
8 N•m
(71 lbf•in)

3.5 N•m
(31 lbf•in)
48 N•m
(35 lbf•ft) European
Community
2.5 N•m
(22 lbf•in)

2.5 N•m
(22 lbf•in)

vmr2008-149-001-a

404 vmr2008-149
 Section 08 CHASSIS
Subsection 06 (BODY)

BODY PARTS (REAR)

4.5 N•m Outlander MAX 400 EFI
(49 lbf•in) Outlander MAX 400 EFI XT

2.5 N•m
(22 lbf•in)

2.5 N•m
(22 lbf•in)

20 N•m European Community

(15 lbf•ft)

25 N•m 10 N•m
(18 lbf•ft) (89 lbf•in)
vmr2008-149-002_a

vmr2008-149 405
Section 08 CHASSIS
Subsection 06 (BODY)

BODY PARTS (SIDE)

Outlander MAX 400 EFI
Outlander MAX 400 EFI XT

4 N•m
(35 lbf•in)

2.5 N•m
(22 lbf•in)
5.5 N•m
(49 lbf•in)

Outlander 400 EFI

Outlander 400 EFI XT

2.5 N•m
(22 lbf•in)

5.5 N•m
(49 lbf•in)
vmr2008-149-003_a

406 vmr2008-149
 Section 08 CHASSIS
Subsection 06 (BODY)

SEAT
Outlander MAX 400 EFI
Outlander MAX 400 EFI XT

25 N•m
(18 lbf•ft)
Operator’s Seat

25 N•m
(18 lbf•ft)

Backrest

Passenger’s Seat

6 N•m
(53 lbf•in)

10 N•m
10 N•m (89 lbf•in)
(89 lbf•in)

10 N•m
(89 lbf•in)

10 N•m
(89 lbf•in)

vmr2008-149-004_a

vmr2008-149 407
Section 08 CHASSIS
Subsection 06 (BODY)

BUMPERS
XT Package

2.5 N•m
(22 lbf•in)

11 N•m
(97 lbf•in)

16 N•m
(142 lbf•in) FRONT

2.5 N•m
(22 lbf•in)

REAR
11 N•m
(97 lbf•in)

25 N•m
(18 lbf•ft)

2.5 N•m
(22 lbf•in)
25 N•m
(18 lbf•ft)
2.5 N•m
(22 lbf•in)
vmr2008-149-005_a

408 vmr2008-149
 Section 08 CHASSIS
Subsection 06 (BODY)

GENERAL PROCEDURES
During assembly/installation, use the torque val-
ues and service products as in the exploded REUSABLE PLASTIC RIVETS
views.
Rivets Removal
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE Reusable plastic rivets are used in the riveting of
APPLICATION at the beginning of this manual for the various body parts. Plastic rivets can be re-
complete procedure. moved carefully with pliers Oetiker 1099 (P/N 295
000 070).
 WARNING NOTE: Reuse the plastic rivets.
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, cotter pins, etc.) must be replaced
with new ones.

Hoses or cables removed or disconnected must

be installed and routed at the same place.
CAUTION: Locking ties removed during a pro-
cedure must be replaced and installed at the
same location.

Vehicle Care
Clean the vehicle thoroughly, removing all dirt and
grease accumulation.
V06L08A 2 1
To clean use a soft clean cloth and either soapy
TYPICAL
water or isopropyl alcohol. 1. Pliers
2. Plastic rivet
To remove grease, oil or glue use isopropyl alco-
hol.
CAUTION: Do not apply isopropyl alcohol or DECALS
acetone directly on decals.
The following products must not be used to clean Decal Removal
or wax any of the plastic components used on the Using a heat gun warm up one end of decal for a
vehicles: few seconds until decal can roll off when rubbing
– Gasoline with your finger.
– Brake fluid Pull decal slowly and when necessary apply more
– Kerosene heat to ease removal on the area that has to be
– Diesel fuel peeled off.
– Lighter fluid If decal tears while pulling off, it has to be heated
– Varsol for a few seconds longer. If decal tends to stretch
– Naphtha while pulling off, stop heating and wait a few sec-
– Acetone onds to let it cool, then peel it off.
– Strong detergents Decal Installation
– Abrasive cleaners
Using isopropyl alcohol, clean the surface and dry
– Waxes containing an abrasive or a cleaning thoroughly.
agent in their formula.
Apply liquid soap to new decal and carefully po-
sition 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.

vmr2008-149 409
Section 08 CHASSIS
Subsection 06 (BODY)

CAUTION: Do not apply isopropyl alcohol or Gently lift the rear of seat.
solvent directly on decals. Use these products Pull seat rearwards.
in a well ventilated area.
Continue lifting movement until you can release
SEAT the front retaining device then completely remove
passengers seat.
Operator's Seat
Outlander MAX/MAX XT Models
Remove passengers seat as mentioned above.
All Models
To remove seat, move latch lever downward while
gently lifting rear of seat.

vmr2008-149-007_a

1. Operator's seat
2. Passenger's seat
3. Backrest

Seat Cleaning
It is recommended to clean seat(s) with a solution
of warm soapy water, using a soft clean cloth.
CAUTION: Avoid use of harsh detergents such vmo2006-005-027_b

as strong soaps, degreasing solvents, abrasive OUTLANDER/OUTLANDER XT

cleaners, paint thinners, etc. that may cause 1. Seat latch
damage to the seat cover.

Seat Removal
Passenger's Seat
Outlander MAX/MAX XT Models
Pull one of the passengers seat latch levers.
Those levers are located underneath the RH or
LH rear end of seat.

vmo2006-008-011_a

OUTLANDER MAX/OUTLANDER MAX XT

1. Seat latch

Pull seat rearward. Continue lifting movement un-

til you can release the front retaining device then
completely remove seat.

Seat Installation
vmo2006-008-009_a
Insert front tabs of seat into frame hooks. When
TYPICAL — LH SIDE
1. Seat latch lever seat rests in its position, firmly push seat down to
latch.
410 vmr2008-149
 Section 08 CHASSIS
Subsection 06 (BODY)

1
A35H0HA

TYPICAL
1. Piece of wood
2. ETN-50 (electric)
V07L05A 2
1. Insert these tabs in hooks After cover installation cut all around the excess
2. Hooks
of material.
NOTE: A distinctive snap will be felt. Double
check that the seat is secure by giving it a tug to CONSOLE
confirm proper latching.

 WARNING
Make sure seat is securely latched before rid-
ing.

Seat Cover Replacement

Remove the old seat cover. Check the foam and
replace if necessary.
Install staples with an electric tacker such as Ar-
row tacker no. ETN-50 or with a manual tacker vmr2008-149-006_a

such as Arrow tacker no. T-50. TYPICAL

1. Console
NOTE: For an easier installation, it is highly recom- 2. Side panels
mended to use an electric tacker. 3. Ignition switch
4. 12-volt power outlet
Ensure that the seat rest firmly against a hard sur- 5. Hazard warning button (CE models)
face such as a piece of wood. This is done to get
the staples completely pushed in place. NOTE: On 2009 CE models, the hazard warning
lights button is located on the LH multifunction
switch.

Console Removal
Remove seat(s).
On each side, come off side panel studs from con-
sole grommets.

vmr2008-149 411
Section 08 CHASSIS
Subsection 06 (BODY)

Lift the console.

Disconnect the following components:
– Ignition switch
– 12-volt power outlet
– Hazard warning button (2008 CE models).
Remove the console.

Console Installation
The installation is the reverse of removal proce-
dure.

VEHICLE LOCK
V07L0HA
2009 CE Models
The vehicle lock is located next to the park position
Remove screws retaining console. of the shift lever, on the right hand side of the
console.
Its purpose is to lock the transmission shift lever
in the park position.

V07L0LA 1 2
1. Console screws
2. Console
vmr2008-149-044_a
Remove plastic rivets near handlebar cover.
VEHICLE LOCK MECHANISM
1. Vehicle lock
2. Lock pin
3. Shift lever pivot
4. Lock pin receiver
5. Shift lever shown in neutral position

Vehicle Lock Removal

Set vehicle parking brake.
Unsure vehicle lock is not engaged.
Move shift lever out of park position for access to
lock mounting screws.
Remove the RH side panel as detailed further in
this section.
From under the RH side of the console, remove
V07L0MA 2 1 3
the lock mounting screws.
NOTE: For clarity purpose, the console and RH
1. LH plastic rivet
2. Handlebar cover side panels are transparent in the following illus-
3. Console tration.

412 vmr2008-149
 Section 08 CHASSIS
Subsection 06 (BODY)

vmr2008-149-044_b

VEHICLE LOCK MOUNTING SCREWS

V07L0HA

Remove the lock from its mounting bracket.

Outlander/Outlander XT Models
Vehicle Lock Installation Remove plastic rivets retaining the front tabs of
side panels.
For lock installation, reverse the removal proce-
dure. All Models
Move the front tabs out of their slots.
SIDE PANEL Remove side panel from vehicle.

vmr2008-149-008_a

1. Side panels

V07L2JA

Side Panel Removal

NOTE: Use the same procedure for the LH and Side Panel Installation
RH side panels.
The installation is the reverse of removal proce-
Remove seat(s). dure.
On each side, come off all side panel studs from
console and front fender grommets.

vmr2008-149 413
Section 08 CHASSIS
Subsection 06 (BODY)

FOOTREST Remove all bolts securing the footrest to front and

rear fenders.

vmr2008-149-009_a vmr2008-149-011_a

1. LH footrest FRONT FENDER

2. Operator's footpeg 1. LH fender bolts
3. Passenger's footpeg

Footrest Removal
Remove SIDE PANEL, see procedure above in this
section.
Unscrew footpeg(s).

vmr2008-149-010_a

REAR FENDER
1. LH fender bolts

Remove the plastic rivet securing the front of

footrest to inner fender.

vmr2008-149-012_a

OUTLANDER MAX SHOWN

1. Operator's footpeg
2. Passenger's footpeg

On Outlander MAX series, remove bolts secur-

ing footrest to footrest supports.

vmr2008-149-014_a

1. LH footrest
2. Plastic rivet
3. Inner fender

Remove footrest from vehicle.

Footrest Installation
vmr2008-149-013_a
The installation is the reverse of removal proce-
1. Passenger's footrest bolts dure.

414 vmr2008-149
 Section 08 CHASSIS
Subsection 06 (BODY)

INNER FENDER HEAVY DUTY BUMPER

Outlander XT Package

vmr2008-149-016_a

1. Inner fender

Inner Fender Removal vmr2008-149-017_a

1. Front heavy duty bumper

Loosen wheel lug nuts from appropriate wheel.
Lift the front of vehicle and support it securely.
Remove wheel.
Remove plastic rivets securing inner fender.

vmr2008-149-018_a

1. Rear heavy duty bumper

Bumper Removal
vmr2008-149-015_a
Front Bumper
1. Plastic rivets
Remove bolts retaining the heavy duty bumper to
Pull the front bottom corner of inner fender to re- the front bumper.
move it.
NOTE: On RH side, unclip the radiator hose.

Inner Fender Installation

The installation is the reverse of removal proce-
dure.

vmr2007-059-003_a

Remove screws that attach the heavy duty

bumper to the rack.

vmr2008-149 415
Section 08 CHASSIS
Subsection 06 (BODY)

Front Fascia Removal

Unplug headlamps.
On CE models, unplug position lamps.
Remove bolts securing front fascia to front skid
plate.

vmr2006-029-021_a

Remove the heavy duty bumper.

Rear Bumper
Unscrew bolts retaining the rear heavy duty
bumper to the rear bumper.
Remove screws that attach the heavy duty
bumper to the rack. vmr2008-149-020_a

1. Remove these bolts

2. Front fascia
3. Front skid plate

Remove and discard the push nut securing front

fascia to bumper.

vmr2006-029-022_a

Bumper Installation
The installation is the reverse of the removal pro-
cedure.

FRONT FASCIA vmr2008-149-025_a

1. Push nut
2. Fascia

Remove plastic rivets securing front fascia to front

fender.

vmr2008-149-019_a

1. Front fascia

416 vmr2008-149
 Section 08 CHASSIS
Subsection 06 (BODY)

vmr2008-149-021_a
vmr2008-149-023_a

1. Plastic rivets
1. Front heavy duty bumper
2. Hook
Remove front fascia. 3. Fairlead

Front Fascia Installation Disconnect headlights.

The installation is the reverse of the removal pro- On CE models, disconnect position lamps.
cedure. Remove and discard the push nut securing front
fascia to bumper.
FRONT SKID PLATE
2009 Models Only

vmr2008-149-025_a

1. Push nut
2. Fascia
vmr2008-149-022_a

1. Front skid plate

Remove plastic rivets securing front fascia to front
fender.

Front Skid Plate Removal

On XT models, remove hook, fairlead and the
front heavy duty bumper.

vmr2008-149-021_a

1. Plastic rivets

Unscrew the bolts securing the front skid plate.

vmr2008-149 417
Section 08 CHASSIS
Subsection 06 (BODY)

vmr2008-149-024_a vmr2008-149-024_b

OUTLANDER CE SHOWN 1. Lower mounting bolts on front skid plate

1. Skid plate bolts
Remove the two center mounting screws from
Remove skid plate and front fascia assembly. lower skid plate, then the two rear mounting
Remove bolts retaining skid plate and front fascia. screws as you support the skid plate.

vmr2008-149-029_a vmr2008-149-143_a

1. Remove these bolts 1. Lower skid plate

2. Lower mounting bolts on front skid plate
3. Lower skid plate mounting screws

Front Skid Plate Installation Pull the front section of lower skid plate out from
The installation is the reverse of the removal pro- between the front skid plate and the frame.
cedure.
Lower Skid Plate Installation
LOWER SKID PLATE Installation is the reverse of removal.
Lower Skid Plate Removal Torque the mounting screws on the front and low-
er skid plates as specified in the exploded views.
Remove the two lower mounting bolts from the
front skid plate.

418 vmr2008-149
 Section 08 CHASSIS
Subsection 06 (BODY)

FRONT BUMPER

vmr2008-149-041_a

vmr2008-149-040_a 1. RH direction indicator lamp support

2. Bumper
1. Front bumper

Remove upper bolts securing front bumper to

Front Bumper Removal fender support.
Using removal instructions described in this sec-
tion, remove the following parts:
– Heavy duty bumper (XT models)
– Front fascia
– Front skid plate.
On CE models, cut locking ties securing direction
indicator harnesses.

vmr2008-149-027_a

1. Front bumper upper bolts

2. Front fender

At the bottom of bumper, remove the 2 last bolts.

vmr2008-149-026_a

1. Cut these locking ties

Unplug both direction indicator lamps.

If front bumper is removed for replacement, un-
screw direction indicator lamp supports from the
bumper.
vmr2008-149-028_a

1. Front bumper lower bolts

Remove the front bumper.

Front Bumper Installation

The installation is the reverse of the removal pro-
cedure.
NOTE: Install all bolts before torquing them.
vmr2008-149 419
Section 08 CHASSIS
Subsection 06 (BODY)

LUGGAGE RACK Rack Installation

The installation is the reverse of removal proce-
dure.

FENDER

vmr2008-149-030_a

1. Front rack
2. Rear rack

Rack Removal vmr2008-149-032_a

NOTE: On XT models, heavy duty bumpers (front 1. Front fender

and rear) must be removed to allow luggage racks 2. Rear fender
removal.
Remove storage or service compartment cover. Fender Removal
Unscrew the four (4) bolts retaining the rack.
Front Fender
Remove bolts that attach both footrests to the
fender.

vmr2006-029-016_a

FRONT RACK BOLTS LOCATION

vmr2008-149-011_a

LH SIDE SHOWN
1. Fender bolts

Remove plastic rivets retaining front fender to

front fascia.

vmr2008-149-031_a

UNDERNEATH REAR FENDER

1. Rear rack bolts

Remove luggage rack.

420 vmr2008-149
 Section 08 CHASSIS
Subsection 06 (BODY)

vmr2008-149-035_a
vmr2008-149-021_a
1. Winch remote control connection connector
1. Plastic rivets

Using removal instructions described in this sec- Remove plastic rivets retaining front fender to con-
tion, remove the following parts: sole.
– Side panels
– Inner fenders
– Front rack.
From the LH side, unscrew the coolant reservoir
support bolt.

vmr2008-149-036_a

1. Plastic rivets to remove

Lift up fender and place it in a safe place to avoid

scratches.
Rear Fender
Remove seat(s).
Remove both side panels.
vmr2008-149-033_a Remove LUGGAGE RACK, see procedure above
1. Coolant reservoir support bolt in this section.
Remove all screws retaining the footrests to rear
On RH side, remove bolt securing the brake pedal fender.
fluid reservoir.

vmr2008-149-037_a
vmr2008-149-034_a
1. RH fender bolts
1. Brake pedal fluid reservoir bolt
Remove bolts securing rear fender on fender sup-
Unplug the winch remote control connection con- port.
nector located behind the RH strut.

vmr2008-149 421
Section 08 CHASSIS
Subsection 06 (BODY)

FENDER SUPPORT

vmr2008-149-038_a

1. RH rear fender bolt

vmr2008-149-042_a

Unplug brake light connector. 1. Front fender support

2. Rear fender support
On CE models, unplug direction indicator lamp
connectors.
Fender Support Removal
Front Fender Support
Remove FRONT FENDER, see procedure in this
section.
Unscrew front bumper bolts and radiator mount-
ing bolts.

vmr2008-149-039_a

1. Brake light connector

2. RH position lamp connector

Cut locking ties retaining brake light and position

lamp harnesses on fender support.
Unscrew the fuel tank cap.
vmr2006-029-015_b
Lift and remove fender. Place it in a place to avoid
scratches. 1. Bumper bolts
2. Radiator bolts
Reinstall the fuel tank cap.
Remove bolts retaining the fender support to the
Fender Installation frame.
The installation is the reverse of removal proce-
dure.

V07L11A

422 vmr2008-149
 Section 08 CHASSIS
Subsection 06 (BODY)

Rear Fender Support

Remove REAR FENDER, see procedure in this
section.
Remove bolts that attach fender support to frame.
Unscrew the exhaust support bolt.

vmr2006-029-019_a

Fender Support Installation

The installation is the reverse of removal proce-
dure.

vmr2008-149 423
 Section 08 CHASSIS
Subsection 07 (FRAME)

FRAME
Outlander 400 EFI and Outlander 400 EFI XT Models

25 N•m
(18 lbf•ft)

34 N•m
(25 lbf•ft)
25 N•m
(18 lbf•ft)

48 N•m
(35 lbf•ft)

vmr2008-150-001_a

vmr2008-150 425
Section 08 CHASSIS
Subsection 07 (FRAME)

Outlander MAX 400 EFI and Outlander MAX 400 EFI XT Models

34 N•m
(25 lbf•ft)

25 N•m
(18 lbf•ft)

25 N•m
(18 lbf•ft)

48 N•m
(35 lbf•ft)

25 N•m
(18 lbf•ft)

25 N•m
(18 lbf•ft)

vmr2008-150-002_a

426 vmr2008-150
 Section 08 CHASSIS
Subsection 07 (FRAME)

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

 WARNING
Torque wrench tightening specifications vmr2008-150-004_a

must strictly be adhered to. 1. Rear footrest support bolts

Locking devices (e.g.: locking tabs, elastic 2. RH rear footrest support

stop nuts, cotter pins, etc.) must be replaced

with new ones. Passenger Footrest Support Removal
Hoses or cables removed or disconnected must All MAX/MAX XT Models
be installed and routed at the same place. Remove both footrests.
Detach rear brake hose from passenger footrest
PROCEDURES supports.
Unscrew passenger footrest support bolts.
FOOTREST SUPPORTS
NOTE: Use the same procedure for RH or LH
footrest supports.

Front Footrest Support Removal

Remove the appropriate footrest. Refer to BODY
section.
Unscrew bolts securing front footrest support to
frame and rear footrest support.

vmr2008-150-005_a

1. Passenger footrest support bolts

Footrest Supports Inspection

Check footrest support(s) for cracks, bending or
other damages. Replace if necessary.

Footrest Supports Installation

vmr2008-150-003_a
The installation is the reverse of removal proce-
dure.
1. Front footrest support bolts
2. RH front footrest support NOTE: Install all bolts before tightening.
Remove the front footrest support.
BATTERY SUPPORT
Rear Footrest Support Removal
Battery Support Removal
Remove the appropriate footrest. Refer to BODY
section. Remove battery (refer to STARTING SYSTEM).
Unscrew the following bolts securing the rear Remove bolts retaining the top of battery support
footrest support to frame and front footrest sup- to frame.
port.
vmr2008-150 427
Section 08 CHASSIS
Subsection 07 (FRAME)

Battery Support Installation

The installation is the reverse of removal proce-
dure.

HITCH
Hitch Removal
Remove the differential protector.
Unscrew bolts retaining the hitch to frame.
vmr2008-150-006_a
Remove lower differential bolts.
1. Battery support upper bolts
2. Voltage regulator
3. Muffler

Remove differential upper bolts.

vmr2008-072-005_a

1. Differential protector bolts

2. Lower differential bolts
3. Hitch bolt

vmr2008-150-007_a
Remove hitch from vehicle.
1. Differential upper bolts
2. Battery support
Hitch Inspection
On both sides, remove bolts that attach fuel tank Check hitch for cracks, bending or other damages.
and its protector to frame. Replace if necessary.

Hitch Installation
The installation is the reverse of removal proce-
dure.

FRAME
Frame Cleaning
Clean frame with appropriate cleaners and rinse
with high pressure hose.
NOTE: Clean the draining holes under frame. The
vmr2008-150-008_a
drain holes are located at the rear of bottom side
1. LH fuel tank rear bolt of frame.
2. Protector
Touch up all metal spots where paint has been
Remove battery support from vehicle. scratched off. Spray all bare metal parts of vehicle
with metal protector.
Battery Support Inspection
Check battery support for cracks or other dam-
ages. Replace if necessary.

428 vmr2008-150
 Section 08 CHASSIS
Subsection 07 (FRAME)

Frame Welding
CAUTION: Before performing electrical weld-
ing anywhere on the vehicle, unplug the
multiple connector at the electronic module
connector. Also unplug the negative cable
and the voltage regulator. This will protect the
electronic module and battery against damage
caused by flowing current when welding.
Use the following specifications for electric weld-
ing:
– Amperage: 70 - 110 A
– Voltage: 20 - 24 V
– Rod: E-7014 (3/32 in).
NOTE: Install the ground as close as possible from
the reparation area.
CAUTION: If welding is to be done near plastic
material, it is recommended to either remove
the part from the area or to protect it with alu-
minum foil to prevent damage.

vmr2008-150 429
 Section 09 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER 400 EFI)

OUTLANDER 400 EFI

OUTLANDER™ 400 EFI
MODEL
STANDARD XT MAX MAX XT

ENGINE
ROTAX 400, 4-stroke, Single Over Head
Engine type
Camshaft (SOHC), liquid cooled
Number of cylinder 1
Number of valves 4 valves (mechanical adjustment)
Bore mm (in) 91 (3.58)
Stroke mm (in) 61.5 (2.42)
Displacement cm³ (in³) 400 (24.41)
Compression ratio 10.3:1
Decompressor type Automatic
Maximum HP RPM RPM 7500
Type Wet sump with replaceable oil filter
Oil filter BRP ROTAX paper type, replaceable
Engine oil pressure Minimum kPa (PSI) 350 (51) at 6000 RPM
Lubrication Capacity 3 (3.17)
L (quarts)
(oil change with filter) (engine/transmission)
Engine oil SAE 5W30 API classification SM, SL or SJ
Recommended see OIL VISCOSITY CHART in the
OPERATOR'S GUIDE
Intake valve opening 15.00° BTDC
Intake valve closing 45.00° ABDC
Exhaust valve opening 50.00° BBDC
Exhaust valve closing 10.00° ATDC
Chain tensioner plunger protrusion Service limit mm (in) 20.0 (.7874)
Intake mm (in) 0.06 to 0.14 (.0024 to .0055)
Valve clearance
Exhaust mm (in) 0.11 to 0.19 (.0043 to .0075)
New mm (in) 4.966 to 4.980 (.1955 to .1960)
Intake
Service limit mm (in) 4.930 (.1940)
Valve stem diameter
New mm (in) 4.956 to 4.970 (.1951 to .1957)
Exhaust
Service limit mm (in) 4.930 (.1940)
New mm (in) 4.998 to 5.018 (.1968 to .1976)
Valve guide diameter
Service limit mm (in) 5.050 (.1988)
New mm (in) 40.81 (1.607)
Valve spring free length
Service limit mm (in) 39.00 (1.535)
New mm (in) 1.05 to 1.35 (.041 to .053)
Intake
Service limit mm (in) 1.8 (.07)
Valve seat contact width
New mm (in) 1.25 to 1.55 (.049 to .061)
Exhaust
Service limit mm (in) 2 (.078)
New mm (in) 90.950 to 90.966 (3.580 to 3.581)
Piston measurement
Service limit mm (in) 90.850 (3.577)
New mm (in) 0.027 to 0.057 (.0011 to .0022)
Piston/cylinder clearance
Service limit mm (in) 0.1 (.004)

vmr2008-151 431
Section 09 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER 400 EFI)

OUTLANDER™ 400 EFI

MODEL
STANDARD XT MAX MAX XT

ENGINE (cont'd)
1st Upper compression ring, rectangular
Piston ring type 2nd Lower compression ring, taper-face
3rd Oil scraper ring, standard
Upper compression
ring mm (in) 0.20 to 0.40 (.008 to .016)
Lower compression New
Piston ring end gap ring mm (in) 0.20 to 0.40 (.008 to .016)
Oil scraper ring mm (in) 0.20 to 0.70 (.008 to .028)
All Service limit mm (in) 1.5 (.06)
Upper compression
ring mm (in) 0.030 to 0.070 (.0012 to .0028)
Lower compression New
ring mm (in) 0.020 to 0.060 (.0008 to .0024)
Oil scraper ring mm (in) 0.010 to 0.180 (.0004 to .0071)
Ring/piston groove clearance
Upper compression
ring mm (in) 0.15 (.006)
Lower compression Service limit
ring mm (in) 0.15 (.006)
Oil scraper ring mm (in) 0.25 (.0098)
New mm (in) 12.036 to 12.050 (.4739 to .4744)
Rocker arm bore diameter
Service limit mm (in) 12.060 (.4748)
New mm (in) 12.000 to 12.018 (.4724 to .4732)
Rocker arm shaft diameter
Service limit mm (in) 11.990 (.4720)
Cylinder bore Nominal new mm (in) 90.993 to 91.007 (3.582 to 3.583)
Maximum new mm (in) 0.038 (.0015)
Cylinder taper
Service limit mm (in) 0.090 (.0035)
Maximum new mm (in) 0.015 (.0006)
Cylinder out of round
Service limit mm (in) 0.020 (.0008)
New mm (in) 21.959 to 21.980 (.8645 to .8654)
PTO side
Service limit mm (in) 21.950 (.8642)
Camshaft main bearing journal
New mm (in) 34.959 to 34.975 (1.3763 to 1.3770)
MAG side
Service limit mm (in) 34.950 (1.3760)
New mm (in) 22.000 to 22.021 (.8661 to .8670)
PTO side
Camshaft main bearing journal Service limit mm (in) 22.040 (.8677)
bore New mm (in) 35.000 to 35.025 (1.3780 to 1.3789)
MAG side
Service limit mm (in) 35.040 (1.3795)
New mm (in) 32.253 to 32.453 (1.2698 to 1.2777)
Intake
Service limit mm (in) 32.235 (1.2691)
Camshaft lobe
New mm (in) 31.937 to 32.137 (1.2574 to 1.2652)
Exhaust
Service limit mm (in) 31.920 (1.2567)
Crankshaft axial clearance New mm (in) 0.1 to 0.4 (.0039 to .0157)
Crankshaft deflection MAG/PTO side New mm (in) 0.05 (.0020)
New mm (in) 40.009 to 40.025 (1.5752 to 1.5758)
Crankshaft pin diameter
Service limit mm (in) 39.980 (1.5740)

432 vmr2008-151
 Section 09 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER 400 EFI)

OUTLANDER™ 400 EFI

MODEL
STANDARD XT MAX MAX XT

ENGINE (cont'd)
Crankshaft main journal New mm (in) 42.024 to 42.040 (1.6545 to 1.6551)
MAG/PTO side
diameter Service limit mm (in) 42.000 (1.6535)
Crankcase plain bearing MAG/PTO side Service limit mm (in) 42.070 (1.6563)
Crankshaft radial play MAG/PTO side Service limit mm (in) 0.070 (.0028)
New mm (in) 40.020 to 40.051 (1.5756 to 1.5768)
Connecting rod big end diameter
Service limit mm (in) 40.100 (1.5787)
Connecting rod big end radial play Service limit mm (in) 0.090 (.0035)
New mm (in) 0.100 to 0.352 (.004 to .014)
Connecting rod big end axial play
Service limit mm (in) 0.500 (.020)
New mm (in) 20.010 to 20.020 (.7878 to .7882)
Connecting rod small end diameter
Service limit mm (in) 20.060 (.7898)
New mm (in) 19.996 to 20.000 (.7872 to .7874)
Piston pin diameter
Service limit mm (in) 19.980 (.7866)
Connecting rod small end radial clearance Service limit mm (in) 0.080 (.0035)
GEARBOX
Type Dual range (HI-LO) with park, neutral
and reverse
Output shaft axial clearance Service limit mm (in) 0.300 (.0120)
New mm (in) 0.020 to 0.110 (.0008 to .0043)
Bevel gear axial clearance
Service limit mm (in) 0.150 (.0059)
New mm (in) 5.000 to 5.100 (.1968 to .2008)
Gear groove width
Service limit mm (in) 5.200 (.2047)
MAG side 17.990 (.7083)
Main shaft Service limit mm (in)
PTO side 24.950 (.9823)
Bevel gear shaft PTO side Service limit mm (in) 24.990 (.9839)
New mm (in) 4.800 to 4.860 (.1890 to .1913)
Shift fork claw thickness
Service limit mm (in) 4.750 (.1870)
COOLING SYSTEM
Liquid cooled, single radiator with
Type
cooling fan
Ethyl glycol/water mix
(50% coolant, 50% water).
Use premixed coolant sold
Type
Coolant by BRP (P/N 219 700 362) or
coolant specifically designed for
aluminum engines
Capacity L (quarts) 2.9 (3.06)
Thermostat Opening temperature °C (°F) 65 (149)
Radiator cap opening pressure kPa (PSI) 110 (16)

vmr2008-151 433
Section 09 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER 400 EFI)

OUTLANDER™ 400 EFI

MODEL
STANDARD XT MAX MAX XT

ELECTRICAL SYSTEM
Magneto generator output 400 W @ 6000 RPM
Ignition system type IDI (Inductive Discharge Ignition)
Ignition timing Not adjustable
Quantity 1
Spark plug Make and type NGK DCPR8E
Gap mm (in) 0.7 to 0.8 (.028 to .032)
Crankshaft position sensor (CPS) 774 to 946 @ 20°C (68°F)
Forward RPM 8000
Engine RPM limiter setting
Reverse RPM 4250
Type Maintenance free
Model YTX20HL-BS
Battery
Voltage 12 volts
Nominal rating 18 A•h
Headlight W 2 x 35
Taillight/brake light W 8/27
Turn signal lights (CE models) W 10
Accessories A 20
Fan A 20
Main 1 A 30
Main 2 A 30
Fuses
Fuel system A 7.5
Ignition system A 7.5
Solenoids/Gauges A 7.5
ECM A 5
FUEL SYSTEM
Fuel delivery Electronic Fuel Injection (EFI)
Throttle body Dell'Orto 46 mm
Type Electric fuel pump in fuel tank
Fuel pump
Operating pressure kPa (PSI) 350 (51)
Idle speed RPM ± 50 1300 (not adjustable)
Type Regular unleaded gasoline
Fuel Inside North America (R+M)/2 87 or higher
Octane rating
Outside North America RON 92 or higher
Fuel tank capacity L (U.S. gal) 20 (5.3)
Fuel tank reserve L (U.S. gal) 2 (0.6)

434 vmr2008-151
 Section 09 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER 400 EFI)

OUTLANDER™ 400 EFI

MODEL
STANDARD XT MAX MAX XT

DRIVE SYSTEM
Engagement RPM ± 100 RPM 2000
Shaft driven/single Auto-lock differential
Front differential (pump driven)
Front differential ratio 3.6:1
Rear axle Shaft driven/single differential
Rear axle ratio 3.6:1
Front ml (U.S. oz) 500 (17)
Capacity
Differential oil Rear ml (U.S. oz) 250 (8.5)
BRP differential oil (P/N 293 600 043) or
Recommended synthetic oil 75W90 (API GL5)
CV joint grease CV joint grease (P/N 293 550 019)
Propeller shaft grease XP-S synthetic grease (P/N 293 550 010)
TRANSMISSION
Transmission type CVT (Continuously Variable Transmission)
Engagement RPM ± 100 RPM 1450
New mm (in) 32.00 (1.260)
Drive belt width
Service limit mm (in) 30.00 (1.181)
New mm (in) 13.70 to 13.90 (.539 to .547)
Governor cup roller outer diameter
Service limit mm (in) 13.20 (.519)
New mm (in) 39.990 to 40.085 (1.574 to 1.578)
One-way clutch bushing diameter
Service limit mm (in) 40.100 (1.579)
New mm (in) 6.078 to 6.100 (.239 to .240)
Centrifugal lever pivot bolt diameter
Service limit mm (in) 6.000 (.236)
Centrifugal lever bore diameter Service limit mm (in) 6.200 (.244)
New mm (in) 6.113 to 6.171 (.241 to .243)
Centrifugal lever pivot bolt bore diameter
Service limit mm (in) 6.300 (.248)
New mm (in) 55.000 to 55.020 (2.165 to 2.166)
Drive pulley sliding sheave large bushing
Service limit mm (in) 55.200 (2.173)
New mm (in) 30.000 to 30.040 (1.181 to 1.183)
Drive pulley sliding sheave small bushing
Service limit mm (in) 30.200 (1.189)
New mm (in) 30.060 to 30.100 (1.183 to 1.185)
Driven pulley sliding sheave bushing
Service limit mm (in) 30.200 (1.189)
New mm (in) 30.060 to 30.100 (1.183 to 1.185)
Driven pulley fixed sheave bushing
Service limit mm (in) 30.200 (1.189)
Torque gear on driven pulley Service limit mm (in) 7.500 (.295)

vmr2008-151 435
Section 09 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER 400 EFI)

OUTLANDER™ 400 EFI

MODEL
STANDARD XT MAX MAX XT

STEERING
Turning radius m (ft) 1.83 (6) 2.0 (6 ft – 7 in)
Total toe (vehicle on ground) mm (in) 0 ± 4 (0 ± .157)
Camber angle 0°
Tie-rod maximum length unengaged threads mm (in) 17.5 ± 5 (11/16 ± 3/16)
FRONT SUSPENSION
Suspension type MacPherson struts
Suspension travel mm (in) 178 (7)
Quantity 2
Shock absorber
Type Oil
Spring free length mm (in) 354 (13-15/16) 375 (14-3/4)
Spring color code Red/Yellow/Red Silver/Yellow/Gold
Front preload adjustment N.A.
REAR SUSPENSION
Suspension type TTI™ independent
Suspension travel mm (in) 203 (8)
Quantity 2
Shock absorber
Type Oil
Spring free length mm (in) 371 (14-3/8) 413 (16-1/4)
Spring color code Blue/White/Blue Silver/Blue/Yellow
Rear preload adjustment 5 settings
BRAKES
Quantity 2
Front brake
Type Hydraulic, discs
Quantity 1
Rear brake
Type Hydraulic, disc
Capacity ml (U.S. oz) 125 (4.3)
Brake fluid
Type DOT 4
Parking brake Hydraulic lock-4 wheels
Caliper Floating
Front Organic
Brake pad material
Rear Metallic
Minimum pad thickness mm (in) 1 (.04)
Front mm (in) 3.5 (.138)
Minimum brake disc thickness
Rear mm (in) 4.3 (.17)
Maximum brake disc warpage mm (in) 0.2 (.01)

436 vmr2008-151
 Section 09 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER 400 EFI)

OUTLANDER™ 400 EFI

MODEL
STANDARD XT MAX MAX XT

TIRES AND WHEELS

TIRES
Maximum 34 kPa (5 PSI) 34 kPa (5 PSI)
Front
Minimum 31 kPa (4.5 PSI) 31 kPa (4.5 PSI)
Pressure
Maximum 34 kPa (5 PSI) 34 kPa (5 PSI)
Rear
Minimum 31 kPa (4.5 PSI) 31 kPa (4.5 PSI)
Minimum tire thread depth mm (in) 3 (1/8)
Front 25 x 8 x 12
Size 25 x 10 25 x 11 25 x 10 25 x 11
Rear
x 12 x 12 x 12 x 12
WHEELS
Front 12 x 6
Size
Rear 12 x 7.5
DIMENSION
Overall length m (in) 2.18 (86) 2.39 (94)
Overall width m (in) 1.17 (46)
Overall height m (in) 1.14 (45)
DIMENSION (cont'd)
Wheelbase m (in) 1.24 (49) 1.45 (57)
Front mm (in) 965 (38)
Wheel track
Rear mm (in) 914 (36)
Ground clearance mm (in) 236 (9.3)
WEIGHT AND LOADING CAPACITY
Dry weight kg (lb) 279 (615) 302 (665)
Weight distribution (front/rear) % 49/51 48/52 46/54
Rear storage box (included with rear rack weight) kg (lb) 10 (22)
Front kg (lb) 45 (100)
Rack Rear
(including rear storage kg (lb) 90 (200)
box and tongue weight)
Total vehicle load allowed (including driver, all other loads and added kg (lb) 227 (500) 235 (517)
accessories)
Gross vehicle weight rating kg (lb) 460 (1014) 554 (1219)
Towing capacity kg (lb) 500 (1100)
Tongue capacity (included with rear rack weight) kg (lb) 14 (30)
MATERIAL
Material Steel
Frame
Color Black
Material Steel Aluminum Steel Aluminum
Wheel
Color Silver Aluminum Silver Aluminum
Material Steel
Front/rear rack
Color Black
Material Aluminum
Front bumper
Color Aluminum

vmr2008-151 437
Section 09 TECHNICAL SPECIFICATIONS
Subsection 01 (OUTLANDER 400 EFI)

OUTLANDER™ 400 EFI

MODEL
STANDARD XT MAX MAX XT

MATERIAL (cont'd)
Material High density polyethylene
Front/rear fender
Color Yellow/Laurentian green/Viper red
Material High density polyethylene
Inner fender
Color Black
Material High density polyethylene
Fuel tank
Color Black
Material High density polyethylene
CVT cover
Color Black
Material High density polyethylene
Fuel tank protector(s)
Color Black
Material Polypropylene
Steering cover
Color Black
Material Polypropylene (glass fiber-reinforced)
Storage compartment cover
Color Black
Material High density polyethylene
Front fascia
Color Yellow/Laurentian green/Viper red
Material High density polyethylene
Front skid plate
Color Black
Material High density polyethylene
Side panel
Color Yellow/Laurentian green/Viper red
Material High density polyethylene
Foot rest
Color Black
Material High density polyethylene
Console
Color Yellow/Laurentian green/Viper red
Material Polypropylene (glass fiber-reinforced)
Air filter housing cover
Color Black
Material Polypropylene (glass fiber-reinforced)
Air filter housing
Color Black
Material Polypropylene (glass fiber-reinforced)
Transmission lever locator
Color Black
Material Polypropylene
Suspension arm protector
Color Black
Material High density polyethylene
Engine cover
Color Black
Material Polypropylene
Seat base
Color Black
Material Thermoformed vinyl
Seat cover
Color Black

438 vmr2008-151
 Section 10 WIRING DIAGRAM
Subsection 01 (OUTLANDER 400 EFI)

OUTLANDER 400 EFI

WIRING DIAGRAM
INFORMATION 1
NOTE: The wiring diagrams are in the manual back
5
cover pocket. 2
3
The wiring diagrams use the following codes. 4
1 2 3 4 5

XX/XX-18 2-BF-A V07A0HA

V00G0FA

1. Wire colors AREA LOCATION

2. Wire gauge
3. Connector location area 1
4. Connector identification Steering area
5. Terminal location in connector
2 ECM area
3 Front of vehicle
Wire Colors
4 Engine area
It identifies the color of a wire. When a 2-color
scheme is used, the first color is the main color 5 Rear of vehicle
while the second color is the tracer color.
Connector Identification
XX/XX Indicates the connector individually. If there are
many connectors in the same area, this helps to
XX/XX identify which wire is in which connector.
-18 2-BF-A
V06G1FA

THE SHADED PART INDICATES THE WIRE COLOR

XX/XX-18 2- BF -A
Example: YL/BK is a YELLOW wire with a BLACK
stripe. V06G1JA
BF
Wire Gauge THE SHADED PART INDICATES A CONNECTOR IDENTIFICATION

The number after wire color indicates the gauge

of a wire. Terminal Location in Connector

18
This is the terminal position in the connector. The
number or letter given refers to the physical iden-
tification stamped on the connector.
XX/XX- 18 2-BF-A NOTE: If no letter or number is indicated on the
V06G1GA
connector, they are indicated where there is a spe-
THE SHADED PART INDICATES THE WIRE GAUGE cific test using this connector.

Connector Location Area XX/XX A

2- BF- A

XX/XX-18 2 -BF-A
A
vmr2008-038-004_a

V06G1HA
2 THE SHADED PART INDICATES THE TERMINAL LOCATION IN
CONNECTOR

THE SHADED PART INDICATES THE CONNECTOR LOCATION

AREA

vmr2008-153 439
 2008-2015 OUTLANDER 400 EFI
GENERAL SYSTEM

vdd2014-001-001
 2010 OUTLANDER 400 EFI CE 2010 OUTLANDER 500/650 EFI CE
SUPPLEMENT (CE MODEL) SUPPLEMENT (CE MODEL)
MUST BE USED IN CONJUNCTION WITH THE GENERAL SYSTEM DIAGRAM. MUST BE USED IN CONJUNCTION WITH THE GENERAL SYSTEM DIAGRAM.

2010 OUTLANDER 800R EFI CE

SUPPLEMENT (CE MODEL)
MUST BE USED IN CONJUNCTION WITH THE GENERAL SYSTEM DIAGRAM.

vdd2010-002-006