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®™ AND THE BRP LOGO ARE TRADEMARKS OF BOMBARDIER RECREATIONAL PRODUCTS INC. OR ITS AFFILIATES.

©2009 BOMBARDIER RECREATIONAL PRODUCTS INC. ALL RIGHTS RESERVED. PRINTED IN CANADA.

219 100 388

CA

DPS/ACS TECHNICAL MANUAL / ENGLISH

MANUEL TECHNIQUE DPS/ACS / ANGLAIS

FAIT AU / MADE IN CANADA

U/M:P.C.

Technical Manual

2 1 9   1 0 0   3 8 8

DPS

TM

/ACS

DPS

TM

/ACS

2010

Summary of Contents for 2010 DPS

Page 1: ...Technical Manual 2 1 9 1 0 0 3 8 8 DPSTM ACS DPSTM ACS 2010...

Page 2: ...2010 DPS ACS Technical Manual...

Page 3: ...Inc BRP 2009 Printed in Canada Technical Publications Bombardier Recreational Products Inc BRP Valcourt Quebec Canada and the BRP logo are trademarks of Bombardier Recreational Products Inc BRP or it...

Page 4: ...OTING 8 PROCEDURES 9 DPS UNIT 9 PITMAN ARM 22 02 AIR CONTROLLED SUSPENSION ACS 23 GENERAL 25 SYSTEM DESCRIPTION FEATURES 25 SYSTEM DESCRIPTION COMPONENTS 27 TROUBLESHOOTING 30 DIAGNOSTIC TIPS 30 TROUB...

Page 5: ...ecom mended 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 documen...

Page 6: ...Red Steel grey 2MAA 2MAB 2MAC 2MAD RENEGADE ENGINE MODEL COLOR MODEL NUMBER 800R X xc Black 4DAA 4DAB 4DAC The information and component system descriptions contained in this manual are correct at tim...

Page 7: ...IV vmr2010 002...

Page 8: ...SERVICE TOOLS INDEX FLUKE 115 MULTIMETER P N 529 035 868 Page 9 11 32 35 37 38 43 44 OETIKER PLIERS P N 295 000 070 Page 44 SPRING REMOVER P N 529 036 007 Page 46 1...

Page 9: ...2...

Page 10: ...RING DPS SERVICE TOOLS Description Part Number Page FLUKE 115 MULTIMETER 529 035 868 9 11 SERVICE TOOLS OTHER SUPPLIER Description Part Number Page SNAP ON TELESCOPING GAUGE SET LST 52616 20 SERVICE P...

Page 11: ...G DPS 38 N m 28 lbf ft If torqued by screw head XPS synthetic grease 400 g NEW NEW XPS synthetic grease 400 g NEW 24 5 N m 18 lbf ft NEW NEW 72 N m 53 lbf ft NEW NEW 24 5 N m 18 lbf ft If torqued by e...

Page 12: ...posi tion there is no steering assist Steering torque may also come from the wheels due to rough terrain Steering kickback is reduced while providing feedback to the driver The greater the power steer...

Page 13: ...003 003 DPS UNIT The DPS module provides DC power to the mo tor The amount and duration of that DC power is determined by the inputs to the DPS module The direction in which the motor turns is change...

Page 14: ...adjusting steering alignment the sensor torque offset must be reset to zero for proper system operation PART ADJUSTED OR REPLACED WHAT TO DO DPS unit Steering column bearing Tie rod Tie rod end Knuckl...

Page 15: ...ailed in this subsection Repair or replace wiring connectors as required 4 No engine RPM signal from ECM If engine RPM can be displayed in the multifunc tion gauge when the engine is running carry out...

Page 16: ...ear in the multifunction gauge If it comes on button and wiring to gauge are good If OVERRIDE message does not appear in gauge test drive vehicle to determine if OVERRIDE func tion can be activated If...

Page 17: ...ght between each DPS PWR connector pins A and B and the battery negative terminal The test light must come on bright DPS Unit Input Voltage Test Control Side 1 Disconnect DPS CTRL control connector an...

Page 18: ...unit must receive an RPM signal to provide power steering assist Disconnect the DPS control connector and the di agnostic connector Test continuity of CAN Bus Wires at DPS1 C and DPS1 D MULTIMETER PR...

Page 19: ...tton on the multimeter to engage the MIN function mmr2009 023 027_e 1 MIN function selected 9 Turn the handlebar momentarily against the steering frame stops to each side NOTE Do not hold steering aga...

Page 20: ...stop and observe the indications on the B U D S DPS Monitoring page The DPS Torque Sensor Nm increase with torque applied to handlebar The DPS Current ammeter should increase pro portionately to the...

Page 21: ...14 055_d TYPICAL 1 Shift lever guide plate 2 Guide plate screws forward screw not visible NOTE It is not necessary to disconnect the shift lever 5 Loosen the gear clamp securing the air filter housing...

Page 22: ...umn pinch bolt and retaining nut Discard the retaining nut vmr2010 003 017_a 1 Steering column pinch bolt 14 Remove and discard the elastic nuts from the 2 hexagonal screws that secure steering column...

Page 23: ...ures both tie rod ends to the pitman arm steering lever Discard cotter pins vmr2010 003 022_a 1 Pitman arm 2 Tie rod ends NOTE Leave the tie rod ends on the pitman arm at this time They will come off...

Page 24: ...rd ened steel washers on the tie rod ends DPS Unit Installation NOTICE The following procedure MUST be followed as specified Failure to do so may re sult in steering column DPS misalignment and poor D...

Page 25: ...eer ing column and ensure the two O ring seals are installed on the shaft and in good condition Re place as required vmr2010 003 029_a 1 O ring seals on steering column 6 Index steering column splines...

Page 26: ...emain floating over the DPS housing vmr2010 003 016_a 1 Locking tie location 2 Steering column bellows vmr2010 003 033_a 1 Drainage hole in DPS ring flange 2 Steering column bellows 9 Apply XPS SYNTHE...

Page 27: ...010 003 036 STEERING COLUMN SHIM MEASUREMENT NOTE Ensure the forward end of the tool is in the center of the steering column and the rearward end does not protrude through the notch in the support 13...

Page 28: ...agonal SCREWS retaining the steering column to 38 N m 28 lbf ft vmr2010 003 021_b Step 1 Hold elastic nuts with wrench not illustrated Step 2 Apply specified torque to hexagonal screws NOTE If torque...

Page 29: ...red up The check engine light will come on and a DPS FAULT message will appear in the multi function gauge When DPS unit installation is complete carry out the following steps 1 Connect the ATV to the...

Page 30: ...LED SUSPENSION ACS SERVICE TOOLS Description Part Number Page FLUKE 115 MULTIMETER 529 035 868 32 35 37 38 43 44 OETIKER PLIERS 295 000 070 44 SPRING REMOVER 529 036 007 46 SERVICE PRODUCTS Descriptio...

Page 31: ...AL Subsection 02 AIR CONTROLLED SUSPENSION ACS 53 N m 39 lbf ft NEW 53 N m 39 lbf ft 53 N m 39 lbf ft Loctite 592 pipe sealant ACS module NEW ACS compressor ACS solenoid release valve ACS hose vmr2010...

Page 32: ...automatically keeps air pres sure constant with changing rider weights or loads applied The system can be adjusted on the fly to suit rider s preferences The multifunction gauge indicates suspension s...

Page 33: ...be displayed instead of acknowledgement message Using the Auxiliary Line to Inflate Tires The ACS system is equipped with an auxiliary line specially designed to inflate tires The air pressure in thi...

Page 34: ...TS Fuse and Relay ACS Fuse F14 1 ACS fuse F14 is located in the front fuse box FRONT FUSES BOX NO DESCRIPTION RATING F14 ACS 20 A vmo2007 003 017_b TYPICAL FRONT SERVICE COMPARTMENT 1 Front fuse box A...

Page 35: ...Section 01 TECHNICAL MANUAL Subsection 02 AIR CONTROLLED SUSPENSION ACS Outlander 800R LTD vmr2010 004 105_a OUTLANDER 800R LTD MODEL 1 ACS compressor relay R5 28 vmr2010 004...

Page 36: ...pressure zone To monitor the air pressure of the auxiliary line Pressure transducer High pressure zone To monitor the air pressure of the shock absorbers Check valve compressor To protect the compress...

Page 37: ...Requested Setting Display Does Not Change in Gauge 1 Check the override ACS button as detailed in OVERRIDE SWITCH in the LIGHTS GAUGE AND ACCESSORIES subsection of the appro priate Shop Manual Suspens...

Page 38: ...nd fittings with soapy water to locate the faulty component If no leak is detected from hoses or fittings in spect the compressor check valve and the auxil iary line check valve with soapy water vmr20...

Page 39: ...Set suspension mode to ACS 2 using the ACS button 5 Wait until the actual setting shows 2 LH dis play vmr2010 004 101_a 1 Actual setting pressure transducer reading NOTE Make sure to wait enough time...

Page 40: ...le threads ACS MANIFOLD ACS Manifold Removal 1 Release air pressure refer to RELEASING AIR PRESSURE IN SYSTEM FOR SERVICING in this subsection 2 Remove solenoid valve Refer to ACS SOLE NOID VALVE REMO...

Page 41: ...pply sealant it should be already applied on male threads On pneumatic valve check valve and solenoid valve apply LOCTITE 592 PIPE SEALANT P N 293 800 018 on all male threads Install check valve with...

Page 42: ...E Gauge pin 19 BE GN Module pin 6 WH BE Close to 0 ACS Module Input Voltage Test 1 Remove seats and RH side panel 2 Disconnect module connector vmr2010 004 011_a 1 Module connector 3 Set the FLUKE 115...

Page 43: ...2_a 1 Module retaining bolt 5 Remove module from vehicle ACS Module Installation The installation procedure is the reverse of re moval procedure however pay attention to the following If a new ACS mod...

Page 44: ...ve post Battery voltage 12 Vdc Outlander 800R LTD TEST PROBES VOLTAGE Fuse box pin 12A OR GN Battery negative post Battery voltage 12 Vdc Outlander 500 LTD TEST PROBES VOLTAGE Fuse box pin 7D BE PK Ba...

Page 45: ...esistance as per the following table Outlander 500 LTD TEST PROBES RESISTANCE Compressor pin C BE VI Fuse box pin 6C BE VI Close to 0 Outlander 800R LTD TEST PROBES RESISTANCE Compressor pin C BE VI F...

Page 46: ...vmr2010 004 013_a 1 Storage tray 4 Remove solenoid valve Refer to ACS SOLE NOID VALVE REMOVAL 5 Remove manifold Refer to ACS MANIFOLD REMOVAL 6 Remove module Refer to ACS MODULE RE MOVAL 7 Remove con...

Page 47: ...ining bolts and nuts vmr2010 004 017_a 1 RH side retaining bolt vmr2010 004 018_a 1 LH side retaining bolt 12 Remove compressor front retaining screws vmr2010 004 019_a 1 Front retaining screws 13 Rem...

Page 48: ...ver pay attention to the following If fitting or valve is the one previously removed old one apply LOCTITE 592 PIPE SEALANT P N 293 800 018 on all male threads If fitting or valve is a new one do not...

Page 49: ...te ACS compressor air filter 6 Unscrew ACS compressor air filter from air box vmo2010 004 009_a 1 ACS compressor air filter 7 Push tabs then open cover vmo2010 004 010_a 1 tabs 8 Remove prefilter foam...

Page 50: ...er connector vmr2010 004 104_a 1 Pressure transducer connector 4 Set the FLUKE 115 MULTIMETER P N 529 035 868 to 5 Measure resistance as per the following table TEST PROBES RESISTANCE Pressure transdu...

Page 51: ...4 Remove pressure transducer from hose vmr2010 004 030_a 1 Auxiliary line pressure transducer 2 Connector 3 Oetiker clamp 5 Install a new pressure transducer on hose 6 Install a new Oetiker clamp usi...

Page 52: ...ed into fitting vmo2010 011 103 HOSE PROPERLY INSERTED INTO FITTING SHOCK ABSORBERS Shock Absorber Removal 1 Lift rear of vehicle until rear shock absorbers are fully extended 2 Install jack stands or...

Page 53: ...k Absorber Inspection Inspect the spring for damage Replace if neces sary Secure the end of shock body in a vise with its rod upward A14F0BA 1 TYPICAL 1 Clamp here NOTICE Do not clamp directly on shoc...

Page 54: ...3 Lower cap 4 Upper cap 5 Large sleeve Install shock absorber cap opening at 180 from spring stopper opening Torque upper and lower shock absorber bolts to 53 N m 39 lbf ft If the same shock absorber...

Page 55: ...hat there is no air leaks from shock ab sorber fitting and air hose Refer to ACS SYSTEM LEAK TEST WITH B U D S NOTICE Never screw shock absorber air hose by using the air hose fitting only To avoid da...

Page 56: ...NOTES...

Page 57: ...NOTES...

Page 58: ...RDIER RECREATIONAL PRODUCTS INC OR ITS AFFILIATES 2009 BOMBARDIER RECREATIONAL PRODUCTS INC ALL RIGHTS RESERVED PRINTED IN CANADA 219 100 388 CA DPS ACS TECHNICAL MANUAL ENGLISH MANUEL TECHNIQUE DPS A...

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