Can-Am Renegade 1000R 2016 Service Manual Download

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Subsection 02 (PERIODIC MAINTENANCE PROCEDURES)

Inspecting the Drive Belt

1. Inspect belt for cracks, fraying or abnormal

wear. Replace if necessary.

2. Check drive belt width at cord level. Replace if

it is out of specification.

DRIVE BELT WIDTH

SERVICE LIMIT

30 mm (1.181 in)

vmr2006-021-005_a

1. Drive belt
2. Cord in drive belt

Drive Pulley, Driven Pulley and
One-Way Bearing Maintenance

Drive and Driven Pulley

Clean and inspect drive and drive pulley sheaves.
Refer to

CONTINUOUSLY VARIABLE TRANSMIS-

SION (CVT)

subsection.

One-way Clutch

Clean parts.

Lubricate:

– Springs
– Spring sleeves
– Room between one-way clutch bearings.

REQUIRED PRODUCT

ISOFLEX GREASE TOPAS NB 52 (P/N 293 550 021)

vmr2006-021-021_a

LUBRICATE

1. Springs
2. Spring sleeves

vmr2015-035-002_b

LUBRICATE

1. Room between one-way clutch bearings
2. Bearings

FUEL SYSTEM

Inspecting and Cleaning the Throttle
Body

1. Remove the air filter housing. Refer to

AIR IN-

TAKE SYSTEM

subsection.

2. Visually inspect throttle plate and throttle body

venturi for cleanliness.

3. Clean inside throttle body if necessary. Refer to

ELECTRONIC FUEL INJECTION (EFI)

subsec-

tion.

Lubricating the Throttle Cable

The throttle cable must be lubricated with a sili-
cone based lubricant.

vmr2016-400

Summary of Contents for Renegade 1000R 2016

Page 1: ...e manual covers the 2 index searchable BESTSHOPMANUALS Combined html 4 4 2014 1 33 25 PM 2016 Can Am Renegade 570 850 Series Here is combined the Base service manual with the 2016 supplement manual into one manual ...

Page 2: ...sting fed eral provincial and state regulations This manual emphasizes particular information de noted by the following wording and symbols WARNING Indicates a potential hazard that if not avoided could result in serious injury or death CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates an instruction which if not followed could r...

Page 3: ...mod els or equipment without incurring obligation VEHICLE INFORMATION VEHICLE IDENTIFICATION NUMBER VIN vmr2012 002 002_a TYPICAL 1 VIN Vehicle Identification Number location A VIN Vehicle Identification Number decal is lo cated under the seat and another on the forward RH side of the lower frame member A vin num ber is also stamped on the frame in this area VIN Decal Description MFD DATEFAB 12 20...

Page 4: ... been certified to applicable emission regulations in your country or state Not as an exhaustive list this may include standards for engine exhaust emissions crankcase emissions permeation emissions and evaporative emissions Servic ing procedures in this manual must be strictly followed in order to keep the vehicle within the factory specifications Failure to follow servicing procedures in this ma...

Page 5: ...c and most components are built with parts dimensioned using the metric system Consult the appropri ate PARTS CATALOG to obtain and use the cor rect parts and fasteners Mismatched or incor rect fasteners could cause damage to the vehi cle MANUAL LAYOUT This manual is divided into many major sections as can be seen in the main table of contents at the beginning of the manual Each section is divided...

Page 6: ...shing process Subsection title Indicates applicable models Document number for publishing process Bold face number is used to identify a part referred to the text Drop represents a service product to be applied Dotted box contains parts applicable to a specific model Page number NEW indicates that the part must be replaced with a new one Pay attention to torque specifications Some of these are in ...

Page 7: ... exploded views Clean threads before applying a threadlocker Re fer to the SELF LOCKING FASTENERS and LOC TITE APPLICATION sections 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 replaced with new ones PROCEDURES MAGNETO FLYWHEEL ...

Page 8: ...to secure a part eg a cylinder head Some parts must be torqued according to a specific sequence and torque pattern as detailed in the installation procedure A00A8BS Property class and head markings Property class and nut markings 5 5 8 8 10 10 12 12 4 8 4 8 4 8 8 8 8 8 8 8 9 8 9 8 9 8 10 9 10 9 10 9 12 9 12 9 12 9 12 9 FASTENER GRADE TORQUE FASTENER SIZE 5 8 Grade 8 8 Grade 10 9 Grade 12 9 Grade M...

Page 9: ...EADLOCKER APPLICATION PROCEDURE The following describes common procedures used when working with Loctite products NOTE Always use proper strength Loctite prod uct as recommended in this Shop Manual Threadlocker Application for Uncovered Holes Bolts and Nuts A00A3LA 1 2 1 Apply here 2 Do not apply 1 Clean threads bolt and nut with solvent 2 Apply LOCTITE 7649 PRIMER P N 293 800 041 on threads and a...

Page 10: ...reads 5 Install stud 6 Install cover part etc 7 Apply a few drops of proper strength Loctite on uncovered stud threads 8 Install and tighten retaining nut s as required Threadlocker Application for Pre Assembled Parts A00A3OA 1 2 1 Apply here 2 Do not apply 1 Clean bolts and nuts with solvent 2 Assemble components 3 Tighten nuts 4 Apply a few drops of proper strength Loctite on bolt nut contact su...

Page 11: ... DO NOT apply release agent on stud 2 Follow Standard Thread Repair procedure 3 Allow 30 minutes for Loctite FORM A THREAD to cure 4 Complete part assembly Gasket Compound Application 2 1 1 3 1 lmr2007 040 006_a 1 Proper strength Loctite 2 Loctite Primer N P N 293 800 041 and Gasket Eliminator 518 P N 293 800 038 on both sides of gasket 3 Loctite Primer N only 1 Remove old gasket and other contami...

Page 12: ... of parts to be installed 2 Continue parts assembly in the prescribed or der Threadlocker Application for Case In Components Metallic Gaskets A00A3VA 1 1 Proper strength Loctite 1 Clean inner housing diameter and outer gasket diameter 2 Spray housing and gasket with LOCTITE 7649 PRIMER P N 293 800 041 3 Apply a strip of proper strength Loctite on lead ing edge of outer metallic gasket diameter NOT...

Page 13: ...EDULE LEGEND Operation in trail riding conditions Operation in severe riding conditions dusty or muddy or carrying heavy loads condition MAINTENANCE SCHEDULE Make sure to perform proper maintenance at recommended intervals as indicated in the tables Some items of the maintenance schedule must be performed in function of the calendar regardless of the distance or time of operation EVERY 1 500 KM 1 ...

Page 14: ...dition LTD The following must be performed at least once a year Change engine oil and filter Lubricate throttle cable Inspect and clean brake system Inspect battery condition Verify steering system for abnormal play Verify front differential and rear final drive oil level and look for contamination Verify gearbox oil level and look for contamination PERFORM AT THE FIRST 3 000 KM 2 000 MI AND AT 6 ...

Page 15: ...t and output shaft seals gearbox differential and final drive Clean vehicle speed sensor Clean and lubricate lower and upper steering column half bushings The following must be performed every 2 years Replace the brake fluid EVERY 12 000 KM 8 000 MI OR 5 YEARS whichever comes first EVERY 6 000 KM 4 000 MI OR 5 YEARS whichever comes first Replace engine coolant vmr2016 427 3 ...

Page 16: ...ection provides Fluid level verifications Maintenance procedures The following systems should be serviced accord ing to the PERIODIC MAINTENANCE SCHED ULE PROCEDURES AIR INTAKE SYSTEM Engine Air Filter Maintenance Guideline As with any ATV air filter maintenance is critical to ensure proper engine performance and life span Air filter maintenance should be adjusted accord ing to riding conditions A...

Page 17: ...liness If any debris or water are found clean air fil ter chamber using a vacuum cleaner NOTICE Do not blow compressed air into air filter chamber 4 Check air filter housing drain tube clean cham ber If any debris or water are found refer to SPE CIAL PROCEDURES subsection Investigate for contamination source vmr2012 010 017_b SOME PARTS REMOVED FOR CLARITY 1 Air filter drain tube Cleaning the Pape...

Page 18: ...y vbs2009 012 005 NOTE A second application may be necessary for heavily soiled elements Oiling the Foam Filter 1 Spray recommended air filter oil on the foam fil ter previously cleaned and dried Follow manu facturer s informations RECOMMENDED PRODUCT AIR FILTER OIL P N 219 700 340 vbs2009 012 014 2 Reinstall oiled foam filter on paper air filter Installing the Engine Air Filter Slightly grease O ...

Page 19: ...ush NOTICE Use a soft brush and be careful to avoid damaging spark arrester mesh tmo2011 001 043_a 1 Clean spark arrester 4 Inspect mesh of spark arrester for any damage Replace as required 5 Inspect spark arrester chamber in muffler Clean as required For installation reverse the removal procedure However pay attention to the following Install new gasket and new retaining screws TIGHTENING TORQUE ...

Page 20: ...peat the above procedures until oil level reaches the dipstick s upper mark Do not over fill Wipe off any spillage Properly tighten dipstick Changing the Engine Oil 1 Start and warm up engine 2 Stop engine 3 Ensure vehicle is on a level surface 4 Remove dipstick 5 Place a drain pan under the engine drain plug area 6 Clean the drain plug area 7 Unscrew magnetic drain plug and discard the gasket rin...

Page 21: ...ankcase then check oil level again 18 Dispose oil and filter as per your local environ mental regulations Replacing the Engine Oil Filter Engine Oil Filter Location vmr2016 400 003_a Removing the Engine Oil Filter 1 Clean oil filter area 2 Remove oil filter cover screws 3 Remove oil filter cover 4 Remove oil filter vmr2016 009 001_a 1 Oil filter screw 2 Oil filter cover 3 O ring 4 Oil filter Insta...

Page 22: ...Level 1 Place vehicle on a level surface 2 Remove gauge support Refer to BODY sub section With the vehicle on a level surface coolant level should be between the MIN and MAX marks of the reservoir vmr2016 400 004 NOTE When checking level at temperature lower than 20 C 68 F it may be slightly lower than MIN mark 3 Add coolant up to MAX mark if required 4 Use a funnel to avoid spillage Do not overfi...

Page 23: ...or too high PRESSURE CAP RELIEF PRESSURE Approximately 110 kPa 16 PSI Engine Cooling System Leak Test 1 Remove the console Refer to BODY subsec tion 2 Remove pressure cap 3 Pressurize cooling system as follows REQUIRED TOOLS TEST CAP P N 529 035 991 VACUUM PRESSURE PUMP P N 529 021 800 COOLING SYSTEM LEAK TEST 110 kPa 16 PSI If there is no pressure drop after 10 minutes there is no leak in the coo...

Page 24: ...ING TORQUE Coolant drain plug 10 N m 1 N m 89 lbf in 9 lbf in 8 Fill cooling system with recommended coolant refer to COOLING SYSTEM FILLING AND BLEEDING procedure Filling and Bleeding the Engine Cooling System 1 Remove cooling system pressure cap 2 Remove RH and LH side panels Refer to BODY subsection 3 Remove outer exhaust heat shield Refer to EX HAUST SYSTEM subsection vmr2015 029 202_a 1 Outer...

Page 25: ...EAD Inspecting and Adjusting Engine Valve Clearance NOTE Check and adjust valve clearance only when engine is cold 1 Remove valve covers refer to TOP END sub section 2 Before checking or adjusting the valve clear ance turn crankshaft clockwise to TDC ignition of the respective cylinder refer to CAMSHAFT TIMING GEAR in the TIMING CHAIN subsec tion NOTICE Crankshaft must be turned clock wise only to...

Page 26: ...3 Check oil level The oil should be level with the bottom of the oil level hole NOTICE Operating the gearbox with an im proper oil level may severely damage gearbox 4 Install the oil level plug with its O ring Tighten plug as per table TIGHTENING TORQUE Oil level plug 5 N m 0 6 N m 44 lbf in 5 lbf in Replacing the Gearbox Oil Draining the Gearbox Oil 1 Start engine and operate vehicle to warm up t...

Page 27: ...er to appropriate GEARBOX AND 4X4 COUPLING UNIT subsection Remove all metal particles and oil from the VSS magnet NOTE A dirty VSS will cause erratic speedometer readings CONTINUOUSLY VARIABLE TRANSMISSION CVT Cleaning the CVT Air Inlet Outlet 1 Remove CVT cover refer to CONTINUOUSLY VARIABLE TRANSMISSION CVT subsection 2 Inspect and clean the air inlet and outlet open ings from inside the CVT cov...

Page 28: ...ction One way Clutch Clean parts Lubricate Springs Spring sleeves Room between one way clutch bearings REQUIRED PRODUCT ISOFLEX GREASE TOPAS NB 52 P N 293 550 021 vmr2006 021 021_a LUBRICATE 1 Springs 2 Spring sleeves vmr2015 035 002_b LUBRICATE 1 Room between one way clutch bearings 2 Bearings FUEL SYSTEM Inspecting and Cleaning the Throttle Body 1 Remove the air filter housing Refer to AIR IN TA...

Page 29: ...hese screws Separate the housing Slide rubber protector back to expose throttle ca ble adjuster V07I0GA 4 3 2 1 1 Cable protector 2 Throttle cable adjuster 3 Lock nut 4 Throttle lever housing Screw in the throttle cable adjuster Remove inner housing protector 1 V07I0HA 1 Inner housing protector Remove the cable from the throttle lever housing NOTE Slide cable in clip slot and remove the end of cab...

Page 30: ...System 1 Visually inspect fuel tank for cracks wear marks signs of leakage or any other damages 2 Visually inspect fuel system hoses for proper rooting cracking wear marks signs of leakage or any other damages 3 Carry out a FUEL TANK LEAK TEST refer to FUEL TANK AND FUEL PUMP subsection WARNING All fuel system leaks must be repaired Dam aged worn or leaking fuel system com ponents should be replac...

Page 31: ...antiseize lubricant on the first 2 spark plug threads 3 Hand screw spark plug into cylinder head then tighten to specification using a torque wrench and an appropriate socket TIGHTENING TORQUE Spark plug 570 engine 20 N m 2 N m 15 lbf ft 1 lbf ft 850 and 1000R engines 11 N m 1 N m 97 lbf in 9 lbf in DRIVE SYSTEM Verifying the Front Differential Oil Level 1 Clean filler plug area prior to checking ...

Page 32: ...ired Verifying the Rear Final Drive Oil Level 1 Ensure vehicle is on a level surface 2 Clean filler plug area 3 Remove filler plug tmr2011 032 006_a LH REAR SIDE OF VEHICLE 1 Filler plug 4 Verify the oil level by inserting a wire with a 90 bend through the oil filler hole 5 Oil level must be within the following specifica tion from the bottom of oil filler hole OIL LEVEL 20 mm 5 mm 9 16 in 3 16 in...

Page 33: ...e NLGI 2 or an equivalent WHEELS AND TIRES Wheel Beadlocks Tighten beadlock screws as per specification and following sequence TIGHTENING TORQUE Beadlock screws 11 N m 1 N m 97 lbf in 9 lbf in vmr2012 038 001_c TIGHTENING SEQUENCE Inspecting the Wheel Bearing 1 Safely lift and support the front of vehicle 2 Hold wheel by the top and the bottom and try to move it by pulling and push alternately wit...

Page 34: ... Refer to REAR SUSPENSION subsec tion Lubricating the Shock Absorber Spherical Bearing HPG Shock Absorber with Remote Reservoir 1 Remove shock absorber from vehicle 2 Remove shock sleeves then O rings from shock absorber vmr2010 004 702_a 1 Sleeve 2 O ring 3 Clean spherical bearing using a shop rag to re move any dirt and debris 4 Lubricate spherical bearing as illustrated SPHERICAL BEARING LUBRIC...

Page 35: ... down 3 If any play is detected inspect Spacers Bearings Inner spacers 4 Check ball joint for Damage Pitting Play 5 Check ball joint bellows for Damage Cracks Inspecting and Lubricating the Rear Stabilizer Bar Bushings Inspecting the Rear Stabilizer Bar Bushings Inspect bushings for Cracks Damage Abnormal wear Lubricating the Rear Stabilizer Bar Bushings Lubricate bushings at grease fittings LUBRI...

Page 36: ...g Remove screws retaining the reservoir cap Remove reservoir cap Add fluid as required using a clean funnel Do not overfill NOTICE Brake fluid can damage plastic and painted surface Wipe off and clean any spillage Reinstall reservoir cap and tighten screws NOTE Ensure filler cap diaphragm is pushed in side the cap before closing the brake fluid reser voir Inspecting and Cleaning the Brake System N...

Page 37: ... for cracks or damage Replace as necessary Hand Lever Check hand lever as follows Lever pivot bolt cleanliness Lever pivot bolt movement Brake Pedal 1 Check brake pedal as follows Brake pedal pivot movement Brake pedal pivot cleanliness 2 If required clean then lubricate brake pedal pivot using XPS SYNTHETIC GREASE P N 293 550 010 Brake Hoses 1 Check hoses for leaks crushed deformations cracking o...

Page 38: ... the other bleed ers 10 Check brakes operation If brakes feel spongy bleed system again then carry out the BRAKE SYSTEM PRES SURE VALIDATION as detailed in BRAKES subsection Bleeding the Brake System Manual Procedure NOTE Brake fluid reservoir must be kept full to prevent air from being pumped into the system 1 Connect a clear hose onto bleeder 2 Pump up system pressure slowly using brake pedal an...

Page 39: ...FUEL STABILIZER P N 413 408 601 NOTICE Fuel stabilizer should be added prior to engine lubrication to ensure fuel sys tem components protection against varnish deposits ENGINE Engine Internal Lubrication Engine internal parts must be lubricated to protect them from rust formation during the storage pe riod Proceed as follows 1 Remove side body panels 2 Remove spark plugs 3 Spray storage oil into e...

Page 40: ...ery as per battery manufac turer s recommendations DRIVE SYSTEM Lubricate rear propeller shaft U joints CHASSIS Lubrication Lubricate front and rear suspension Tire Pressure Inflate tires to recommended pressure Vehicle Cleaning Wash and dry the vehicle NOTICE Never use a high pressure washer to clean the vehicle USE LOW PRESSURE ONLY such as a garden hose The high pressure can cause electrical or...

Page 41: ...RTS XPS MULTI PURPOSE CLEANER P N 219 701 709 To clean heavily soiled parts of the vehicle includ ing metallic parts use the following RECOMMENDED PRODUCT FOR HEAVILY SOILED PARTS 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 an appropriate lubricant for rust protection RECOMME...

Page 42: ...nspection of entire engine air inlet system Check for animal nests and other foreign material Reinstall re moved parts Drain fuel tank and fill with fresh fuel if a fuel sta bilizer was not used for storage Reinstall battery Refer to CHARGING SYSTEM subsection Inflate tires to the recommended pressure Do each items indicated in the table entitled EVERY 3 000 KM 2 000 MI OR 100 HOURS whichever come...

Page 43: ... CVT cover remove the cover and properly ser vice the CVT WHAT TO DO IF WATER IS IN THE AIR FILTER HOUSING Inspect the drain reservoir underneath the air filter housing to validate if water is present vmo2012 012 054_a TYPICAL 1 Air filter housing drain reservoir If water is present press clamp and remove reser voir to drain water from air filter housing If one of the following conditions is met r...

Page 44: ...Drain muffler and exhaust pipes removal re quired Clean muffler spark arrester Remove fuse box covers Check for presence of water Dry as necessary Disconnect clean and dry the following electrical connectors ECM Multifunction gauge DPS Replace the engine oil without starting the en gine Replace gearbox oil Inspect fuel tank for water intrusion If in doubt flush fuel tank and refill with new fuel I...

Page 45: ...ption Part Number Page ENGINE LIFTING TOOL 529 036 022 5 Component must be replaced when removed NEW 1000 1000 Outlander models 13 2 N m 115 18 lbf in 7 1 N m 62 9 lbf in NEW 62 5 7 5 N m 46 6 lbf ft 4 9 0 4 N m 43 4 lbf in 62 5 7 5 N m 46 6 lbf ft 4 1 N m 35 9 lbf in vmr2013 009 100_a vmr2013 009 1 ...

Page 46: ...TAKE SYSTEM Remove muffler Remove exhaust pipes EXHAUST SYSTEM Remove CVT air inlet Remove CVT air outlet CONTINUOUSLY VARIABLE TRANSMISSION CVT Disconnect positive starter cable STARTING SYSTEM Disconnect TPS connector Disconnect MAPTS connector ELECTRONIC FUEL INJECTION EFI Remove intake manifold INTAKE MANIFOLD Remove spark plug cables IGNITION SYSTEM 4 Remove RH footrest support vmr2012 009 00...

Page 47: ...ICAL 1 Engine harness connectors HIC 9 Move ECM as illustrated vmr2012 009 006 TYPICAL 10 Cut locking ties from ignition coil harness 11 Disconnect ignition coil connector vmr2012 009 007_a TYPICAL FROM LH SIDE 1 Ignition coil connector 12 Remove the following locking ties vmr2012 009 008_a TYPICAL 1 Locking ties 13 Remove plastic cover from engine vmr2013 009 3 ...

Page 48: ... OUTLANDER SHOWN 1 Magneto connector 16 Remove magneto harness from its location along vehicle and gather it in a bundle near engine NOTE It may be necessary to slightly lift the rear body module to ease magneto harness removal Refer to BODY subsection vmr2012 009 011_a MAGNETO HARNESS SOME PARTS REMOVED FOR CLARITY 17 Disconnect vent hose from gearbox vmr2012 009 012_a TYPICAL OUTLANDER SHOWN 1 V...

Page 49: ...R CLARITY 1 Disconnect the following coolant hoses 19 Remove main ground wire from engine vmr2012 009 014_a TYPICAL OUTLANDER SHOWN 1 Main ground wire Engine Lifting 1 Install the ENGINE LIFTING TOOL P N 529 036 022 on engine 529036022 vmr2012 009 015 TYPICAL 2 Remove upper retaining screws from engine vmr2012 009 016_a LH SIDE 1 Upper retaining screws 3 Remove rear retaining bolt from engine vmr2...

Page 50: ...a RH SIDE 1 Engine support plate screws 6 Remove the following Oetiker clamps from front propeller shaft vmr2012 009 020_a 1 Oetiker clamps 7 Move front propeller shaft bellows forward vmr2012 009 021_a 1 Front propeller shaft bellows 8 Remove propeller shaft screw from gearbox output shaft vmr2012 009 022_a 1 Rear propeller shaft screw 9 Slightly lift engine and move it forward to dis connect rea...

Page 51: ...aining bolts to specification TORQUE Engine retaining bolts 62 5 N m 7 5 N m 46 lbf ft 6 lbf ft 6 If applicable fill engine as per specification Re fer to LUBRICATION SYSTEM subsection 7 Fill and bleed cooling system Refer to PERI ODIC MAINTENANCE PROCEDURE subsec tion 8 Check for any leaks 9 Reinstall all the remaining parts as the reverse of removal procedure Refer to exploded views and proper s...

Page 52: ...TEM AIR FILTER HOUSING 1 6 0 4 N m 14 4 lbf in 6 1 N m 53 9 lbf in 2 5 0 5 N m 22 4 lbf in To throttle body To engine 6 1 N m 53 9 lbf in Loctite 5150 silicone sealant Suspension grease Loctite 5150 silicone sealant vmr2012 010 100_a vmr2013 010 1 ...

Page 53: ...NG Air Filter Housing Removal 1 Remove front body module Refer to BODY subsection 2 On applicable models remove the following plastic rivets vmr2012 013 005_a TYPICAL 1 Plastic rivets 3 On applicable models move dashboard support toward front vmr2012 033 001_a TYPICAL 1 Dashboard support 4 Remove screws securing CVT air inlet to air fil ter housing vmr2012 010 002_a TYPICAL 1 CVT air inlet screws ...

Page 54: ...w 9 Move air intake tube to gain access to coolant tank LH screw 10 Remove coolant tank retaining screws vmr2012 010 004_a AIR INTAKE TUBE MOVED TO GAIN ACCESS 1 Coolant tank LH retaining screw vmr2012 010 005_a 1 Coolant tank RH retaining screw 11 Detach link rod from shift lever vmr2012 010 006_a TYPICAL OUTLANDER SHOWN 1 Link rod retaining bolt 12 Carefully move link rod downward vmr2013 010 3 ...

Page 55: ...09_a TYPICAL OUTLANDER SHOWN 1 Locking ties to remove 14 Detach gearbox vent hose from air filter hous ing vmr2012 010 010_a TYPICAL 1 Gearbox vent hose 15 Detach crankcase vent hose from air filter housing vmr2012 010 011_a TYPICAL 1 Crankcase vent hose 16 Remove air filter housing retaining screws vmr2012 010 012_a SCREWS LOCATED NEAR SEAT ANCHORAGE 1 Air filter housing retaining screws 4 vmr201...

Page 56: ...dy aside to make room vmr2012 010 015_a TYPICAL OUTLANDER SHOWN 1 Throttle body 20 Remove air filter housing by pulling it towards rear vmr2012 010 016_a AIR FILTER HOUSING REMOVAL 21 Remove remaining components from air filter housing Air Filter Housing Inspection Check air filter housing for cracks or other dam age Replace if necessary Air Filter Housing Installation The installation is the reve...

Page 57: ...be replaced when removed 13 1 N m 115 9 lbf in 10 2 N m 89 18 lbf in 13 1 N m 115 9 lbf in 9 1 N m 80 9 lbf in 9 1 N m 80 9 lbf in 40 1 N m 30 1 lbf ft Bolt down nut facing outwards NEW NEW NEW 9 1 N m 80 9 lbf in 9 1 N m 80 9 lbf in vmr2016 401 001_a vmr2016 401 1 ...

Page 58: ...ove bolts 3 Refer to BODY and remove both rear bumper braces vmr2012 011 007_d 1 Brace 2 Remove fasteners 4 Remove muffler Muffler Inspection Check muffler and cover for cracks or other dam ages Replace if necessary Check if the rubber support is brittle hard or oth erwise damaged Replace if needed Muffler Installation For the installation reverse the removal proce dure However pay attention to th...

Page 59: ...014 512_a 1 Inner heat shield 2 M6 x 16 bolts Heat Shield Installation For the installation reverse the removal proce dure However pay attention to the following Refer to exploded view for torque specifications and following illustration for rear heat shield tight ening sequence vmr2015 027 101_a REAR HEAT SHIELD TIGHTENING SEQUENCE Y EXHAUST PIPE Y Exhaust Pipe Removal 1 Remove MUFFLER See proced...

Page 60: ...Removal 1 Remove Y EXHAUST PIPE See procedure in this subsection 2 From RH side of vehicle remove head pipe re taining nuts vmr2015 027 004_a 1 Head pipe retaining nuts 3 Remove front head pipe from vehicle vmr2012 011 011_a 1 Head pipe NOTE The space to remove the front head pipe is limited Remove it without force Front Head Pipe Inspection Check head pipe for cracks bending or other dam ages Rep...

Page 61: ...htening System Sequence Install all nuts and bolts loosely Install springs Tighten all fasteners as per following tightening sequence Refer to exploded view for torque specifications vmr2016 401 002_a EXHAUST SYSTEM TIGHTENING SEQUENCE vmr2016 401 5 ...

Page 62: ...RICATION SYSTEM SERVICE TOOLS Description Part Number Page ADAPTER HOSE 529 035 652 5 DISCONNECT TOOL 529 035 714 5 PRESSURE GAUGE 529 035 709 5 SERVICE PRODUCTS Description Part Number Page LOCTITE 243 BLUE 293 800 060 7 11 vmr2016 402 1 ...

Page 63: ...d NEW 20 2 N m 15 1 5 lbf ft NEW 10 1 N m 89 9 lbf in NEW Engine oil Loctite 243 12 1 N m 106 9 lbf in NEW Engine oil Loctite 243 7 0 5 N m 62 4 lbf in Engine oil 10 1 N m 89 9 lbf in 6 0 7 N m 53 6 lbf in Loctite 243 Engine oil 20 2 N m 15 1 5 lbf ft Engine oil vmr2015 028 001_a 2 vmr2016 402 ...

Page 64: ... NEW NEW NEW NEW NEW Loctite 243 Loctite 243 Loctite 243 Loctite 243 Engine oil Engine oil Engine oil 20 2 N m 15 1 5 lbf ft 10 1 N m 89 9 lbf in 12 1 N m 106 9 lbf in 30 2 N m 22 1 5 lbf ft 7 0 5 N m 62 4 lbf in 8 1 N m 70 9 lbf in 10 1 N m 89 9 lbf in 6 0 7 N m 53 6 lbf in vmr2015 114 001_a vmr2016 402 3 ...

Page 65: ...BRICATION CIRCUIT vmr2007 033 001_a 1 Camshaft bearings 2 Oil pressure switch 3 Oil filter 4 Oil pressure regulator valve 5 Oil strainer 6 Oil pump 7 Crankshaft main bearings 8 Crankshaft support bearing 9 Connecting rod bearings 4 vmr2016 402 ...

Page 66: ... level is too low Refill engine with recommended engine oil Re fer to OIL LEVEL VERIFICATION in the PERIODIC MAINTENANCE PROCEDURES subsection Check for high oil consumption refer to HIGH OIL CONSUMPTION in thisTROUBLESHOOTING Check for engine oil leaks For leak indicator hose and leak indicator hole refer to COOLING SYSTEM INSPECTION in the PERIODIC MAIN TENANCE PROCEDURES subsection Repair if ne...

Page 67: ...he Oil Cooler Refer to PERIODIC MAINTENANCE PROCE DURES subsection to Drain engine oil Refer to ENGINE OIL CHANGE Drain coolant Refer to ENGINE COOLANT RE PLACEMENT Remove oil cooler retaining screws tmr2011 010 006_a 1 Retaining screws 2 Oil cooler Place rags or towels under oil cooler to catch re maining oil and coolant Remove oil cooler and discard gasket tmr2011 010 007_a 1 Oil cooler 2 Gasket...

Page 68: ...nector from the oil pressure switch Check resistance as per following tables OPS CONNECTOR ENGINE ENGINE NOT RUNNING PIN RESISTANCE 1 Engine ground Close to 0 normally closed switch OPS CONNECTOR ENGINE ENGINE RUNNING PIN RESISTANCE 1 Engine ground Infinite open when pressure reaches 30 kPa 10 kPa 4 35 PSI 1 45 PSI vmr2006 014 009_a If resistance values are incorrect replace the oil pressure switc...

Page 69: ...ing and valve for scoring or other damages Check spring for free length SPRING FREE LENGTH NEW NOMINAL 39 mm 1 535 in SERVICE LIMIT 37 mm 1 457 in NOTE Replace worn or damaged components Clean bore and thread in the magneto housing from metal shavings and other contaminations Installing the Oil Pressure Regulator For installation reverse the removal procedure Pay attention to the following details...

Page 70: ...tor 2 Needle pin 3 Oil pump shaft 4 Inner rotor Inspecting the Oil Pump Inspect oil pump and oil pump cover bore for marks scratches or other damages Check for scratches in crankcase between outer rotor and oil pump bore If so replace damaged parts Check oil pump cover for damages and for surface straightness with a straightedge vmr2006 042 012_a 1 Oil pump bore 2 Outer rotor 3 Oil pump shaft 4 Ne...

Page 71: ...tor and its bore in crankcase exceeds the tolerance replace the complete oil pump rotors and or the crankcase Using a depth gauge measure the axial clearance of the oil pump as shown vmr2006 042 015 OIL PUMP MEASUREMENT A vmr2006 042 016 OIL PUMP COVER MEASUREMENT B Substract measurement B from measurement A to obtain axial clearance OIL PUMP AXIAL CLEARANCE SERVICE LIMIT 0 20 mm 008 in NOTE When ...

Page 72: ...late Pull out engine oil strainer vmr2006 042 017_a 1 Engine oil strainer 2 Retaining plate 3 Screws Cleaning and Inspecting the Oil Strainer Clean engine oil strainer with a part cleaner then use an air gun to dry it WARNING Always wear eye protector Chemicals can cause a rash break out and injure your eyes Check engine oil strainer for cracks or other dam age Replace if damaged Installing the Oi...

Page 73: ...from vehicle PTO cover refer to PTO COVER in the BOT TOM END subsection Reed valve retaining screws Stopper plate Reed valve Inspecting the Reed Valve Check reed valve for cracks or other damage Replace reed valve if damaged Installing the Reed Valve The installation is the reverse of the removal pro cedure 12 vmr2016 402 ...

Page 74: ...er Page HANDLE 420 877 650 17 OIL SEAL PUSHER 529 035 757 17 ROTARY SEAL PUSHER PLATE 529 036 130 14 SEAL PUSHER 529 035 766 14 17 SERVICE PRODUCTS Description Part Number Page DOW CORNING 111 413 707 000 17 LOCTITE 243 BLUE 293 800 060 7 vmr2016 417 1 ...

Page 75: ...RADIATOR 570 Engine 2 5 0 5 N m 22 4 lbf in NEW 10 2 N m 89 18 lbf ft NEW Component must be replaced when removed 10 2 N m 89 18 lbf ft vmr2016 417 100_a 2 vmr2016 417 ...

Page 76: ...850 and 1000R Engine 2 5 0 5 N m 22 4 lbf in 10 2 N m 89 18 lbf ft 850 1000R X mr STD X xc Component must be replaced when removed NEW NEW NEW NEW NEW vmr2016 417 102_a vmr2016 417 3 ...

Page 77: ...f in Loctite 243 16 2 N m 142 18 lbf in CTS See Electronic Fuel Injection EFI 10 1 N m 89 9 lbf in 2 5 0 3 N m 22 3 lbf in Molycote 111 Engine oil Engine oil Component must be replaced when removed NEW NEW NEW NEW NEW NEW NEW NEW NEW 3 5 0 4 N m 31 4 lbf in 3 5 0 4 N m 31 4 lbf in vmr2013 013 002_b 4 vmr2016 417 ...

Page 78: ...S see ELECTRONIC FUEL INJECTION EFI NEW NEW Loctite 243 6 0 7 N m 53 6 lbf in 20 2 N m 15 1 5 lbf ft Engine oil 2 5 0 3 N m 22 3 lbf in NEW Molycote 111 Engine oil 10 1 N m 89 9 lbf in NEW Component must be replaced when removed See BOTTOM END NEW NEW NEW NEW NEW 3 5 0 4 N m 31 4 lbf in vmr2013 013 001_b vmr2016 417 5 ...

Page 79: ... 850 and 1000R Engines The thermostat is located between the front cylin der and the radiator behind the RH front inner fender vmr2016 417 001_a Removing the Thermostat Drain engine coolant refer to PERIODIC MAINTE NANCE PROCEDURES subsection 570 Engine 1 Remove thermostat housing screws and re move thermostat cover vmr2015 115 003_a 1 Thermostat cover 2 Thermostat housing 3 Cover screws 4 Bleed s...

Page 80: ...ver pay attention to the following 570 Engine TIGHTENING TORQUE Thermostat cover retaining screws 6 N m 0 7 N m 53 lbf in 6 lbf in LOCTITE 243 BLUE P N 293 800 060 850 and 1000R Engines Install NEW Oetiker clamps All Engines Refill and bleed cooling system refer to PERI ODIC MAINTENANCE PROCEDURES subsec tion Check cooling system for leaks RADIATOR Inspecting the Radiator Check radiator fins for c...

Page 81: ... the fan motor may be damaged due to improper venting Tighten radiator upper retaining bolts to specifica tion TIGHTENING TORQUE Radiator upper retaining bolts 10 N m 2 N m 89 lbf in 18 lbf in Refill and bleed cooling system refer to PERI ODIC MAINTENANCE PROCEDURES subsec tion Check cooling system for leaks COOLANT TEMPERATURE SENSOR CTS Refer to ELECTRONIC FUEL INJECTION EFI subsection RADIATOR ...

Page 82: ...the engine is operating in the fan activation temperature range Refer to RADIA TOR COOLING FAN OPERATION COOLING FAN TROUBLESHOOTING CHART Is fan working YES Everything is OK NO Check FAN fuse F9 Is fuse burnt YES Replace fuse Is fan working NO Bypass fan relay R1 refer to RELAY OPERATION TEST Fan turns YES Replace relay Is fan working NO Apply 12 Vdc and a ground to fan connector refer to RADIATO...

Page 83: ... locate proper terminals 3 If the radiator cooling fan is activated replace the relay Relay Continuity Test Refer to POWER DISTRIBUTION AND GROUNDS subsection WATER PUMP HOUSING Water Pump Housing Location The water pump housing is located on the engine MAG side Water Pump Housing Access Remove RH footrest panel refer to BODY sub section Removing the Water Pump Housing WARNING To avoid potential b...

Page 84: ...ecting the Water Pump Impeller Check impeller for cracks or other damage Re place impeller if damaged Installing the Water Pump Impeller The installation is the reverse of the removal pro cedure However pay attention to the following NOTICE Be careful not to damage impeller fins during installation WATER PUMP SHAFT AND SEALS Use these guidelines to service these parts DEFECTIVE PART ACTION Rotary ...

Page 85: ...ly bend down the outer part of rotary seal lip using a small chisel tmr2011 011 051_a 1 Small chisel 4 Use 2 screwdrivers and carefully remove the outer part of the rotary seal tmr2011 011 052_a 1 Screwdrivers NOTICE Be careful not to damage the crankcase while removing outer part of the rotary seal 12 vmr2016 417 ...

Page 86: ...ws with pliers tmr2011 011 055_a 1 Pull on screws to remove seal 8 Check water pump shaft axial play NOTE If axial play is not adequate engine must be disassembled to replace water pump shaft 9 Clean oil seal seat tmr2011 011 056_a Seals Installation 1 Apply engine oil on water pump shaft 2 Apply grease on the lips of the oil seal 3 Carefully install oil seal over the water pump shaft 4 Push oil s...

Page 87: ...he shaft 8 Place a robust M8 flat washer P N 420 227 935 onto water pump shaft 9 Install a M8 x 1 25 nut P N 233 281 414 onto water pump shaft by hand 10 Thread nut 1 1 2 turns to pull the shaft into rotary seal tmr2011 011 057_a 1 Rotary seal 2 M8 robust flat washer P N 420 227 935 3 M8 x 1 25 nut P N 233 281 414 11 Remove M8 nut NOTE The robust M8 flat washer must remain on water pump shaft REQU...

Page 88: ...M6 x 85 screw 4 Pusher bolt 12 4 Install seal pusher between rotary seal pusher plate and water pump shaft tmr2011 011 060_a SEAL PUSHER INSTALLATION 1 Seal pusher aligned with pusher bolt 12 5 Tighten the pusher bolt by hand until it stops against the seal pusher 13 Carefully thread the pusher bolt 1 1 2 turns 14 Ensure that the rotary seal is going straight into crankcase 15 Remove rotary seal i...

Page 89: ... Shaft and Seals Replacement Disassembled Engine Water Pump Shaft and Seals Removal 1 Remove the following parts see procedure in this subsection WATER PUMP HOUSING WATER PUMP IMPELLER WATER PUMP GEARS 2 Push out water pump shaft with inner portion of rotary seal from inside of crankcase MAG side REQUIRED TOOL Soft hammer tmr2011 011 010_a 1 Water pump shaft 2 Crankcase MAG side 3 Install a blind ...

Page 90: ...ary seal surface of any old sealant Install oil seal REQUIRED TOOL OIL SEAL PUSHER P N 529 035 757 HANDLE P N 420 877 650 When installing the oil seal on the pusher make sure the sealing lip points outwards Push NEW oil seal in place tmr2011 011 014_a 1 Oil seal 2 Installer handle with oil seal pusher Lubricate sealing lip of the oil seal SERVICE PRODUCT Sealing lip of the oil seal DOW CORNING 111...

Page 91: ...R PUMP GEARS Water Pump Gears Identification vmr2012 013 009_a 1 Water pump shaft 2 Water pump gear 3 Water pump intermediate drive gear 4 Water pump intermediate shaft 5 Water pump drive gear See BOTTOM END subsection Inspecting the Water Pump Gears Water Pump Gear Inspect water pump gear for wear and damage on the snap mechanism to the needle pin Replace if damaged tmr2011 011 008_a CRANKCASE MA...

Page 92: ...t washer tmr2011 011 009_a CRANKCASE MAG SIDE 1 Water pump gear 2 Needle pin 3 Thrust washer Water Pump Intermediate Drive Gear 1 Remove circlip retaining water pump interme diate drive gear and discard it vmr2015 029 001_a CRANKCASE PTO SIDE 1 Water pump intermediate drive gear 2 Circlip 3 Water pump intermediate shaft 4 Crankcase PTO side 2 Remove the following parts Water pump intermediate driv...

Page 93: ...ver use the circlip a second time Always install a NEW one tmr2011 011 008_a 1 Circlip 2 Water pump gear Water Pump Intermediate Drive Gear Install the following parts on water pump interme diate shaft Needle pin Water pump intermediate drive gear Install NEW circlip to retain water pump interme diate drive gear NOTICE Never use the circlip a second time Always install a NEW one Water Pump Drive G...

Page 94: ...MULTIMETER 529 035 868 4 MAGNETO PULLER 529 035 748 6 SERVICE PRODUCTS Description Part Number Page DIELECTRIC GREASE 293 550 004 11 DREI BOND SEALING COMPOUND 420 297 906 4 LOCTITE 243 BLUE 293 800 060 6 LOCTITE 648 GREEN 413 711 400 8 LOCTITE 767 ANTISEIZE LUBRICANT 293 800 070 10 11 LOCTITE CHISEL GASKET REMOVER 413 708 500 3 PULLEY FLANGE CLEANER 413 711 809 7 8 vmr2016 403 1 ...

Page 95: ... in Multi Purpose Grease BP LS3 See ELECTRONIC FUEL INJECTION EFI 10 1 N m 89 9 lbf in 10 1 N m 89 9 lbf in Loctite 243 Drei Bond sealing compound 4 0 5 N m 35 4 lbf in Engine oil Engine oil Loctite 648 150 10 N m 111 7 lbf ft 30 2 N m 22 1 5 lbf ft 25 3 N m 18 2 lbf ft Loctite 767 antiseize lubricant NEW Engine with 650W magneto vmr2016 403 100_a 2 vmr2016 403 ...

Page 96: ...ATOR CONNECTOR ACCESS in this subsection Remove dipstick with O ring vmr2015 030 002_a 1 Dipstick 2 O ring 3 Crank position sensor CPS Remove magneto cover retaining screws vmr2015 030 003_a 1 Magneto cover 2 Retaining screws Pull out magneto cover Inspecting and Cleaning the Magneto Cover Check magneto cover for cracks or other damage Replace if necessary NOTE Clean all metal components in a non ...

Page 97: ...TENING SEQUENCE TIGHTENING TORQUE Magneto cover screws 10 N m 1 N m 89 lbf in 9 lbf in Refill engine with recommended oil STATOR Stator Connector Access NOTE The stator is directly connected to the volt age regulator rectifier vmr2016 403 003_a vmr2012 014 020_a 1 Voltage regulator rectifier 2 Three YELLOW wires Testing the Stator Static Continuity 1 Disconnect the stator connector on the voltage ...

Page 98: ...g connectors properly Removing the Stator Remove MAGNETO COVER See procedure in this subsection Remove screws securing the wire holding strip Remove stator retaining screws then the stator tmr2013 014 001_a 1 Holding strip screws 2 Wire holding strip 3 Stator retaining screws 4 Stator Inspecting the Stator Check stator windings and insulation for cracks or other damages If damaged replace it Check...

Page 99: ...EQUIRED TOOL CRANKSHAFT LOCKING BOLT P N 529 035 617 Heat screw in order to break the Loctite Remove screw and washer securing rotor to crankshaft vmr2006 041 007_a 1 Screw M16 2 Washer 3 Rotor Remove rotor REQUIRED TOOL CRANKSHAFT PROTECTOR P N 529 036 034 MAGNETO PULLER P N 529 035 748 NOTE Use grease to place protector on crank shaft end prior to screw on the magneto puller vmr2006 041 010_a 1 ...

Page 100: ...rts Crankshaft taper Oil passage in crankshaft taper Thread in crankshaft Rotor taper Oil bore in rotor NOTICE Taper on crankshaft and rotor must be free of grease tmr2011 012 008_a 1 Crankshaft MAG side 2 Oil passage 3 Threads Oil sprag clutch and install sprag clutch gear vmr2006 041 015_b 1 Sprag clutch 2 Sprag clutch housing 3 Sprag clutch gear 4 Apply engine oil here Slide rotor onto cranksha...

Page 101: ...ting the Sprag Clutch Inspect sprag clutch and sprag clutch housing for wear and damage Also check the collar of the sprag clutch gear Rotate sprag clutch gear in sprag clutch NOTE Sprag clutch must lock in counterclock wise direction vmr2006 041 014_a SPRAG CLUTCH FUNCTIONAL TEST 1 Lock NOTE Sprag clutch housing and gear must be replaced at the same time if damaged Installing the Sprag Clutch For...

Page 102: ...lutch Gear Inspect gear especially teeth and sprag clutch col lar for wear and other damage Check needle bearing condition Replace sprag clutch gear if necessary vmr2006 041 016_a INSPECT 1 Teeth 2 Collar 3 Needle bearing Installing the Sprag Clutch Gear The installation is the reverse of the removal pro cedure However pay attention to the following NOTE Apply engine oil on needle bearing and col ...

Page 103: ...e from starter so lenoid and pull cable out to RH side of the vehi cle vmr2015 030 102_a 1 Starter 2 Starter power cable connection at starter 3 Starter power cable 4 Starter power cable connection at solenoid vmr2012 033 003_a 1 Power cable from starter solenoid to starter 2 Power cable from battery to starter solenoid not visible 3 Fuel tank 4 RH rear fender 2 Using booster cables carefully supp...

Page 104: ...urfaces are free of debris Serious problems may arise if the starter is not properly aligned Lubricate starter O ring STARTER O RING AND MATING SURFACE Service product LOCTITE 767 ANTISEIZE LUBRICANT P N 293 800 070 Bring starter close to its location Rotate it so that its mounting ear allows installation in engine crankcase and on its alignment pin Push starter in place and align mounting ear to ...

Page 105: ...be replaced when removed NEW See ELECTRONIC FUEL INJECTION EFI Loctite 243 Engine oil 6 0 7 N m 53 6 lbf in Engine oil 10 1 N m 89 9 lbf in Engine oil 0 7 0 1 N m 6 1 lbf in 20 2 N m 15 1 5 lbf ft See ELECTRONIC FUEL INJECTION EFI vmr2016 117 001_a vmr2016 418 1 ...

Page 106: ...rom fuel rails refer to ELECTRONIC FUEL INJECTION EFI sub section CAUTION The fuel hose may still be un der pressure vmr2015 031 002_a 1 Forward fuel rail disconnect 2 Rear fuel rail disconnect 4 Disconnect fuel injector electrical connectors 5 Disconnect MAPTS connector vmr2015 031 003_a 1 Forward fuel injector connector 2 Rear fuel injector connector 3 MAPTS connector 6 Disconnect throttle body ...

Page 107: ...cks warping at flanges or any other damage Replace if neces sary Installing the Intake Manifold The installation is the reverse of the removal pro cedure However pay attention to the following Tighten intake manifold retaining screws to spec ified torque one cylinder at a time TIGHTENING TORQUE Intake manifold retaining screws 20 N m 2 N m 15 lbf ft 1 lbf ft Enable fuel pump using B U D S vmr2016 ...

Page 108: ... 24 TDC DIAL INDICATOR 414 104 700 6 VALVE GUIDE INSTALLER 529 036 140 18 VALVE GUIDE INSTALLER 529 036 269 18 VALVE GUIDE REMOVER 6 MM 529 036 074 18 VALVE GUIDE REMOVER 5 MM 529 035 924 18 VALVE SPRING COMPRESSOR CUP 529 035 764 14 VALVE SPRING COMPRESSOR CUP 529 036 270 14 VALVE SPRING COMPRESSOR 529 035 724 14 SERVICE TOOLS OTHER SUPPLIER Description Part Number Page SNAP ON PLIERS YA 8230 16 ...

Page 109: ...removed NEW NEW Engine oil Loctite 648 NEW Engine oil Engine oil See tightening procedure Engine oil NEW Engine oil See ignition system 7 0 8 N m 62 7 lbf in 12 1 N m 106 9 lbf in 12 1 N m 106 9 lbf in 10 1 N m 89 9 lbf in 10 1 N m 89 9 lbf in tmr2013 068 001_b 2 vmr2016 419 ...

Page 110: ...removed NEW Engine oil NEW Loctite 648 Engine oil NEW Engine oil See tightening procedure See ignition system Engine oil Engine oil 10 1 N m 89 9 lbf in 12 1 N m 106 9 lbf in 7 0 8 N m 62 7 lbf in 10 1 N m 89 9 lbf in 10 1 N m 89 9 lbf in NEW tmr2013 068 002_b vmr2016 419 3 ...

Page 111: ...Subsection 08 TOP END CYLINDERS AND PISTONS Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil NEW NEW NEW NEW NEW vmr2006 043 003_d 4 vmr2016 419 ...

Page 112: ...d be done with the engine at normal operating temper ature WARNING Prevent burning yourself on hot engine parts Preparing the Leak Test 1 Disconnect battery WARNING Always respect this order for disassembly disconnect BLACK cable first 2 Remove radiator cap WARNING To prevent being burned ensure the radiator is cool and wear the appropriate safety equip ment before removing the radiator cap 3 Unpl...

Page 113: ...N 0 to 15 Excellent condition 16 to 25 Good condition 26 to 40 Fair condition reduced engine performance 41 and higher Poor condition diagnose and repair engine NOTE To make sure there is no false reading due to a valve not being perfectly seated tap each valve adjustment screw on the rocker arm using a soft hammer Diagnosis Listen for air leaks Air escaping in intake port throttle body means leak...

Page 114: ...ket on the valve cover if it is brittle cracked or hard If so replace the gasket Installing the Valve Cover For installation reverse the removal procedure However pay attention to the following Tighten valve cover retaining screws to specified torque in a criss cross sequence TIGHTENING TORQUE Valve cover retaining screws 7 N m 0 8 N m 62 lbf in 7 lbf in ROCKER ARM Removing the Rocker Arm 1 Remove...

Page 115: ...rm exhaust side 3 Cylinder head spark plug side 4 Big taper to spark plug side Inspecting the Rocker Arm Inspect each rocker arm for cracks and scored fric tion surfaces If so replace rocker arm assembly Check the rocker arm rollers for free movement wear and excessive radial play Replace rocker arm assembly if necessary 1 R400motr68A A 2 1 Rocker arm exhaust side 2 Roller A Bore for rocker arm sh...

Page 116: ...mfered edge first through rocker arm pin bore 3 Install a thrust washer at timing chain side then the proper rocker arm exhaust side or intake side 4 Push in rocker arm shaft until its chamfer reaches the end of rocker arm bore vmr2006 043 016_b 1 Rocker arm shaft 2 Thrust washer timing chain side 3 Thrust washer spark plug side 5 Place the other thrust washer and push rocker arm shaft to end posi...

Page 117: ...ms see ROCKER ARM in this subsection 5 Remove the camshaft NOTE For removal rotate camshaft so that intake exhaust lobe shows to upper side of cylin der head tmr2011 013 014_a 1 Camshaft retaining plate 2 Area for camshaft lobes 3 Camshaft Inspecting the Camshaft Inspecting the Camshaft Lobe Check each lobe for scoring scuffing cracks or other signs of wear Measure camshaft lobe height using a mic...

Page 118: ...002_a A Camshaft lobe exhaust valves B Camshaft lobe intake valves C Camshaft journal timing chain side D Camshaft journal spark plug side CAMSHAFT JOURNAL TIMING CHAIN SIDE NEW 34 959 mm to 34 975 mm 1 3763 in to 1 377 in SERVICE LIMIT 34 950 mm 1 376 in CAMSHAFT JOURNAL SPARK PLUG SIDE NEW 21 959 mm to 21 980 mm 8645 in to 8654 in SERVICE LIMIT 21 950 mm 8642 in Installing the Camshaft Reverse t...

Page 119: ...owing parts Chain tensioner Camshaft timing gear 10 First remove the M6 cylinder head screws then the cylinder head screws M10 tmr2011 013 011_a 1 Cylinder head screws M10 2 Cylinder head screws M6 11 Pull up cylinder head 12 Remove timing chain guide fixed 13 Remove and discard the cylinder head gasket R400motr72A 3 1 2 4 1 Cylinder head 2 Timing chain 3 Chain guide fixed 4 Cylinder head gasket I...

Page 120: ...nder heads are not iden tical Never interchange cylinder heads Reverse the removal procedure Pay attention to the following details Ensure dowel pins are in place NOTICE Timing chain guide fixed has to be fixed between cylinder and cylinder head vmr2016 033 002_b 1 Timing chain guide tensioner side mounted in crankcase 2 Timing chain guide fixed between cylinder and cylinder head Install a NEW cyl...

Page 121: ...QUE M6 cylinder head screws 10 N m 1 N m 89 lbf in 9 lbf in Check timing chain guide tensioner side for movement Refer to applicable subsection for installation de tails of remaining removed parts VALVE SPRINGS Removing the Valve Spring 1 Refer to following procedures in this subsection to remove CAMSHAFT CYLINDER HEAD 2 Remove valve spring ENGINE REQUIRED TOOL All engines VALVE SPRING COMPRESSOR ...

Page 122: ...ENGINES NOMINAL NEW 40 41 mm 1 591 in ALL ENGINES Service limit 39 00 mm 1 535 in Replace valve springs if not within specifications Installing the Valve Spring For installation reverse the removal procedure Pay attention to the following details Colored area of the valve spring must be placed on top To ease installation of cotters apply oil or grease on them so that they remain in place while rel...

Page 123: ...alves are removed always inspect valve guides Refer to VALVE GUIDES in this subsection Valve Stem Seal Always install NEW seals whenever valves are re moved Inspecting the Valve Inspect valve surface check for abnormal stem wear and bending If out of specification replace by a new one mmr2009 115 072_a VALVE OUT OF ROUND INTAKE AND EXHAUST VALVES NEW 0 005 mm 0002 in SERVICE LIMIT 0 06 mm 0024 in ...

Page 124: ...erly Apply some lap ping compound to valve face and work valve on its seat with a lapping tool see VALVE GUIDES in this subsection Measure valve face contact width NOTE The location of contact area should be in center of valve seat Measure valve seat width using a caliper VALVE SEAT CONTACT WIDTH EXHAUST VALVE NEW 1 25 mm to 1 55 mm 049 in to 061 in SERVICE LIMIT 2 00 mm 079 in INTAKE VALVE NEW 1 ...

Page 125: ...IT 5 050 mm 1988 in NEW 5 506 mm to 5 518 mm 2168 in to 2172 in 850 AND 1000R ENGINES SERVICE LIMIT 5 568 mm 2192 in Removing the Valve Guide 1 Remove cylinder head see CYLINDER HEAD in this subsection 2 Remove valves see VALVES in this subsec tion NOTE Clean valve guide area from contamination before removal 3 Drive valve guide out of cylinder head using specified tool ENGINE REQUIRED TOOL 570 en...

Page 126: ... EXHAUST 14 00 mm to 14 40 mm 5512 in to 5669 in INTAKE 13 1 mm to 13 5 mm 5157 in to 5315 in 850 AND 1000R ENGINES EXHAUST 14 3 mm to 14 7 mm 563 in to 579 in Apply some lapping compound to valve face and work valve on its seat with a lapping tool A R400motr89A 1 2 3 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...

Page 127: ...90 mm 0035 in Distance between measurements should not ex ceed the service limit Otherwise replace cylin der and piston rings Cylinder Out of Round Measure cylinder diameter in piston axis perpendicular to piston axis NOTE Use the same measuring points as de scribed in CYLINDER TAPER R400motr92A A B A Perpendicular to crankshaft axis B Parallel to crankshaft axis CYLINDER OUT OF ROUND NEW MAXIMUM ...

Page 128: ...fer to CRANKSHAFT in the BOTTOM END subsection Install cylinder head and the other parts in accor dance with the proper installation procedures PISTON Removing the Piston 1 Refer to following procedures in this subsection and remove following parts Cylinder head Cylinder 2 Place a rag under piston and in the area of tim ing chain compartment WARNING Piston circlips are spring loaded 3 Remove one p...

Page 129: ...B08A 1 1 Micrometer set to the piston dimension With the micrometer set to the dimension adjust a cylinder bore gauge to the micrometer dimen sion and set the indicator to 0 zero F00B09A 1 2 1 Use the micrometer to set the cylinder bore gauge 2 Dial bore gauge F00B0AA 1 TYPICAL 1 Indicator set to 0 zero Position the dial bore gauge 20 mm 787 in above cylinder base measuring perpendicularly 90 to p...

Page 130: ...er of connecting rod small end bushing 2 R1004motr11A 1 1 Bore gauge 2 Connecting rod CONNECTING ROD SMALL END DIAMETER NEW 20 010 mm to 20 020 mm 7878 in to 7882 in 570 AND 850 ENGINES SERVICE LIMIT 20 060 mm 7898 in NEW 22 010 mm to 22 020 mm 8665 in to 8669 in 1000R ENGINE SERVICE LIMIT 22 050 mm 8681 in Replace connecting rod if diameter of connecting rod small end is out of specifications Ref...

Page 131: ...TON CIRCLIP INSTALLER P N 529 036 153 NOTICE Always replace disassembled piston circlip s by NEW ones Place a rag on cylinder base to avoid dropping the circlip inside the en gine Place circlip in sleeve as per following illustration 3 R400motr100A 1 2 1 Circlip 2 Sleeve 3 Assembly jig from piston clip installer Push taper side of assembly jig until circlip reaches middle of sleeve Align sleeve wi...

Page 132: ...d Gap RING END GAP UPPER COMPRESSION RING NEW 0 10 mm to 0 30 mm 004 in to 012 in 570 engine SERVICE LIMIT 0 50 mm 02 in NEW 0 20 mm to 0 35 mm 008 in to 014 in 850 engine SERVICE LIMIT 0 60 mm 024 in NEW 0 20 mm to 0 40 mm 008 in to 016 in 1000R engine SERVICE LIMIT 0 60 mm 024 in LOWER COMPRESSION RING NEW 0 35 mm to 0 55 mm 014 in to 022 in 570 and 850 engines SERVICE LIMIT 0 85 mm 033 in NEW 0...

Page 133: ...d TOP facing up 1 2 3 vmr2007 036 009_a 1 Upper compression ring 2 Lower compression ring 3 Oil scraper ring NOTICE Ensure that top and second rings are not interchanged 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 A31C2OA 1 2 A A A 1 DO NOT align ring gap with piston thrust s...

Page 134: ... LOCTITE 243 BLUE 293 800 060 6 11 Loctite 243 6 0 7 N m 53 6 lbf in 10 1 N m 89 9 lbf in Loctite 243 10 1 N m 89 9 lbf in Loctite 243 4 5 0 5 N m 40 4 lbf in 10 1 N m 89 9 lbf in Loctite 243 10 1 N m 89 9 lbf in Loctite 243 Loctite 243 6 0 7 N m 53 6 lbf in Loctite 243 6 0 7 N m 53 6 lbf in 4 5 0 5 N m 40 4 lbf in Engine oil Engine oil 0 1 N m 0 89 lbf in 0 1 N m 0 89 lbf in vmr2015 033 010_a vmr...

Page 135: ...nents and readjust camshaft timing PROCEDURES TIMING CHAIN TENSIONERS Timing Chain Tensioner Location 570 Engine The timing chain tensioner is located on the back of each cylinder head tmr2011 045 005_a 570 ENGINE FRONT CYLINDER SHOWN 1 Timing chain tensioner 850 and 1000R Engines The timing chain tensioner is located in the cylin der tmr2011 045 002_a 850 AND 1000R ENGINES FRONT CYLINDER SHOWN 1 ...

Page 136: ...oner Reverse the removal procedure However pay at tention to the following NOTE Before installing the chain tensioner make sure the camshaft timing gear can be moved back and forth tmr2011 045 003_a MOVE GEAR BACK AND FORTH 1 Apply engine oil on the chain tensioner plunger before installation 2 Slightly turn the camshaft timing gear in order to move the timing chain excess play to the ten sioner s...

Page 137: ... overstressed timing chain the plug must engage into threads within the first full turn tmr2013 069 008_a Step 1 Compress spring Step 2 Screw in plug 9 Remove locking tool and install all other re moved parts 10 Tighten the chain tensioner screw plug to specification TIGHTENING TORQUE Chain tensioner plug 4 5 N m 0 5 N m 40 lbf in 4 lbf in CAMSHAFT TIMING GEARS Removing the Camshaft Timing Gear 1 ...

Page 138: ...ng camshaft timing gear tmr2011 045 004_a 1 Camshaft mating surface 2 Camshaft screw threads 2 Set applicable piston to TDC ignition position and install the crankshaft position tool refer to CAMSHAFT TIMING in this subsection REQUIRED TOOL CRANKSHAFT TDC POSITION TOOL P N 529 036 201 3 Install camshaft timing tool on the cylinder head REQUIRED TOOL CAMSHAFT TIMING TOOL P N 529 036 268 NOTE Proper...

Page 139: ...n this subsection 7 Install and tighten camshaft timing gear retain ing screws to specified torque vmr2015 033 004_a 1 Camshaft timing gear 2 Timing gear retaining screws TIGHTENING TORQUE Service product LOCTITE 243 BLUE P N 293 800 060 Camshaft timing gear retaining screws 10 N m 1 N m 89 lbf in 9 lbf in 8 Remove the camshaft timing tool Camshaft Timing NOTE If a piston cylinder 1 or 2 is set to...

Page 140: ... 5 1 The rear piston is at TDC when it s index mark on the magneto flywheel is aligned with the notch in the magneto cover vmr2007 037 008_b PISTON NO 2 AT TDC 1 Piston no 2 identifier 2 Index mark on magneto flywheel 3 Notch on magneto cover 4 CPS bore in magneto cover 5 2 Confirm printed marks on the camshaft timing gear are parallel with cylinder head base in the lowest position In this posi ti...

Page 141: ...rk on the magneto flywheel is aligned with the notch in the magneto cover vmr2007 036 006_b CYLINDER 1 AT TDC 1 Number 1 piston identifier 2 Index mark 1 on magneto flywheel 3 Notch on magneto cover 4 Crankshaft position sensor bore 3 2 Confirm printed marks on the camshaft timing gear are parallel with cylinder head base in the lowest position In this posi tion the piston is set to TDC ignition t...

Page 142: ...over 2 TDC position tool TIMING CHAIN Timing Chain Location The engine is equipped with two timing chains MAG side timing chain is located behind the magneto cover PTO side timing chain is located behind the PTO cover Removing the Timing Chain MAG Side 1 Refer to MAGNETO AND STARTER subsection and remove following parts Magneto cover Rotor Sprag clutch gear 2 Refer to TOP END subsection and remove...

Page 143: ...Refer to applicable procedures in this subsec tion and remove following parts Chain tensioner Camshaft timing gear 4 Remove timing chain guide tensioner side and lower timing chain guide tmr2011 045 015_a 1 Timing chain 2 Lower timing chain guide 3 Timing chain guide tensioner side NOTE Mark the operating direction of the timing chain and check for excessive radial play before removal Refer to TIM...

Page 144: ...gear NOTE Ensure to carry out proper valve timing re fer to CAMSHAFT TIMING GEARS in this subsec tion NOTICE Improper valve timing will damage engine components TIMING CHAIN GUIDE TENSIONER SIDE tmr2011 045 019_a 1 Timing chain guide tensioner side 2 Bearing screw Removing the Timing Chain Guide Tensioner Side Refer to TIMING CHAIN in this subsection Inspecting the Timing Chain Guide Tensioner Sid...

Page 145: ...ER 529 035 917 14 15 PLAIN BEARING REMOVER INSTALLER 529 036 032 9 PTO COVER OIL SEAL INSTALLER 529 036 033 8 SERVICE PRODUCTS Description Part Number Page LOCTITE 243 BLUE 293 800 060 6 LOCTITE 5910 293 800 081 5 LOCTITE CHISEL GASKET REMOVER 413 708 500 5 ENGINE DRIVE SHAFT Engine oil 10 1 N m 89 9 lbf in Petamo grease Loctite 5910 Engine oil Engine oil Loctite 767 antiseize lubricant Loctite 59...

Page 146: ...ctite 243 6 0 7 N m 53 6 lbf in 12 1 N m 106 9 lbf in 10 1 N m 89 9 lbf in Engine oil Engine oil 10 1 N m 89 9 lbf in Engine oil 10 1 N m 89 9 lbf in 25 3 N m 18 2 lbf ft 25 3 N m 18 2 lbf ft Engine oil Petamo Grease See tightening sequence See tightening sequence See tightening sequence vmr2015 034 001_b 2 vmr2016 421 ...

Page 147: ...Subsection 10 BOTTOM END CRANKSHAFT Engine oil Engine oil NEW NEW See tightening procedure See tightening procedure vmr2016 421 100_a vmr2016 421 3 ...

Page 148: ... its O ring tmr2011 014 006_a 1 Bearing cover screws 2 O ring 3 Bearing cover gearbox side Removing the Front Bearing Cover Remove the bearing cover at the front of the en gine NOTICE Check ends of the circlip for sharp edges or burrs before removing the drive shaft to avoid damaging the oil seal tmr2011 014 007_a 1 Bearing cover front drive side 2 Circlip 3 Drive shaft Removing the Engine Drive S...

Page 149: ...the assembly and the first torquing should be done within 10 minutes It is suggested to have all you need on hand to save time Use a plexiglass plate and apply some sealant on it Use a soft rubber roller 50 mm 75 mm 2 in 3 in available in arts products suppliers for printing and roll the sealant to get a thin uniform coat on the plate spread as necessary When ready apply the sealant on bearing cov...

Page 150: ...move front propeller shaft 2 Remove adapter sleeve between propeller shaft and front engine drive shaft 3 Remove the front bearing cover refer to EN GINE DRIVE SHAFT REMOVAL INSTALLATION in this subsection 4 Remove drive shaft seal from bearing cover tmr2013 018 005_a 1 Bearing cover 2 Oil seal 5 Install drive shaft oil seal using the following tool REQUIRED TOOL DRIVE SHAFT OIL SEAL INSTALLER P N...

Page 151: ... OIL SEAL INSTALLER P N 529 036 028 vmr2013 018 002_a 1 Bearing cover 2 Oil seal 3 Oil seal installer 6 Install O ring in rear bearing cover vmr2013 018 004_a 1 O ring 2 Bearing cover 7 Reinstall remaining parts in the reverse order of removal PTO COVER OIL SEAL NOTE To replace oil seal it is not necessary to remove engine from vehicle Removing the PTO Oil Seal 1 Refer to CONTINUOUSLY VARIABLE TRA...

Page 152: ...ED TOOL PTO COVER OIL SEAL INSTALLER P N 529 036 033 vmr2015 034 004_a 1 PTO cover 2 Oil seal installer 3 Oil seal PTO COVER Removing the PTO Cover 1 Refer to CONTINUOUSLY VARIABLE TRANS MISSION CVT subsection to remove the fol lowing parts CVT cover Drive pulley Driven pulley CVT air guide 2 Disconnect vent hose 3 Remove PTO cover screws and pull on PTO cover to remove it vmr2006 044 003_a 1 PTO ...

Page 153: ... Bearing PTO Cover Removing the Plain Bearing NOTICE Unless otherwise instructed never use a hammer to install plain bearings Always use a press 1 Carefully remove the PTO oil seal with a screw driver without damaging the PTO cover 2 Press out the plain bearings from the outside towards the inside REQUIRED TOOL PLAIN BEARING REMOVER INSTALLER P N 529 036 032 NOTE The PTO cover has to be supported ...

Page 154: ... be positioned near the oil bore in a counterclockwise direction tmr2011 014 013_c 1 Plain bearing joint 2 PTO cover inside surface 3 Oil bore Installing the PTO Cover For installation reverse the removal procedure however pay attention to the following details NOTE At installation replace PTO cover gasket and oil seal Tighten PTO cover screws following the sequence illustrated vmr2006 044 003_b T...

Page 155: ...ve needle pin and pull water pump drive gear out 7 Remove thrust washer from intermediate shaft tmr2011 014 016_a 1 Thrust washer 2 Water pump drive gear 3 Needle pin Inspecting the Drive Gears Intermediate Gear Oil Pump Drive Gear Water Pump Drive Gear Inspect gears for wear or other damage Replace if damaged Breather Gear Check if oil seal is brittle hard or damaged Re place if necessary tmr2011...

Page 156: ...e gears Bearing covers of engine drive shaft 8 Refer to TIMING CHAIN subsection and re move the following parts Chain tensioners Camshaft timing gears Timing chains Timing chain guides 9 Refer to TOP END subsection and remove the following parts Front cylinder head Rear cylinder head Cylinders 10 Refer to COOLING SYSTEM subsection and remove the following parts Water pump housing 11 Refer to LUBRI...

Page 157: ...ut of crankcase 16 Remove the water pump intermediate shaft vmr2006 044 023_b 1 Water pump intermediate shaft 17 Remove engine oil strainer NOTE Oil strainer removal for inspection and cleaning is recommended Refer to LUBRICA TION SYSTEM subsection vmr2006 042 017_a 1 Engine oil strainer 2 Retaining plate 3 Screws Cleaning the Crankcase WARNING Use safety goggles to avoid eye injuries Clean crankc...

Page 158: ...t crankcase halves when removing plain bearings Dam age to crankcase halves may occur if this pro cedure is not performed correctly NOTE Always use a press for removal of plain bearings Carefully press the plain bearings out from the crankcase half from the inside towards the out side NOTE Place an appropriate support under crankcase halves before removing plain bear ings REQUIRED TOOLS CRANKCASE ...

Page 159: ...3 Oil bore position marked on crankcase NOTICE Misalignment of the plain bearing and crankcase oil bores will prevent proper oil supply to plain bearings 4 Carefully press in the plain bearings from inside the crankcase towards the outside NOTICE The joint of the plain bearings in crankcase half MAG side must be positioned near the oil bore in a clockwise direction tmr2011 014 027_a 1 Crankcase ha...

Page 160: ...016 035 002_b M8 SCREWS TIGHTENING SEQUENCE TIGHTENING TORQUE M8 crankcase screws 25 N m 3 N m 18 lbf ft 2 lbf ft Models Without Oil Cooler vmr2016 035 002_c M6 SCREWS TIGHTENING SEQUENCE Models With Oil Cooler tmr2011 014 021_c M6 SCREWS TIGHTENING SEQUENCE All Models TIGHTENING TORQUE M6 crankcase screws 10 N m 1 N m 89 lbf in 9 lbf in CRANKSHAFT vmr2006 044 035_b 1 Crankcase MAG 2 Crankshaft 16...

Page 161: ...ers 2 Remove screw plug and O ring from magneto cover vmr2015 033 005_a 1 Plug screw 2 O ring 3 Remove crankshaft position sensor vmr2015 033 006_a 1 Crankshaft position sensor 2 Screw 4 Remove screw plug and discard sealing ring vmr2015 034 005_a 1 Sealing ring 2 Plug screw 3 Crankcase PTO side front side 5 Use a 14 mm Allen key to turn crankshaft until the rear piston no 2 is at TDC vmr2015 033 ...

Page 162: ...the tool in the crankshaft groove Make sure that the tool tip enters the groove and does not jam on the crankshaft balancer surface Removing the Crankshaft Refer to CRANKCASE Inspecting the Crankshaft NOTE Check each crankshaft bearing journal for scoring scuffing cracks or other signs of wear NOTE Replace crankshaft if the crankshaft tim ing gears are worn or otherwise damaged NOTICE Components o...

Page 163: ...200 mm to 0 500 mm 008 in to 02 in 1000R ENGINE NEW 0 250 mm to 0 550 mm 0098 in to 0217 in All SERVICE LIMIT 0 600 mm 024 in Connecting Rod Piston Pin Clearance Refer to TOP END subsection Connecting Rod Big End Radial Play NOTE Prior to removing connecting rod from the crankshaft mark big end halves together to en sure a correct reinstallation cracked surface fits in only one position 1 Remove c...

Page 164: ...m 1 5787 in 1000R ENGINE SERVICE LIMIT 42 100 mm 1 6575 in If connecting rod big end diameter is out of spec ification replace plain bearings and recheck CONNECTING ROD BIG END RADIAL CLEARANCE SERVICE LIMIT 0 09 mm 0035 in If connecting rod big end radial clearance is out of specification replace plain bearings and recheck Crankshaft Radial Play MAG PTO Side Measure crankshaft main bearing journa...

Page 165: ...ly with compressed air Insert plain bearings in the connecting rods as il lustrated 2 1 R1004motr20A 3 1 Half plain bearing of connecting rod big end 2 Mating surface of the connecting rod 3 Joining surface of plain bearing in line with connecting rod groove Oil the plain bearing surface of the connecting rod and crankshaft pin before installation NOTICE Lower cap and rod must match to gether sinc...

Page 166: ...a 1 Connecting rod small ends 2 Connecting rod offset 3 Connecting rod screws TIGHTENING TORQUE Step A Tighten to 1 2 of specified torque Step B Tighten to 30 N m 2 N m 22 lbf ft 1 lbf ft Connecting rod screws Step C Torque an additional 90 5 turn using an angle torque wrench Installing the Crankshaft For installation of crankshaft in crankcase reverse the removal procedure However pay attention t...

Page 167: ...Subsection 10 BOTTOM END vmr2006 044 035_a 1 Crankcase half MAG side 2 Connecting rod cylinder 1 3 Connecting rod cylinder 2 vmr2016 421 23 ...

Page 168: ...scription Part Number Page CLUTCH HOLDER 529 036 238 6 14 20 22 CLUTCH PULLER 529 035 746 6 PULLER LOCKING TOOL 529 036 098 5 19 22 SERVICE PRODUCTS Description Part Number Page ISOFLEX GREASE TOPAS NB 52 293 550 021 12 LOCTITE 767 ANTISEIZE LUBRICANT 293 800 070 19 PULLEY FLANGE CLEANER 413 711 809 9 15 16 18 vmr2016 404 1 ...

Page 169: ...ulley flange cleaner Isoflex grease Topas NB 52 Loctite 243 10 1 N m 89 9 lbf in Isoflex grease Topas NB 52 5 0 6 N m 44 5 lbf in 7 0 8 N m 62 7 lbf in 570 engine 850 engine NEW NEW NEW Component must be replaced when removed NEW Loctite 767 NEW Loctite 243 10 1 N m 89 9 lbf in vmr2016 404 001_a 2 vmr2016 404 ...

Page 170: ...VARIABLE TRANSMISSION CVT 570 850 Component must be replaced when removed NEW 2 5 0 5 N m 22 4 5 lbf ft 5 1 N m 44 9 lbf in 5 1 N m 44 9 lbf in NEW 2 5 0 5 N m 22 4 5 lbf ft NEW 8 1 N m 71 9 lbf in vmr2016 404 100_a vmr2016 404 3 ...

Page 171: ...move the follow ing LH side and extension panels LH footboard panel Draining the CVT Cover If water is present in CVT cover it can be drained as follows 1 Remove drain reservoir from CVT cover Vmr2012 018 003_b 1 Drain reservoir 2 Spring clip 2 Let water drain from CVT cover 3 Reinstall drain reservoir NOTICE If an appreciable amount of water or any debris entered the CVT cover CVT must be cleaned...

Page 172: ...e it Vmr2012 018 006_a Inspecting the Drive Belt For drive belt inspection refer to DRIVE BELT INSPECTION in the PERIODIC MAINTENANCE PROCEDURES subsection Installing the Drive Belt 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...

Page 173: ...ft hammer 5 Remove service tool 6 Apply axial pressure with your hand on the slid ing sheave and governor cup 7 Remove drive pulley screw with its conical spring washer and thrust washer CAUTION Sliding sheave of drive pulley is spring loaded tmr2011 015 004_a Step 1 Push 1 Thrust washer 2 Conical spring washer 3 Drive pulley screw 4 Sliding sheave with governor cup 8 Slowly release and remove sli...

Page 174: ...governor cup arm Use a flat screwdriver if necessary 1 R400motr171A 1 Slider shoe 3 Place the governor cup on a vice to push out the roller sleeve in the direction illustrated against insertion arrow marked on governor cup arm Use an appropriate punch diameter of punch must be smaller than the diameter of the sleeve bore in the governor cup arm NOTICE Do not clamp the governor cup in the vice to p...

Page 175: ...th 4 levers Remove centrifugal lever and both thrust wash ers Vmr2012 018 024_a 1 Lock nut 2 Centrifugal lever pivot bolt 3 Centrifugal lever 4 Thrust washers Fixed Sheave WARNING Always wear safety glasses to remove spring sleeves Pull and rotate one way clutch slowly until the spring sleeves are visible vmr2006 021 020_a 1 One way clutch 2 Fixed sheave 3 Spring sleeve area Hold both spring sleev...

Page 176: ...GE CLEANER P N 413 711 809 Wipe off the mounting surfaces with a clean dry paper towel NOTICE Mounting surfaces must be free of any oil cleaner or towel residue vmr2015 121 002_a 1 Taper of fixed sheave Only use petrol base cleaner when cleaning slid ing sheave bushings NOTICE Do not use acetone to clean bush ing tmr2011 015 006_a 1 Sliding sheave 2 Bushings Inspecting the Drive Pulley Bushings Fo...

Page 177: ...centrifugal lever if necessary tmr2011 015 007_a 1 Centrifugal lever 2 Bushing A Bushing inner diameter CENTRIFUGAL LEVER BORE DIAMETER NEW 6 035 mm to 6 078 mm 238 in to 239 in SERVICE LIMIT 6 200 mm 244 in Inspect and replace as necessary the following items if their contact surfaces are heavy worn Centrifugal lever Thrust washers Centrifugal lever pivot bolts Lock nuts Vmr2012 018 024_b 1 Lock ...

Page 178: ...e A Bore diameter of bushing SLIDING SHEAVE LARGE BUSHING NEW 55 000 mm to 55 040 mm 2 165 in to 2 167 in SERVICE LIMIT 55 200 mm 2 173 in R610tran11A A 1 1 Bushing on governor cup side A Bore diameter of bushing SLIDING SHEAVE SMALL BUSHING NEW 32 000 mm to 32 040 mm 1 26 in to 1 261 in SERVICE LIMIT 32 200 mm 1 268 in Replace sliding sheave if one of the bushings is out of specification Visually...

Page 179: ...me SPRING SLEEVE LENGTH NEW 9 2 mm to 9 4 mm 362 in to 37 in SERVICE LIMIT 9 0 mm 354 in Assembling the Drive Pulley For assembly reverse the disassembly proce dure Pay attention to following details One Way Clutch Clean parts Lubricate springs spring sleeves and between one way clutch bearings using recommended product REQUIRED PRODUCT ISOFLEX GREASE TOPAS NB 52 P N 293 550 021 Friction Washer NO...

Page 180: ...e following details WARNING Do not apply antiseize or any lubricant on crankshaft and drive pulley tapers NOTICE Never use any type of impact wrench for drive pulley removal and instal lation Clean mounting surfaces as described in DRIVE PULLEY CLEANING Install drive pulley on crankshaft extension NOTICE Do not forget to install thrust washer and conical spring washer as per illustration that foll...

Page 181: ...lder P N 529 036 238 3 Remove service tool 4 Apply axial pressure with your hand on driven pulley and maintain during screw removal 5 Remove driven pulley screw and washer Dis card driven pulley screw CAUTION Driven pulley is spring loaded Hold driven pulley tight and slowly remove the driven pulley screw to release spring tension Vmr2012 018 011_a 1 Driven pulley screw 2 Thrust washer 6 Remove th...

Page 182: ...Use a soft hammer to push shaft and bearing out of fixed sheave 2 R610tran18A 1 1 Soft hammer 2 Shaft 4 Remove shaft from ball bearing 5 Remove distance sleeve and O ring from coun tershaft 6 Replace O ring if brittle hard or damaged vmr2006 021 044_b 1 O ring 2 Distance sleeve Cleaning the Driven Pulley When a dust deposit has to be removed from the cam or the shaft use a dry cloth Clean pulley f...

Page 183: ... specification Visually inspect coatings vmr2006 021 038_a 1 Bushings 2 Backside of sliding sheave of driven pulley REQUIRED TOOL Dial bore gauge MEASURING POINT At least 5 mm 1 4 in from bushing edge BUSHING INNER DIAMETER NEW 30 060 mm to 30 100 mm 1 183 in to 1 185 in SERVICE LIMIT 30 200 mm 1 189 in Fixed Sheave Check fixed sheave for cracks and excessive wear Replace fixed sheave if necessary...

Page 184: ...n Cam Check cam for visible damage and measure for wear using a caliper tmr2011 015 012_a 1 Caliper 2 Contact surface WIDTH ON TOP SURFACE SERVICE LIMIT 16 0 mm 63 in vmr2006 021 041_a 1 Caliper 2 Sliding sheave 3 Contact surface A Wear to be measured WEAR ON CONTACT SURFACE SERVICE LIMIT 1 00 mm 039 in Spring 570 Engine Tmr2013 071 037_a CVT DRIVEN SPRING A Spring free length 850 Engine Vmr2012 0...

Page 185: ...ust be pressed in only 2 R610tran37A 1 3 1 Shaft 2 Fixed sheave 3 Press machine Install torque gear then secure it with the retaining ring vmr2006 021 035_a 1 Retaining ring 2 Torque gear 3 Fixed sheave of driven pulley Installing the Driven Pulley For installation reverse the removal procedure Pay attention to the following details Place O ring on countershaft splines and move it and the distance...

Page 186: ...he shaft to compress the spring NOTICE A cam not correctly engaged will cause damage to the driven pulley and cam As you hold the pulley compressed install a NEW driven pulley screw and thrust washer NOTICE This assembly uses a stretch screw Always install a NEW screw NOTE Tighten the screw with your hand suffi ciently for the cam to remain engaged Vmr2012 018 011_a 1 Driven pulley screw 2 Thrust ...

Page 187: ...re Place cam on the opposite end of the spring and engage the other spring end in the cam spring bore Vmr2012 018 017_a 850 ENGINE 1 Cam 2 Spring end 3 Spring bore Install pre assembled cam with spring and driven pulley on countershaft end NOTICE Cam must engage on countershaft splines Vmr2012 018 018_a 850 ENGINE 1 Countershaft splines 2 Cam 3 Spring 4 Sliding sheave 5 Fixed sheave With your hand...

Page 188: ...DER P N 529 036 238 tmr2013 019 008_a 850 ENGINE 1 Fixed sheave 2 Clutch holder 3 Screwdriver Turn the screwdriver approximately 20 counter clockwise until cam engages in the driven pulley sliding sheave and hold it in this position spring preload tmr2013 019 009_a 850 ENGINE 1 Clutch holder 2 Screwdriver A Turn counterclockwise Using a socket and extension hand tighten the driven pulley screw NOT...

Page 189: ...ctly engaged in the sliding sheave Tighten driven pulley screw as specified REQUIRED TOOL CLUTCH HOLDER P N 529 036 238 TIGHTENING SEQUENCE DRIVEN PULLEY SCREW STEP 1 20 N m 1 N m 15 lbf ft 1 lbf ft STEP 2 180 5 tmr2013 019 007_a 1 Driven pulley screw 2 Clutch holder Check driven pulley end play SPECIFICATION Driven pulley end play 0 mm 0 in CVT AIR GUIDE Removing the CVT Air Guide 1 Remove the DR...

Page 190: ...ARIABLE TRANSMISSION CVT 570 850 vmr2012 018 020_a 1 CVT air guide 2 O rings Installing the CVT Air Guide For installation reverse the removal procedure Always install NEW O rings before installing the CVT air guide vmr2016 404 23 ...

Page 191: ...HER 529 036 222 11 DRIVE SHAFT OIL SEAL INSTALLER 529 036 028 12 FLUKE 115 MULTIMETER 529 035 868 6 9 HANDLE 420 877 650 12 29 OIL SEAL INSTALLER GEARBOX 529 035 758 12 SERVICE TOOLS OTHER SUPPLIER Description Part Number Page FLUKE RIGID BACK PROBE TP88 6 SERVICE PRODUCTS Description Part Number Page LOCTITE 243 BLUE 293 800 060 34 LOCTITE 5910 293 800 081 8 9 17 18 33 LOCTITE CHISEL GASKET REMOV...

Page 192: ...UPLING MECHANISM Super Lube grease 25 3 N m 18 2 lbf ft NEW Component must be replaced when removed NEW 10 1 N m 89 9 lbf in Loctite 243 Super Lube grease Super Lube grease Engine oil Engine oil Loctite 243 Engine oil Engine oil Engine oil NEW Engine oil Engine oil vmr2012 019 001_a 2 vmr2016 422 ...

Page 193: ...AND 4X4 COUPLING UNIT WITH EXTERNAL SWITCHES GEARBOX HOUSING AND 4X4 ACTUATOR UNIT Component must be replaced when removed NEW Petamo grease Petamo grease Petamo grease 2 5 0 3 N m 22 3 lbf in vmr2015 036 001_a vmr2016 422 3 ...

Page 194: ...ountershaft 7 Shift shaft 8 Actuator TROUBLESHOOTING UNUSUAL GEARBOX NOISE AND OR VIBRATIONS 1 Low oil level in gearbox Oil leakage from gearbox Replace damaged gas ket s and or oil seal s 2 Defective bearings Bearing s do es not turn smoothly Replace bearing s 3 Damaged or worn gears Inspect gears for damages or missing teeth Re place respective gears GEAR INDICATION FAILS 1 Check contact screws ...

Page 195: ...D SENSOR VSS VSS Location The vehicle speed sensor is located on the right housing of the gearbox behind the actuator vmr2016 123 004_a 1 VSS Vehicle Speed Sensor 2 Right housing of gearbox 3 Actuator The VSS connector is located between the cylin ders behind the OPS cover vmr2016 123 002_a 1 VSS connector 2 OPS Oil Pressure Switch VSS Access To reach the VSS refer to BODY subsection and remove th...

Page 196: ...ry voltage If voltage is not as specified test positive and ground circuits separately Testing the VSS Signal 1 Lift rear of vehicle so that rear wheels are off the ground 2 Set transmission to 2WD and to NEUTRAL 3 Back probe the VSS connector REQUIRED TOOL FLUKE RIGID BACK PROBE P N TP88 4 Turn ignition switch ON 5 Set emergency engine stop switch to RUN 6 Set multimeter to Vdc 7 Measure voltage ...

Page 197: ...o GEARBOX POSITION INDICATOR SWITCH ACCESS in this subsection NOTE Take note of corresponding switch posi tion and wire color 2 Disconnect wires from switches NOTE Remove insulating paint to obtain correct readings 3 Using a multimeter measure the resistance from the indicator switch to engine ground while selecting the gearbox to each position Compare results with the logic table below vmr2012 01...

Page 198: ...g Take care to avoid damaging threads in switch bores during installation Carefully apply some sealant on threads of shift indicator switches NOTICE Do not apply sealant on switch plunger as it will lead to switch malfunction TIGHTENING TORQUE Service product LOCTITE 5910 P N 293 800 081 Indicator switches 2 5 N m 0 3 N m 22 lbf in 3 lbf in If all switches are removed make sure to put the wires ba...

Page 199: ... refer to BODY and remove the RH engine cover vmr2016 422 003 Testing the 4WD Actuator Check if the 2WD 4WD selector works properly REQUIRED TOOL FLUKE 115 MULTIMETER P N 529 035 868 Unplug actuator connector Turn ignition key ON Set emergency engine stop switch to RUN Measure voltage as follows SWITCH POSITION SWITCH WIRE VOLTAGE 2WD WHITE BLUE 4WD WHITE BLACK WHITE Battery voltage If the selecto...

Page 200: ...t or break the actuator O ring Install all actuator screws and tighten them TIGHTENING TORQUE Actuator screws 25 N m 3 N m 18 lbf ft 2 lbf ft Connect actuator Lift the front of vehicle Turn front wheels The front propeller shaft should not turn the PARK position must be se lected If the front propeller shaft turns the actuator is not installed correctly Remove actuator and reinstall it Set ignitio...

Page 201: ...Oil Seal When installing or reinstalling oil seals use PETAMO GREASE GHY 133N P N 420 899 271 to Lubricate sealing lips all around Fill up the room between sealing lips halfway around the perimeter vmr2013 020 001_a 1 Sealing lips 2 Room between sealing lips Countershaft Oil Seal The countershaft oil seal can be removed without removing gearbox from vehicle Remove drive and driven pulley and CVT a...

Page 202: ...seal If gearbox housing is apart the following tools can be used for shift shaft oil seal installation REQUIRED TOOL OIL SEAL INSTALLER GEARBOX P N 529 035 758 HANDLE P N 420 877 650 NOTICE Oil seal must be installed with seal ing lip toward gearbox Output Shaft Oil Seal Remove propeller shaft Refer to REAR DRIVE subsection Punch a sharp screwdriver through oil seal for re moval NOTE When oil seal...

Page 203: ...asure will indicate if output shaft adjustment is necessary Output Shaft Backlash Procedure 1 Engage PARK position on the gear shaft to block gearbox 2 Remove bearing cover with oil seal vmr2006 022 010_a 1 Bearing cover 2 Oil seal 3 Remove Distance sleeve O ring vmr2006 022 011_a 1 Distance sleeve 2 O ring 4 Install the measurement tool at the end of out put shaft REQUIRED TOOL BACKLASH MEASUREME...

Page 204: ...LIMIT 0 25 mm 0098 in If backlash is not within the specification remove the output shaft and select the next thicker or thin ner shim to meet the specifications NOTE Use next thicker shim to increase back lash and next thinner shim to reduce backlash Removing the Output Shaft and Coupling Mechanism 1 Remove actuator 2 Remove the bearing cover with oil seal 3 Unscrew all bolts retaining the right ...

Page 205: ...sher 3 Distance ring 8 Remove Screw Pin Coupling fork vmr2015 036 002_a 1 Screw 2 Pin 3 Coupling fork Inspecting the Output Shaft and Coupling Mechanism Check output shaft and its gear for cracks bend pitting or other visible damages Check output shaft splines for wear or other dam ages NOTICE Always replace output shaft and bevel gear shaft at the same time Adjust these components upon replacemen...

Page 206: ...ation Installing the Output Shaft and Coupling Mechanism Reverse the removal procedure However pay at tention to the following Install thrust washer bearing O ring and coupling sleeve onto the output shaft Install distance ring thrust washer and ball bear ing NOTE O ring and distance sleeve are not in stalled at this time Place the output shaft into the center housing Use soft hammer to put bearin...

Page 207: ...e LOCTITE 5910 P N 293 800 081 on mating sur faces Use a plexiglass plate and apply some sealant on it Use a soft rubber roller 50 75 mm 2 3 in available in arts products suppliers for printing and roll the sealant to get a thin uniform coat on the plate spread as necessary When ready apply the sealant on housing mating surfaces F12R17A Do not apply in excess as it will spread out inside housings ...

Page 208: ... INSTALLATION subsection for the proce dure 2 Drain gearbox Refer to GEARBOX OIL DRAIN ING PROCEDURE in PERIODIC MAINTE NANCE PROCEDURES subsection 3 Remove drive and driven pulley and CVT air guide refer to CONTINUOUSLY VARIABLE TRANSMISSION CVT subsection 4 Unscrew the three 3 nuts that attach the gear box to the engine 5 Pull gearbox to separate it from engine Disassembling the Gearbox NOTE Dur...

Page 209: ... big flat screwdrivers lift the center housing vmr2006 022 045 POSITION FOR BIG FLAT SCREWDRIVER vmr2006 022 046 POSITION FOR BIG FLAT SCREWDRIVER 6 Remove center housing completely 7 Remove shift shaft assembly vmr2006 022 055_a 1 Shift shaft assembly 8 Remove shift fork shaft 9 Disengage shift forks from shift drum and re move shift fork vmr2006 022 056_a 1 Shift fork shaft 2 Shift fork 3 Shift ...

Page 210: ... gear with shift fork vmr2006 022 059_a 1 Sliding gear 2 Shift fork 12 Remove thrust washer needle bearing and re verse gear vmr2006 022 060_a 1 Thrust washer 2 Needle bearing 3 Reverse gear 13 Remove shim on CVT side vmr2006 022 061_a 1 Shim on CVT side 14 Remove countershaft with low range gear and high range gear assembly 20 vmr2016 422 ...

Page 211: ...kwise and remove shift drum vmr2006 022 065_a 1 Index lever 2 Shift drum 16 Remove parking lock lever vmr2006 022 066_a 1 Parking lock lever 17 Remove index lever with washer step ring and spring vmr2006 022 067_a 1 Index lever 2 Washer 3 Step ring 4 Index spring 18 Remove support flange NOTE To remove intermediate gear and needle bearing use a press bench to push out the inter mediate gear shaft ...

Page 212: ...amages may occur if this procedure is not performed cor rectly To remove bevel gear needle bearing use a punch vmr2006 022 049_a 1 Bevel gear needle bearing 2 Punch 3 Center housing To remove ball bearings of bevel gear and needle bearing of countershaft use a blind hole bearing puller For countershaft ball bearing remove screw and intermediate gear shaft then push with a suitable puller from outs...

Page 213: ...4 90 mm 189 in to 193 in SERVICE LIMIT 4 70 mm 185 in 4 70 mm 185 in SHIFT FORK CLAW THICKNESS LOW REVERSE GEAR SHIFTING NEW 5 10 mm to 5 20 mm 201 in to 205 in SERVICE LIMIT 5 00 mm 197 in Measure shift fork pins vmr2006 022 076_a 1 Micrometer A Shift fork pin diameter SHIFT FORK PIN DIAMETER NEW 6 920 mm to 6 970 mm 272 in to 274 in SERVICE LIMIT 6 850 mm 27 in Shift Drum Check shift drum tracks...

Page 214: ...2006 022 080_a TYPICAL 1 Micrometer 2 Free pinion DIAMETER FREE PINION NEW 29 000 mm to 29 013 mm 1 1417 in to 1 1422 in SERVICE LIMIT 29 015 mm 1 1423 in Shafts Check shift shaft for worn splines and gears Check intermediate shaft for wear vmr2012 019 012_a 1 Intermediate gear bearing INTERMEDIATE GEAR SHAFT NEW 24 979 mm to 25 000 mm 9834 in to 9843 in SERVICE LIMIT 24 977 mm 9833 in Check count...

Page 215: ... specification or if parts are changed output shaft bevel gear shaft or housing There are 2 adjustments to perform on the bevel gear Bevel gear backlash on center housing Bevel gear axial clearance on left housing The bevel gear backlash is adjusted by finding the proper shim thickness E as per following illustra tion The bevel gear axial clearance is adjusted by find ing the proper shim thickness...

Page 216: ... 2 Mating surface left housing Bevel Gear Backlash Procedure Use the following course of calculation to determine the theoretical shim thickness D D B C A B The distance between the thrust surface of the bevel gear and the theoretical center of its taper This is defined by manufacturer and is written on the bevel gear shaft 26 vmr2016 422 ...

Page 217: ...theoretical shim thickness D using the formula D B C A Take the obtained theoretical shim thickness D and choose the corresponding shim number E according to the following table THEORETICAL SHIM THICKNESS D SHIM NUMBER E 1 20 mm to 1 29 mm 0472 in to 0508 in 120 1 30 mm to 1 39 mm 0512 in to 0547 in 130 1 40 mm to 1 49 mm 0551 in to 0587 in 140 1 50 mm to 1 59 mm 0591 in to 0626 in 150 1 60 mm to ...

Page 218: ... the following table THEORETICAL SHIM THICKNESS I SHIM NUMBER J 1 22 mm to 1 31 mm 048 in to 0516 in 120 1 32 mm to 1 41 mm 052 in to 0555 in 130 1 42 mm to 1 51 mm 0559 in to 0594 in 140 1 52 mm to 1 61 mm 0598 in to 0634 in 150 1 62 mm to 1 71 mm 0638 in to 0673 in 160 1 72 mm to 1 81 mm 0677 in to 0713 in 170 1 82 mm to 1 91 mm 0717 in to 0752 in 180 For example if the theoretical shim thicknes...

Page 219: ...dle bearing installer 4 Installer handle Install bevel gear needle bearing REQUIRED TOOL BEARING INSTALLER GEARBOX P N 529 035 763 HANDLE P N 420 877 650 vmr2006 022 051_a 1 Bevel gear needle bearing 2 Center housing 3 Needle bearing installer 4 Installer handle Install new oil seals with the proper installer refer to GEARBOX OIL SEALS in this subsection Other Gearbox Components Fit intermediate g...

Page 220: ...ng into index lever vmr2006 022 090_a 1 Washer 2 Index lever 3 Step ring 4 Index spring Install parking lock lever teeth showing to coun tershaft vmr2006 022 066_a 1 Parking lock lever Place shim of CVT side on bearing vmr2006 022 092_a 1 Shim CVT side Place reverse gear with needle bearing and thrust washer NOTE Check if the screw to secure countershaft bearing is installed 30 vmr2016 422 ...

Page 221: ...k NOTE If a new bevel gear and output shaft are used it is necessary to verify the shim adjustment prior to finalize assembly Refer to ADJUSTMENT in this subsection If the existing bevel gear is used it is mandatory to use a new shim with the same thickness a new needle bearing and shim vmr2006 022 095_a 1 Bevel gear 2 Sliding gear 3 Shift fork Install a new needle bearing and shim vmr2006 022 096...

Page 222: ...ing washer and shift shaft must align vmr2006 022 098_a 1 Shift shaft assembly 2 Isolating washer 3 Marks Install shift fork then engage both shift fork pins in their corresponding groove on the shift drum NOTE Move sliding gears to facilitate engage ment of pins inside grooves vmr2006 022 099_a 1 Shift fork pins 2 Sliding gear Install shift fork shaft NOTE Run all gears as a final function check ...

Page 223: ...ing mating surfaces F12R17A Do not apply in excess as it will spread out inside gear housing NOTE It is recommended to apply this specific sealant as described here to get a 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 the adhesion Tighten gear housing screws in a crisscross se que...

Page 224: ...Bearing cover Tighten the three 3 nuts that attaching the gear box to the engine TIGHTENING TORQUE Service product LOCTITE 243 BLUE P N 293 800 060 Gearbox retaining nuts 25 N m 3 N m 18 lbf ft 2 lbf ft After installation refill gearbox oil refer to PERI ODIC MAINTENANCE PROCEDURES 34 vmr2016 422 ...

Page 225: ...5 868 5 10 HANDLE 420 877 650 12 OIL SEAL INSTALLER GEARBOX 529 035 758 12 OIL SEAL INSTALLER 529 036 204 13 SERVICE TOOLS OTHER SUPPLIER Description Part Number Page FLUKE RIGID BACK PROBE TP88 5 6 8 SERVICE PRODUCTS Description Part Number Page LOCTITE 243 BLUE 293 800 060 27 LOCTITE 5910 293 800 081 9 25 LOCTITE CHISEL GASKET REMOVER 413 708 500 25 PETAMO GREASE GHY 133N 420 899 271 11 SUPER LU...

Page 226: ... 9 lbf in 10 1 N m 89 9 lbf in 25 3 N m 18 2 lbf ft 3 0 3 N m 27 3 lbf in 10 1 N m 89 9 lbf in Petamo Grease 10 1 N m 89 9 lbf in Loctite 243 10 1 N m 89 9 lbf in 25 3 N m 18 2 lbf ft Engine oil Loctite 243 Engine oil Engine oil Loctite 5910 Engine oil Engine oil Engine oil Engine oil Engine oil The shaded parts are not serviceable Gearbox replacement is requied tmr2015 023 001_a 2 vmr2016 424 ...

Page 227: ...removed NEW NEW NEW Loctite 5910 Super Lube Grease Loctite 243 Loctite 648 Engine oil Loctite 648 Petamo Grease 20 2 N m 15 1 5 lbf ft 10 1 N m 89 9 lbf in 28 3 N m 21 2 lbf ft 10 1 N m 89 9 lbf in 5 0 6 N m 44 5 lbf in 25 3 N m 18 2 lbf ft 3 0 3 N m 27 3 lbf in NEW 10 1 N m 89 9 lbf in Petamo Grease tmr2015 023 002_a vmr2016 424 3 ...

Page 228: ...on indicator switches 2 Output shaft GEARBOX OVERVIEW Tmr2011 016 003_a 1 Gearbox position sensor GBPS 2 Right cover 3 Vehicle speed sensor VSS 4 Actuator 5 4WD indicator switch Tmr2011 016 004_a 1 Center housing 2 Left cover 3 Countershaft 4 Output shaft 5 Shift shaft TROUBLESHOOTING UNUSUAL GEARBOX NOISE AND OR VIBRATIONS 1 Low oil level in gearbox Oil leakage from gearbox Replace damaged gas ke...

Page 229: ...icle speed sensor is located on the right housing of the gearbox behind the actuator Tmr2011 016 006_a 1 Right housing of gearbox 2 Actuator 3 VSS Vehicle Speed Sensor The VSS connector is located between the cylin ders behind the OPS cover VSS Access To reach the VSS refer to BODY subsection and remove the RH engine cover To reach the VSS connector remove the OPS cover VSS Wire Identification FUN...

Page 230: ...r REQUIRED TOOL FLUKE RIGID BACK PROBE P N TP88 4 Turn ignition switch ON 5 Set emergency engine stop switch to RUN 6 Set multimeter to Vdc 7 Measure voltage while slowly rotating rear wheels by hand VEHICLE SPEED SENSOR SIGNAL TEST TEST PROBES RESULT WHILE ROTATING WHEELS PIN B WHITE wire PIN C BLACK wire Alternate reading between battery voltage and 0 Vdc NOTE Since we measure pulsating voltage ...

Page 231: ...y Shift drum GBPS ECM 1 Connect vehicle to the latest applicable version of B U D S software refer to COMMUNICA TION TOOLS AND B U D S subsection NOTE Ignition key must stay ON and emergency engine stop switch must remain to RUN during the reset procedure Otherwise the procedure must be carried out again 2 In B U D S select the following Read Data button Setting tab ECM tab tmr2011 016 090_a TYPIC...

Page 232: ...rts and reset fault codes Testing the GBPS Signal Wire Continuity Unplug ECM connector and connect it to the adapter tool REQUIRED TOOL ECM ADAPTER TOOL P N 529 036 166 MULTIMETER PROBE POSITIONS RESISTANCE 20 C 68 F GBPS connector pin 2 and ECM adapter tool pin D2 Below 1 If resistance is out of specification check wires and connectors Repair and reset fault codes If resistance is good and the ot...

Page 233: ...dicator Switch Measure switch resistance as follows SWITCH POSITION SWITCH WIRE RESISTANCE 2WD Close to 0 4WD BLACK BEIGE Engine ground Infinite OL If the resistance is out of specification replace the 4WD indicator switch Installing the 4WD Indicator Switch For installation reverse the removal procedure Pay attention to the following details Take care do not damage indicator switch threads during...

Page 234: ...WD Actuator NOTE Clean area of dirt before removing the 4WD actuator Make sure the actuator is in 4WD position Remove the RH floorboard Place a drain pan under actuator Remove actuator screws Tmr2011 016 025_a 1 Actuator 2 Washer 3 Screw Pull the actuator out of housing Installing the 4WD Actuator Lubricate actuator O ring ACTUATOR O RING Service product SUPER LUBE GREASE P N 293 550 030 Vmr2015 1...

Page 235: ...e actuator and reinstall it NOTICE Refill gearbox refer to GEARBOX OIL FILLING PROCEDURE in PERIODIC MAIN TENANCE PROCEDURES subsection Install all other removed parts GEARBOX OIL SEALS Gearbox Oil Seal Replacement Replace oil seals if they are brittle hard or dam aged A small flat screwdriver can be used to remove most of these oil seals NOTICE Avoid scoring parts during oil seal removal When rep...

Page 236: ...anel Shift plate from shift shaft refer to SHIFTER Use a suitable tube with the proper diameter to install the oil seal If gearbox housing is apart use following tools for shift shaft oil seal installation REQUIRED TOOL OIL SEAL INSTALLER GEARBOX P N 529 035 758 HANDLE P N 420 877 650 NOTICE Oil seal must be installed with seal ing lip toward gearbox Shift Drum Shaft Oil Seal To replace the shift ...

Page 237: ...during installation Place oil seal on output shaft and install it using the following tools REQUIRED TOOL OIL SEAL INSTALLER P N 529 036 204 Flat washer P N 250 200 102 M12 x 1 25 x 35 hexagonal screw tmr2011 016 020_a 1 Output shaft oil seal 2 Oil seal installer 3 Flat washer P N 250 200 102 4 M12 x 1 25 x 35 hexagonal screw 5 Apply engine oil on outer diameter of oil seal GEARBOX Removing the Ge...

Page 238: ...nspect the condition of each part closely Gearbox Left Cover Set gearbox to NEUTRAL position Unscrew all bolts retaining the gearbox left cover Tmr2011 016 043_a 1 3 screws M6 x 35 2 13 screws M6 x 55 Place the center housing on a wood stand left cover pointing upwards Using a big flat screwdriver and a soft hammer to lift the left cover Tmr2011 016 044 POSITION FOR SOFT HAMMER Tmr2011 016 045 POS...

Page 239: ...asher Tmr2011 016 074_a 1 Index lever 2 Index washer 3 Shift drum Remove the index lever with washer step ring and spring Tmr2011 016 075_a 1 Washer 2 Index lever 3 Step ring 4 Index spring Main Shaft and Shift Forks Remove bearing pin reverse intermediate gear and thrust washers NOTE Take care not to lose lower thrust washer during removal Tmr2011 016 046_a 1 Bearing pin 2 Reverse intermediate ge...

Page 240: ...ork vmr2012 020 006_a 1 Shifting sleeve HIGH range gear 2 Shift fork When required remove from main shaft assem bly Snap ring discard HIGH range gear LOW range gear Needle bearings vmr2012 020 007_a 1 Snap ring 2 Free pinion HIGH range gear 3 Free pinion LOW range gear 4 Needle bearing 5 Main shaft assembly Remove from main shaft assembly Snap ring discard Shifting sleeve LOW REVERSE range gear Sn...

Page 241: ... procedures in this subsec tion Unscrew all bolts retaining the gearbox right cover Tmr2011 016 031_a 1 5 screws M8 x 55 2 2 screws M6 x 85 3 2 screws M6 x 55 4 8 screws M6 x 35 To remove cover use 2 big screwdrivers Tmr2011 016 032 POSITION FOR BIG FLAT SCREWDRIVER Tmr2011 016 033 POSITION FOR BIG FLAT SCREWDRIVER Shift Shaft and Shift Drum Withdraw shift shaft assembly Tmr2011 016 071_a 1 Shift ...

Page 242: ...ft fork 3 Shift drum Remove shift drum and thrust washer Tmr2011 016 077_a 1 Shift drum 2 Thrust washer Output Shaft and 4x4 Coupling Mechanism Remove output shaft from center housing and withdraw 4x4 coupling sleeve NOTICE Use a soft hammer to remove output shaft Tmr2011 016 034_a 1 Output shaft 2 4x4 coupling sleeve 3 Soft hammer Remove hexagonal screw coupling fork shaft and coupling fork from ...

Page 243: ... housing before heating NOTICE Always support gearbox housings properly when ball bearings are removed Housing damages may occur if this procedure is not performed correctly To remove ball bearings of countershaft right cover and main shaft left cover use a blind hole bearing puller Remove screw securing the countershaft bearing in the left cover For ball bearings of countershaft left cover and ma...

Page 244: ... bearings bearing points tooth flanks and taper grooves Free Pinions NOTE Always replace snap rings and use special pliers to install them Check free pinions for wear vmr2006 022 080_a TYPICAL 1 Micrometer 2 Free pinion DIAMETER FREE PINION NEW 29 000 mm to 29 013 mm 1 1417 in to 1 1422 in SERVICE LIMIT 29 015 mm 1 1423 in Shifting Sleeves Check shifting sleeves for worn inner splines and rounded ...

Page 245: ...786 in COUNTERSHAFT BEARING JOURNALS MAG SIDE CVT SIDE NEW 24 977 mm to 24 990 mm 983 in to 984 in SERVICE LIMIT 24 970 mm 983 in Check main shaft for wear Tmr2011 016 059_b A Bearing journal MAG side B Free pinion bearing C Bearing journal CVT side MAIN SHAFT FREE PINION BEARING NEW 24 987 mm to 25 000 mm 984 in to 984 in SERVICE LIMIT 24 984 mm 984 in BEARING JOURNAL CVT MAG SIDE NEW 16 980 mm t...

Page 246: ...straight Index Lever and Parking Lever Index lever with roller must move freely Check parking lever for cracks or other damages Output Shaft Check output shaft and its gear for cracks bend pitting or other visible damages Check output shaft splines for wear or other dam ages Check if the output shaft bearings turn freely and smoothly Replace oil seal if brittle hard or damaged 4x4 Coupling Sleeve ...

Page 247: ...installing ball bearings of countershaft and main shaft NOTE Place gearbox housings on a wood stand before installing ball bearings Install new oil seals with the proper installer refer to OIL SEALS in this subsection Main Shaft and Shift Forks Install NEW snap rings NOTE Ensure snap rings are installed in the grooves properly Install free pinion REVERSE range gear and shift ing sleeve LOW REVERSE...

Page 248: ...o index lever Tmr2011 016 075_b 1 Index spring 2 Step ring 3 Index lever 4 Washer 5 Screw Install index washer on shift drum Insert a flat screwdriver in the slot of the index lever turn screwdriver clockwise and engage lever in index washer in NEUTRAL position as per following illustration Tmr2011 016 086_a 1 Index lever 2 Index washer 3 Neutral position 4 High range gear position 5 Low range gea...

Page 249: ...sh a first pass in one direction then make the final brushing perpendicularly 90 to the first pass cross hatch NOTICE Do not wipe with rags Use a new clean hand towel only IMPORTANT When beginning the application of the gear housing sealant the assembly and the first torquing should be done within 10 minutes It is suggested to have all you need on hand to save time Use LOCTITE 5910 P N 293 800 081...

Page 250: ...e of distance sleeve has to face the gearbox Tmr2011 016 067_a COUNTERSHAFT END CVT SIDE 1 O ring 2 Distance sleeve 3 Countershaft end CVT side Right Cover Apply sealing compound on mating surfaces of central housing Refer to SEALING COMPOUND APPLICATION To install the right cover align the coupling fork with the groove in the coupling sleeve Install all screws on right cover and tighten them as p...

Page 251: ...eplace if nec essary Tmr2011 016 040_a 1 Bearing cover 2 O ring Tighten the four 4 nuts that attach the gearbox to the engine TIGHTENING TORQUE Service product LOCTITE 243 BLUE P N 293 800 060 Gearbox retaining nuts 25 N m 3 N m 18 lbf ft 2 lbf ft After installation refill gearbox oil Refer to PERI ODIC MAINTENANCE PROCEDURES vmr2016 424 27 ...

Page 252: ... SERVICE PRODUCTS Description Part Number Page LOCTITE 243 BLUE 293 800 060 2 Loctite 243 9 1 N m 80 9 lbf in NEW NEW 13 2 N m 115 18 lbf in Renegade CE models Component must be replaced when removed NEW NEW 10 2 N m 89 18 lbf in NEW NEW 5 1 N m 44 9 lbf in NEW vmr2016 406 100_a vmr2016 406 1 ...

Page 253: ...hreads SHIFT LEVER Shift Lever Access 1 Refer to BODY subsection and remove the fol lowing components Seat Console RH side panel Shift Lever Removal 1 Remove body parts as required Refer to SHIFT LEVER ACCESS in this subsection 2 Place shift lever in NEUTRAL position vmr2015 024 004_a SHIFT LEVER POSITION 3 Secure vehicle using wheel chocks 4 Remove parts as indicated in following illustra tions v...

Page 254: ...dure However pay attention to the following Adjust shift lever handle as per following illustra tion vmr2012 021 005_a SHIFT LEVER HANDLE ALIGNMENT 1 Handle 2 Ridge A Handle parallel with ridge Check if shift lever works properly in all positions Ensure throttle cable does not interfere with shift lever in all positions NOTE Shift lever must be perfectly centered with the neutral position indicato...

Page 255: ...shift lever in neutral notch vmr2015 037 003_b 1 Shift rod adjuster vmr2012 021 006_a SHIFT LEVER CENTERED WITHIN NEUTRAL NOTCH A Shift lever B Neutral notch 6 Move shift lever in R position then in H position 7 Place shift lever in NEUTRAL position 8 Check if shift lever is properly centered in neu tral notch Readjust as required 9 Hold adjuster steady and tighten lock nuts vmr2015 037 002_a 1 Ad...

Page 256: ...2015 037 005_a 1 Bolt 2 Spacer 3 Nut 4 Trace an index mark on shift plate and shift shaft vmr2015 037 006_a 1 Trace a mark on both parts 5 Remove shift plate nut and bolt vmr2015 037 007_a 1 Shift plate nut 6 Remove shift plate Shift Plate Inspection Check shift plate for Cracks Bending Spline condition Shift Plate Installation The installation is the reverse of the removal pro cedure However pay ...

Page 257: ... shift plate 3 Horizontal plane top surface of gearbox 4 Center of bolt secondary alignment reference A 110 2 5 Ensure that shift shaft protrudes shift plate as per illustration vmr2015 037 009_a 1 Shift shaft end 2 Shift plate A 2 5 mm 1 mm 1 in 040 in Adjust shift rod refer to SHIFT ROD ADJUST MENT in this subsection Tighten shift plate nut to specification TIGHTENING TORQUE Shift plate nut 9 N ...

Page 258: ...UCTS Description Part Number Page LOCTITE 243 BLUE 293 800 060 2 Component must be replaced when removed NEW NEW NEW 10 2 N m 89 18 lbf in NEW 5 1 N m 44 9 lbf in NEW Loctite 243 9 1 N m 80 9 lbf in NEW NEW Renegade CE models 13 2 N m 115 18 lbf in vmr2016 407 001_a vmr2016 407 1 ...

Page 259: ...Access 1 Refer to BODY subsection and remove the fol lowing components Seat Console RH side panel Shift Lever Removal 1 Remove body parts as required Refer to SHIFT LEVER ACCESS in this subsection 2 Place shift lever in NEUTRAL position 3 Secure vehicle using wheel chocks 4 Unscrew shift lever handle 5 Unhook spring vmr2012 021 002_a 1 Unhook 6 Detach shift rod from shift lever vmr2012 021 003_a 1...

Page 260: ...d Adjustment 1 Place shift lever in NEUTRAL position NOTICE Move vehicle back and forth to en sure gearbox is set in neutral position 2 Secure vehicle using wheel chocks 3 Remove body parts as required Refer to SHIFT LEVER ACCESS in this subsection 4 Loosen shift rod adjustment nuts NOTE Be aware that a nut has LH threads vmr2012 021 007_a TYPICAL SOME PARTS REMOVED FOR CLARITY 1 Adjustment nuts 5...

Page 261: ...ace a mark on both parts 5 Remove shift plate nut and bolt vmr2012 021 008_c 1 Shift plate nut 6 Remove shift plate Shift Plate Inspection Check shift plate for Cracks Bending Spline condition Shift Plate Installation The installation is the reverse of the removal pro cedure However pay attention to the following Place gearbox in NEUTRAL position before shift plate installation Position shift plat...

Page 262: ...te as per illustration vmr2012 021 011_a 1 Shift shaft end 2 Shift plate A 2 5 mm 1 mm 1 in 040 in Adjust shift rod refer to SHIFT ROD ADJUST MENT in this subsection Tighten shift plate nut to specification TIGHTENING TORQUE Shift plate nut 9 N m 1 N m 80 lbf in 9 lbf in vmr2016 407 5 ...

Page 263: ...S ENGINE MANAGEMENT SYSTEM EMS Engine with Gearbox using External Switches ECM VSS GBPS CTS IACV INJ 2 INJ 1 IGN COIL OPS 4WD TPS MAPTS CPS COOLING FAN IGN SW FUEL PUMP STARTER SOLENOID START SW ECM ECM OUT IN vmr2015 064 001_aen vmr2016 127 1 ...

Page 264: ...Subsection 01 ENGINE MANAGEMENT SYSTEM EMS Engine with Gearbox using External Switches MD CPS OPS GBPS BA INJ2 INJ1 HIC1 HIC2 CTS TPS ECM IACV MAPTS VSS SD vmr2015 064 002_a 2 vmr2016 127 ...

Page 265: ...E MANAGEMENT SYSTEM EMS Engine with Gearbox using GBPS ECM VSS GBPS CTS IACV INJ 2 INJ 1 IGN COIL OPS 4WD TPS MAPTS CPS COOLING FAN IGN SW FUEL PUMP STARTER SOLENOID START SW ECM ECM OUT IN vmr2015 125 001_a vmr2016 127 3 ...

Page 266: ...Subsection 01 ENGINE MANAGEMENT SYSTEM EMS Engine with Gearbox using GBPS MD CPS OPS GBPS BA INJ2 INJ1 HIC1 HIC2 CTS TPS ECM IACV MAPTS VSS SD vmr2015 125 002_a 4 vmr2016 127 ...

Page 267: ...ion system 4 Starting system 5 Fuel pump system 6 D E S S system NOTE For further information related to these systems refer to the applicable subsection The ECM Engine Control Module is the central point of the engine management system vmr2008 132 005 TYPICAL ECM The ECM is located behind the LH panel vmr2012 022 002_a LH PANEL REMOVED 1 ECM location The ECM reads input signals from various switc...

Page 268: ...hrottle lever will bring back the nor mal mode Monitoring System The ECM monitors the electronic components of the fuel injection system and also parts of the electrical system For more information refer to DIAGNOSTIC AND FAULT CODES Limp Home Mode The ECM may automatically set default parame ters to the engine management to ensure the ad equate operation of the engine if a component of the fuel i...

Page 269: ...air of wires WHITE BEIGE and BEIGE GREEN If a component or system malfunction is de tected a module ECM multifunction gauge or DPS may generate a fault code which it trans mits through the CAN bus as a signal The fault signal may be used for various functions such as triggering the display of an error message in the multifunction gauge cluster turning on a fault indicator light limiting or inhibit...

Page 270: ...851 OPTIONAL TOOL Extension cable available at electronic retail outlets Do not exceed 7 5 m 25 ft TROUBLESHOOTING DIAGNOSTIC TIPS IMPORTANT Make sure all connections are made and vehicle is powered up before starting B U D S to allow proper communication between the vehicle and the BRP Utility and Diagnostic Software B U D S Multi Purpose Interface Card Connection Troubleshooting MPI Status Light...

Page 271: ...nd multifunction gauge Models with DPS 3 ECM DPS and multifunction gauge vmr2016 128 002_a TYPICAL 1 Number of modules If one or more ECU is not communicating with the MPI card refer to DIAGNOSTIC AND FAULT CODES No Vehicle is Detected If an X is shown in the status bar and the pro tocol indication is blinking between Kw2000 500K and KW2000 it means that no ECU is communi cating with the MPI card ...

Page 272: ...computer mmr2006 079 200 MPI CARD CABLE CONNECTED TO USB PORT 6 Use B U D S as described further in B U D S SOFTWARE topic B U D S SOFTWARE B U D S is designed for Programming ignition key s to the vehicle Monitoring some electrical and electronic com ponents Activating certain components for diagnostic purposes Updating electronic module software And to carry out setting changes Always use the la...

Page 273: ...odule Whenever B U D S is first connected to a vehicle check for an update icon in the status bar at the bottom of the Vehicle page smr2010 030 002_a TYPICAL If the update icon is visible B U D S indicates that a file is available to update at least one of the elec tronic modules NOTE If an update file is available on KNOWL EDGE CENTER but the B U D S software being used is not up to date the upda...

Page 274: ...he update menu in B U D S a dialog box will appear and the update file description may give some clue to finding the vehicle related information on KNOWLEDGE CENTER mbg2008 022 100_a TYPICAL 1 File description Saving Changes to an ECU If the word Modified appearsat the end of the ve hicle file name at the top of the B U D S page then a change has been made that requires it to be saved to the prope...

Page 275: ...ar before disconnect ing the MPI Disconnect MPI card and store the vehicle diag nostic connector in its protective cap vmr2012 023 003_a 1 Diagnostic connector in its storage cap NOTICE Failure to secure the diagnostic con nector in its protective cap may result in corro sion or other damage to the terminals 6 vmr2016 128 ...

Page 276: ...nk in the multifunction gauge If the fault that caused the pilot lamp to come on is momen tary the pilot lamp may turn off automatically or may need to be reset by powering down the ve hicle and then restarting it A message may also be displayed to provide ad ditional information related to the fault that turned on the pilot lamp Refer to the following chart NOTE In some cases the CHECK ENGINE mes...

Page 277: ...ed Fault Codes An occurred fault code indicates a fault that was active but no longer is The occurred fault does not presently affect sys tem or component operation but is retained as a history of the faults that were detected The fault may have been generated due to a system or component that was momentarily op erating outside normal parameters Repeated occurred faults of this type should be cons...

Page 278: ...ist FAULT STATE INFORMATION All faults Display all possible faults regardless of state Active faults Display only faults matching this state Empty area if there is no active fault Active and occurred faults Display only faults that have either state Empty area if there is neither active nor occurred fault vbl2012 007 011_a FAULT PAGE 1 Fault tab 2 Fault indicator light 3 Fault code state drop box ...

Page 279: ...is is the module that detects or has received a message of an anomaly and reports it List of modules Cluster multifunction gauge DPS dynamic power steering ECM engine control module Count Number of times this fault occurred within the driving cycle Value From 0 to 255 Cycle time Not to be used Value From 0 to 255 minutes Total time Not to be used Value From 0 to 64 255 minutes Description Provides...

Page 280: ...propriate counter s and will also record that the problem has been fixed in the related ECU memory NOTE An active fault code cannot be cleared In other words the problem relevant to the fault code must be repaired before the fault can be cleared FAULT CODE DIAGNOSTIC Missing Module If a module is missing several fault codes will ap pear To quickly find which module is missing perform the following...

Page 281: ...ts currently not operating normally Display Occurred faults to troubleshoot intermittent problems Monitor system s sensor s switches and actual conditions Activate component s for troubleshooting Set components resets etc Know the last minute of operating conditions by using the History page Know the operating conditions if available when a fault code occurred by using the More details button in t...

Page 282: ...e pins and wiring terminals Then the other modules should stop reporting that module is missing May have been generated due to a system or component that was momentarily operating outside normal parameters May be generated when disconnecting and reconnecting a component replacing a burnt fuse or may be due to a momentary high or low voltage Occurred fault s Before being Occurred a fault has always...

Page 283: ...ems FAULT CODE TABLE ACRONYMS USED IN THE FAULT CODE TABLE USED IN FAULT CODE TABLE MEANING ECM Engine Control Module DPS Dynamic Power Steering CAN Controller Area Network TPS Throttle Position Sensor GBPS Gearbox Position Sensor SCM Suspension Control Module HOW TO FIND FAULT CODE DESCRIPTIONS For the latest fault code table use the Info Cen ter submenu in BOSSWeb and enter the following search ...

Page 284: ...ions have to be done Mud dust or water in the release tube may explain the fault code If the Test status shows a Fail_release proceed to next action step 2 Verify the release tube orange for obstruction If nothing is found go to next action step 3 Unplug the valves block connector and measure that 12V is present between pin D of the connector on the SCM side and the battery negative post If not ve...

Page 285: ...r Auxiliary Line Pressure sensors is defective 2 Make sure to have no pressure in the system by activating the relief valve in Activation SCM Connect the supplied air hose into the compressor fitting and plug it to a known pressure supply in the range of 30 to 120 psi as car tire and compare it to the Shock absorber pressure and Auxiliary line pressure it should be similar If the Shock absorber pr...

Page 286: ...ar go to action step 6 3 Test the compressor with an external power supply as a 12V battery If the compressor is functional go to next action step 4 Unplug the relay and make sure to have 12V between battery negative post and relay pin 30 If not check the compressor fuse and harness If 12V is present test the relay If the relay is functional plug it back and go to next action step 5 Disconnect the...

Page 287: ...d fault and no more actions have to be done If the air do not blow out continue to next action step 2 Verify the air tube black from the valve to the rear suspension If nothing found go to next action step 3 Unplug the valve block electrical connector and verify that 12V is present between pin A and battery negative post If not verify valve fuse relay and harness refer to schematics for more infor...

Page 288: ...ar go to action step 6 3 Test the compressor with an external power supply as a 12V battery If the compressor is functional go to next action step 4 Unplug the relay and make sure to have 12V between battery negative post and relay pin 30 If not check the compressor fuse and harness If 12V is present test the relay If the relay is functional plug it back and go to next action step 5 Disconnect the...

Page 289: ...e from the valves to both front shocks If clear go to next action step 3 Unplug the valve block electrical connector and verify that 12V is present between pin B and battery negative post right between pin C and battery negative post left If not verify valve fuse relay and harness refer to schematics for more information If both 12V are read go to next action step 4 Verify the front valves activat...

Page 290: ... connector is fully inserted Measure voltage between harness connector pins 1 and 3 Expected value 4 8 to 5 1 volts Measure resistance from connector ECM F3 to MAPTS 2 Expected value 2 ohms Measure resistance from connector ECM A1 to MAPTS 3 Expected value 2 ohms Measure resistance from connector ECM G2 to MAPTS 1 Expected value 2 ohms Measure resistance from connector ECM F2 to MAPTS 4 Expected v...

Page 291: ...d value 4 8 to 5 1 volts Measure resistance from connector ECM F3 to MAPTS 2 Expected value 2 ohms Measure resistance from connector ECM A1 to MAPTS 3 Expected value 2 ohms Measure resistance from connector ECM G2 to MAPTS 1 Expected value 2 ohms Measure resistance from connector ECM F2 to MAPTS 4 Expected value 2 ohms P0116 ECM Engine Coolant Temperature Sensor 1 circuit range performance Damaged...

Page 292: ...or or damaged ECM pins Make sure sensor connector is fully inserted Measure resistance from connector ECM A1 to TPS 1 Expected value 2 ohms Measure resistance from connector ECM G3 to TPS 3 Expected value 2 ohms Measure resistance from connector ECM G2 to TPS 2 Expected value 2 ohms P0123 ECM Throttle Position Sensor TPS shorted to battery Damaged circuit wires damaged sensor or damaged ECM pins M...

Page 293: ...res damaged connectors or damaged ECM output pins Check fuse Measure voltage between harness connector PF1 12B and ground Expected value 11 to 13 volts Measure voltage between harness connector PF1 11B and ground Expected value 11 to 13 volts Measure resistance from harness connector ECM J1 to PF1 12A Expected value 2 ohms Measure resistance from harness connector PF1 11A to FP 3 Expected value 2 ...

Page 294: ...1 Expected value 2 ohms P0265 ECM Cylinder 2 injector shorted to battery Damaged injector damaged circuit wires damaged connector or damaged ECM output pins Disconnect injector 2 Measure resistance between injector pin 1 and 2 Expected value 14 to15 ohms Measure resistance from harness connector INJ2 1 to INJ2 2 Expected value OPEN Measure voltage between harness connector INJ2 2 and ground Expect...

Page 295: ...ohms on ATV P0508 ECM Idle Air Control System Circuit Low Damaged IDLE damaged circuit wires damaged connector or damaged ECM output pins Make sure IDLE connector is fully inserted Measure resistance from connector ECM D4 to IDLE D Expected value 2 ohms Measure resistance from connector ECM D3 to IDLE A Expected value 2 ohms Measure resistance from connector ECM E4 to IDLE B Expected value 2 ohms ...

Page 296: ...ssible Replace the DPS P0552 DPS TORQUE_ SENSOR_ SHORT_GND Damaged DPS External troubleshooting is not possible Replace the DPS P0553 DPS TORQUE_ SENSOR_ SHORT_5V Damaged DPS External troubleshooting is not possible Replace the DPS P0562 DPS System voltage low Blown fuse battery low damaged magneto regulator damaged circuit wires or connection intense winch usage Check the two DPS fuses Validate t...

Page 297: ...n Lost of power on reflash If an update file is available reflash the SCM if not clear the fault if it returns replace the SCM P0615 ECM Starter Relay circuit open Damaged relay Danaged start switch damaged circuit wires damaged connector damaged ECM pins Check start button Check Run Stop button check if free weeling diode is in the good way Disconnect starter solenoid relay Measure resistance fro...

Page 298: ...l error or damaged DPS External troubleshooting is not possible Replace the DPS P0642 ECM Sensor Reference Voltage Low Damaged sensor connected to ECM voltage supply Damaged ECM voltage supply output Measure voltage between harness connector ECM A1 and ground Expected value 4 8 to 5 1 volts Check sensor connected to ECM voltage supply output P0643 ECM Sensor Reference Voltage High Damaged sensor c...

Page 299: ...use Disconnect Accessory relay and Lights relay turn key switch on w lights Measure voltage between harness connector PF1 10E and ground Expected value 11 to 13 volts Measure voltage between harness connector PF1 6D and ground Expected value 11 to 13 volts Measure resistance from harness connector ECM K2 to PF1 12D Expected value 2 ohms Measure resistance from harness connector ECM K2 to PF1 7C Ex...

Page 300: ...stance between terminals 85 and 86 on relay Expected value 70 to 90 ohms P0705 ECM Subtransmission Internal switch Combinations error Wrong Switch Combinations Damaged Switch damaged circuit wires damaged connectors or damaged ECM pins Check for disconnected transmission connector Check for misplaced terminal on gearbox Measure resistance form each switch to ground in all position PR N Expected va...

Page 301: ... GBPS 3 Expected value 2 ohms Replace GBPS sensor P1562 ECM System voltage low from Key switch Blown fuse FC battery failure voltage regulator failure damaged circuit wires or connection damaged magneto generator An external battery charger may have been used Measure battery voltage with engine stopped Expected value 11 to 13 volts Measure battery voltage with engine running Expected value 13 to 1...

Page 302: ...ble Replace the DPS P2300 ECM Cyllinder 1 Ignition output shorted to ground Damaged ignition coil damaged circuit wires damaged connector or damaged ECM output pins Open the ECM Activation page in BUDS Perform an ignition coil activation and check if ignition coil is reacting as expected Measure resistance from harness connector ECM M2 to BA 3 Expected value 2 ohms Measure voltage between harness ...

Page 303: ...uit wires damaged connector or damaged ECM output pins Open the ECM Activation page in BUDS Perform an ignition coil activation and check if ignition coil is reacting as expected Measure resistance from harness connector ECM M1 to BA 1 Expected value 2 ohms Measure voltage between harness connector BA 2 and ground Expected value 11 to 13 volts Refer to the service manual for detailed ignition coil...

Page 304: ...of Shock absorber or Auxiliary Line Pressure sensors is defective 2 Make sure to have no pressure in the system by activating the relief valve in Activation SCM Connect the supplied air hose into the compressor fitting and plug it to a known pressure supply in the range of 30 to 120 psi as car tire and compare it to the Shock absorber pressure and Auxiliary line pressure it should be similar If th...

Page 305: ...essor is running and the Test Status show a Fail_Pumping go to action step 6 3 Test the compressor with an external power supply as a 12V battery If the compressor is functional go to next action step 4 Unplug the relay and make sure to have 12V between battery negative post and relay pin 30 If not check the compressor fuse and harness If 12V is present test the relay If the relay is functional pl...

Page 306: ...information Verify the harness and the connection between the valve and the SCM If everything is fine go to next action step 4 Verify the release valve activation by disconnecting the valve block electrical connector and applying 12V across pin 1 and 2 on valve connector If the release valve is operating change the SCM otherwise change the valve block P3003 SCM LTD System high leakage detected Lea...

Page 307: ...Bus wires to cluster Damaged circuit wires or damaged Cluster module pins Measure voltage between harness connector CL 17 and ground Expected value 11 to 13 volts Disconnect MPI2 from DB connector Measure resistance between DB 1 and DB 2 Expected value 50 to 70 ohms Measure resistance between DB 1 and CL 4 Expected value 5 ohms Measure resistance between DB 2 and CL 19 Expected value 5 ohms U0155 ...

Page 308: ...Immobilizer Control Module The Vehicle Immobilizer is reporting an electrical fault on the communication line Check for dirty or oxidized Key contact Clean key contact if needed Check for broke key contact Ensure sensor connector is fully inserted Measure resistance between ECMB A1 and CC C Expected value 2 ohms Measure resistance between ECMB C2 and CC E Expected value 2 ohms U0167 ECM Lost commu...

Page 309: ...r the fault if it returns replace the SCM U0426 ECM Invalid Data Received From Vehicle Immobilizer Control Module The Vehicle Immobilizer could not read the number of the access key Check for dirty or oxidized Key contact Clean key contact if needed Check for broke key contact Ensure sensor connector is fully inserted Measure resistance between ECMB A1 and CC C Expected value 2 ohms Measure resist...

Page 310: ...CRIPTION Refer to the appropriate ENGINE MANAGEMENT SYSTEM subsection for a general layout of the various EFI system components The electronic fuel injection system EFI is com prised of various sensors used for detecting ongo ing operating conditions of the engine and vehicle and includes all the components that perform the required adjustments to the engine Electrical System ECM Electronic Contro...

Page 311: ...e fuel pressure applied to the fuel rails is regu lated by the fuel pressure regulator located in the fuel pump module Fuel Injectors The fuel injectors are used to inject fuel into the intake ports of the cylinder head One injector is used per cylinder Fuel Pump An electric fuel pump with an integrated pressure regulator and fuel system filters is used For more details on the fuel pump unit refer...

Page 312: ...pen throttle approximately one quarter then quickly release Repeat 2 3 times to settle throt tle plate If stopper does not rest against its stop lever perform throttle cable adjustment Refer to THROTTLE CABLE in this subsection To reset IACV and TPS perform the following 1 Connect the vehicle to the latest applicable B U D S version refer to COMMUNICATION TOOLS AND B U D S subsection 2 In B U D S ...

Page 313: ...lar attention to ensure that terminals and pins are not out of their connectors corroded or out of shape When probing terminals pay attention not to de form the terminals as this could cause a loose or intermittent connection that would be difficult to troubleshoot PROCEDURES ENGINE CONTROL MODULE ECM As a first troubleshooting step always check for applicable fault codes using B U D S software Qu...

Page 314: ... Ground Circuits 1 Disconnect ECM connector 2 Install the ECM adapter tool on ECM connector 3 Set multimeter to and probe adapter termi nals as per following table ECM ADAPTER BATTERY POST RESISTANCE Pins M3 and M4 Ground Close to 0 continuity smr2009 030 010_a If any measurement is out of specification refer to POWER DISTRIBUTION and check all grounds Testing the CAN Resistor Remove the DPS1 conn...

Page 315: ...cables NOTICE Always disconnect the BLACK battery cable first then disconnect RED cable 2 Disconnect ECM connector 3 Unscrew all retaining screws and pull out ECM Installing the ECM Reverse removal procedure however pay atten tion to the following 1 Reconnect ECM connector 2 Reconnect battery cables WARNING Always reconnect the RED battery cable first then reconnect BLACK cable 3 If a new ECM is i...

Page 316: ... BUDS version_VIN_date read yyyymmdd _hour read hhmmss mpem Example A3 5 0 3_3JBLKCK11DJ000319_20130924_093618 mpem B U D S version A3 5 0 3 VIN 3JBLKCK11DJ000319 Date file was read 2013 09 24 Hour file was read 09h 36m 18s 4 Go to the Vehicle tab and record the following information Vehicle V I N number Engine number without the leading M Model number Customer vmr2008 022 008 5 Remove the origina...

Page 317: ...also identifies the part num ber 11 Click on the OK button 12 Click on the Write Data button vmr2006 012 100_ben FUEL INJECTOR Refer to the applicable ENGINE MANAGEMENT SYSTEM subsection for component and connec tor locations Fuel Injector Leak Test Carry out the FUEL PUMP PRESSURE TEST as detailed in the FUEL TANK AND FUEL PUMP sub section Testing the Fuel Injector Input Voltage Disconnect the fu...

Page 318: ...12 6 If resistance value obtained is incorrect perform an INJECTOR GROUND CIRCUIT RESISTANCE TEST Testing the Injector Ground Circuit Resistance Disconnect the fuel injector connector Disconnect ECM connector Install the ECM adapter tool on the ECM connec tor Using a multimeter check resistance value be tween terminals as follows INJECTOR GROUND CIRCUIT CYLINDER WIRE ECM ADAPTER MEASUREMENT FRONT ...

Page 319: ...ail from hose cut clamp on fuel hose Refer to FUEL TANK AND FUEL PUMP for clamp removal installation procedures REQUIRED TOOL OETIKER PLIERS P N 295 000 070 NOTE If fuel rail is removed for access to fuel in jector it is not necessary to cut hose clamp Only to replace fuel rail Installing the Fuel Rail For installation reverse the removal process how ever pay attention to the following Install new...

Page 320: ... in the cable vmr2006 014 064_b 1 Contact here 2 Free play here CAUTION If there is no free play at idle position it may cause poor idling and starta bility problems Improper cable adjustment will cause strain on cable and or damage cable bracket or throttle lever at handlebar WARNING Make sure idle speed stopper contacts throt tle cam when throttle lever is fully released at handlebar If adjustme...

Page 321: ...rew is loose or worn Cleaning the Throttle Body 1 Check throttle body cleanliness using a flash light Fully open throttle plate and verify Throttle body bore Throttle plate edge Look for Dirt Oily surfaces Carbon and salt deposits on throttle plate and the surrounding bore 2 Clean as necessary 3 Use a throttle body cleaner such as GUNK IN TAKE MEDIC or an equivalent Refer to manu facturer s instru...

Page 322: ... 026 004_a Step 1 Loosen Step 2 Rotate Step 3 Remove 7 Rotate throttle lever and pull out cable barrel vmr2006 014 060_b 1 Throttle lever 2 Cable barrel 8 Remove barrel from cable 9 Pull out throttle cable 10 Pull out throttle body Installing the Throttle Body Installation of the throttle body is the reverse of the removal procedure However pay attention to the following Temporarily install thrott...

Page 323: ...section THROTTLE POSITION SENSOR TPS Refer to the applicable ENGINE MANAGEMENT SYSTEM subsection for component and connec tor locations General The throttle position sensor TPS is a potentiome ter that sends a signal to the ECM which is propor tional to the throttle plate angle vmr2008 022 010_b 1 Throttle position sensor TPS The ECM may generate several fault codes per taining to the TPS Refer to...

Page 324: ...hrottle cable adjustment Refer to THROTTLE CABLE ADJUSTMENT in this subsec tion Ensure TPS is connected to wiring harness Disconnect the ECM connector Using the ECM adapter tool and a multimeter check resistance values ECM ADAPTER THROTTLE IDLE POSITION WIDE OPEN THROTTLE POSITION PIN RESISTANCE 20 C 68 F G3 G2 900 1600 2600 3100 G2 A1 1800 2200 1800 2200 G3 A1 2200 3100 800 1200 vmr2008 022 005_a...

Page 325: ...rews 3 N m 27 lbf in Perform the Closed Throttle And Idle Actuator Reset procedure Refer to CLOSED THROTTLE AND IDLE ACTUATOR RESET in this subsection IDLE AIR CONTROL VALVE IACV Refer to the applicable ENGINE MANAGEMENT SYSTEM subsection for component and connec tor locations An idle air control valve with good resistance measurement can still be faulty It is also pos sible that a mechanical fail...

Page 326: ...ompressed air to dry it vmr2006 014 085_a 1 Clean bore from contamination Clean all remaining parts and install the idle air control valve on the throttle body Proceed with the Closed Throttle and Idle Actu ator Resetand the IACV CALIBRATION See pro cedures in this subsection IACV Calibration The IACV calibration is required to avoid a poten tial erratic or frozen RPM needle 1 Start the vehicle to...

Page 327: ...ring of CPS O RING Service product XPS SYNTHETIC GREASE P N 293 550 010 Install new CPS and secure harness with a new locking tie as applicable Tighten CPS retaining screw to specification TIGHTENING TORQUE CPS retaining screw 10 N m 1 N m 89 lbf in 9 lbf in MANIFOLD ABSOLUTE PRESSURE AND TEMPERATURE SENSOR MAPTS Refer to applicable ENGINE MANAGEMENT SYS TEM subsection for component and connector ...

Page 328: ... test Repair or replace wiring VALUE IS OUT OF RANGE Replace MAPTS Testing the MAPTS Input Voltage Check the voltage output from ECM to the pres sure sensor 1 Turn ignition key ON 2 Set emergency engine stop switch to RUN 3 Remove electrical connector from MAPTS 4 Using a multimeteras per following table MAPTS CONNECTOR MEASUREMENT PIN VOLTAGE 1 3 5 Vdc If voltage test is good replace the MAPTS If...

Page 329: ...specification replace the MAPTS If resistance tests good reconnect the MAPTS and disconnect the ECM connector Install the ECM adapter tool on the ECM connec tor Using a multimeter recheck resistance value as per following table ECM ADAPTER MEASUREMENT PIN RESISTANCE 20 C 68 F F3 G2 2280 2740 MAPTS TEMPERATURE SENSOR TEST RESULTS RESULT SERVICE ACTION NO READING Circuit Continuity Test of MAPTS Tem...

Page 330: ...d a multimeter check resistance values ECM ADAPTER MEASUREMENT PIN RESISTANCE 20 C 68 F C3 F4 2280 2736 If resistance value is incorrect check wiring con tinuity between ECM connector and the CTS Re fer to CTS CIRCUIT CONTINUITY TEST in this sub section Testing the CTS Circuit Continuity 1 Disconnect connector from CTS and check the circuit continuity CTS CIRCUIT CONTINUITY TEST ECM ADAPTER CTS CO...

Page 331: ... 3 Disconnect CTS connector and remove CTS 4 Install the new CTS and torque as specified TIGHTENING TORQUE CTS 16 N m 2 N m 142 lbf in 18 lbf in 5 Reinstall remaining removed parts 6 Refill and bleed the cooling system Refer to COOLING SYSTEM subsection 22 vmr2016 423 ...

Page 332: ...IMETER 529 035 868 11 FUEL HOSE ADAPTER 529 036 023 5 FUEL PUMP NUT TOOL 529 035 899 13 OETIKER PLIERS 295 000 070 8 PRESSURE GAUGE 529 035 709 5 SMALL HOSE PINCHER 295 000 076 18 VACUUM PRESSURE PUMP 529 021 800 4 18 SERVICE TOOLS OTHER SUPPLIER Description Part Number Page FLUKE RIGID BACK PROBE TP88 11 vmr2016 409 1 ...

Page 333: ...Subsection 02 FUEL TANK AND FUEL PUMP NEW Component must be replaced when removed To engine EUROPE NEW NEW NEW NEW NEW NEW NEW NEW NEW NEW vmr2015 043 100_a 2 vmr2016 409 ...

Page 334: ...rovides over pressure relief and negative pres sure relief of the fuel tank vmr2015 130 001_a TYPICAL FUEL TANK VENT SYSTEM 1 Vent hose 2 Vent system hose inlet 3 Vent system connected to fuel pump 4 Fuel tank 5 Engine air intake system Air can enter the fuel tank at all times through the vent system INLET check valve This prevents negative pressure within the fuel tank which could cause fuel star...

Page 335: ...r the EFI system INSPECTION FUEL TANK LEAK TEST WARNING Always carry out a fuel tank leak test when ever the fuel tank shows signs of wear or damage which may cause a leak or when the fuel pump has been removed or replaced or if you suspect a leak If the fuel tank is damaged the fuel tank should be replaced even if no leak is present Do not attempt to repair the fuel tank 1 Refill fuel tank and en...

Page 336: ...012 028 009_a TYPICAL 1 Forward injector rail fitting 2 Locking ties 7 Install the fuel pressure gauge and fuel hose adapter between the disconnected injector hose and fuel rail in line installation REQUIRED TOOLS PRESSURE GAUGE P N 529 035 709 FUEL HOSE ADAPTER P N 529 036 023 vmr2012 028 010_a TYPICAL PRESSURE GAUGE SETUP 1 Pressure gauge to fuel hose adapter 2 Fuel hose adapter to fuel rail 3 F...

Page 337: ...re drop after the engine is stopped check for a fuel injector leak Refer to ELECTRONIC FUEL INJECTION EFI subsection NOTE The fuel pressure regulator or fuel pump check valve integral to the fuel pump module may also be at fault If no leak is detected replace fuel pump 6 vmr2016 409 ...

Page 338: ...place if necessary Fuel pressure within specifications Fuel pressure more than specifications Fuel pressure less than specifications Perform fuel pump test Check fuel line rail for leaks Fuel pressure less than specifications Fuel pressure more than specifications Check fuel injector Fails Activate electric system to enable fuel pump Fuel pump runs Fuel pressure within specifications OK OK Yes No ...

Page 339: ...iker Clamp Replacement REQUIRED TOOL OETIKER PLIERS P N 295 000 070 FUEL TANK Fuel Tank Draining Remove fuel tank cap and siphon gas into an ap proved fuel container Fuel Tank Removal 1 Drain fuel tank Refer to FUEL TANK DRAINING in this subsection 2 Disconnect the fuel pressure hose from the fuel injector fuel rail Refer to DISCONNECTING A FUEL PRESSURE HOSE in FUEL HOSE AND OETIKER CLAMPS 3 Disc...

Page 340: ...e upper mounting bolt from both rear shock absorbers 12 Block the front wheels with wheel chocks 13 Lift back end of vehicle and properly support under the lower rear portion of the frame near the final drive CAUTION Before working on vehicle en sure the vehicle is securely supported 14 Remove vent tube from final drive vmr2012 028 017_a 1 Final drive unit 2 Vent tube to remove 15 Remove fuel tank...

Page 341: ...Inspect fuel tank and fuel tank protector on frame 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 Installation is the reverse of the removal proce dure However pay attention to the following Install a bushing on ...

Page 342: ...k fuel pump relay fuse F15 and fuel pump relay R4 Check in B U D S for applicable fault codes Refer to COMMUNICATION TOOLS AND b u d s subsection Carry out a fuel pump input voltage test vmr2012 028 006_b 1 Fuel pump relay fuse Fuel Pump Connector Access 570 Engine Remove rear fender Refer to BODY subsection vmr2015 043 025_a 850 and 1000R Engines The fuel pump connector can be accessed from under...

Page 343: ...con nected 2 Remove fuel pump relay R4 vmr2012 028 006c 1 Fuel pump relay 3 Measure fuel pump resistance as follows FUEL PUMP RESISTANCE TEST AT FUSE BOX TEST PROBES RESISTANCE 20 C 68 F Fuse box contact A11 Battery ground Approximately 2 vmr2012 028 006_a FUSE BOX COORDINATES If resistance test failed disconnect fuel pump connector and measure resistance at fuel pump connector FUEL PUMP RESISTANC...

Page 344: ... TOOL P N 529 035 899 vmr2012 028 026_a TYPICAL FUEL PUMP REMOVAL 1 Fuel pump retaining nut 4 Carefully pull out and rotate fuel pump as re quired NOTICE Pay attention not to damage fuel sender and fuel pump prefilter 5 Discard gasket ring 6 Wipe off any fuel spillage Fuel Pump Installation The installation is the reverse of the removal pro cedure However pay attention to the following Rotate fuel...

Page 345: ... pressure hose and electrical wiring connector 5 While firmly holding pump against tank engage fuel pump retaining nut on fuel tank flange NOTE If necessary move the pump in order to ensure the flange is sitting completely flat on the tank 6 Tighten fuel pump retaining nut to specification 6 1 Ensure pump locking ring is fully engaged 6 2 To apply the proper torque to the fuel pump retaining nut i...

Page 346: ...performing a FUEL TANK LEAK TEST and a FUEL PUMP PRESSURE TEST as described in this subsection 12 Check fuel level sender operation FUEL PUMP PRE FILTER STRAINER Fuel Pump Pre filter Replacement 570 Engine 1 Remove FUEL PUMP see FUEL PUMP RE MOVAL in this subsection 2 Unlock 3 tabs on strainer plastic ring vmr2015 043 027_a 3 Remove rubber pad vmr2015 043 028_a 4 Remove push nut securing strainer ...

Page 347: ...s 1 Remove FUEL PUMP see FUEL PUMP RE MOVAL in this subsection 2 Unlock 3 tabs on strainer plastic ring vmr2008 135 220_a Step 1 Lift these tabs to unlock ring Step 2 Pull ring off pump inlet 3 Remove rubber pad vmr2008 135 221_a 4 Remove push nut securing strainer to fuel pump Be careful not to break the plastic pin vmr2008 135 222_a 5 Pull strainer off fuel pump vmr2008 135 223_a NOTE A non serv...

Page 348: ...0 C 68 F Full 5 1 Empty Pins 4 and 21 100 5 vmr2006 020 052_c If readings are out of specification refer to FUEL LEVEL SENDER RESISTANCE TEST AT FUEL PUMP CONNECTOR If readings are as specified refer to FUEL LEVEL SENDER INPUT VOLTAGE TEST Fuel Level Sender Resistance Test at Fuel Pump Connector FUEL LEVEL SENDER RESISTANCE TEST FUEL LEVEL FUEL PUMP CONNECTOR RESISTANCE 20 C 68 F Full 5 1 Empty Pi...

Page 349: ...re relief valve 2 Fuel pump vent inlet 3 Install small hose pincher here 4 Connect the vacuum pressure pump to the fuel tank vent hose inlet REQUIRED TOOL VACUUM PRESSURE PUMP P N 529 021 800 vmr2012 028 008_a 1 Fuel tank vent hose inlet 2 Gauge connector 5 Remove fuel tank cap 6 Set vacuum pressure pump to PRESSURE and activate pump The gauge on the pump should not change in reading 7 Set vacuum ...

Page 350: ... properly in stalled refer to PRESSURE RELIEF VALVE INSTALLATION in this subsection Replace pressure relief valve if it fails the test vmr2015 130 002_f 1 Pressure relief valve flow direction arrow Fuel Tank Vent Valve Installation Inlet Check Valve Installation Ensure white portion of inlet check valve is to wards the vent breather filter vmr2015 130 002_g 1 Vent breather filter 2 White portion o...

Page 351: ... SENSOR 2WD 4WD SWITCH WINCH SWITCH ECM WAKE UP IGNITION SWITCH FAN MOTOR CLOCK HAZARD DC OPTION CONNECTORS DC5 DC6 FUEL PUMP RELAY R4 FUSE BOX 2 ACCESSORIES RELAY R3 F3 40A 12 V POWER OUTLET DC OPTION CONNECTOR DC3 COMMUNICATION CONNECTOR DB 5 DPS2 16 awg TAILLIGHTS LICENSE PL COMMUNICATION CONNECTOR DB 6 COMMUNICATION CONNECTOR DB 4 DPS1 A HEADLIGHT RELAY R5 HORN FLASHERS EUROPE HICA C BRAKE SWI...

Page 352: ...n See COOLING SYSTEM R2 Main When ignition key is turned ON AND Run Stop switch is set to RUN Approximately 30 seconds after ignition key is turned OFF R3 Accessories Same as main relay When ignition key is turned OFF OR When engine speed is less than 1000 RPM for at least 50 minutes R4 Fuel pump See FUEL TANK AND FUEL PUMP R5 Headlights Same as main relay When ignition key is turned OFF OR When e...

Page 353: ... A FUSE LINK Measure the fuse link output voltage at the fuse box Refer to the WIRING DIAGRAM If no voltage is measured carry out the following Remove the right side panel and extension panel Grab each end of the fuse link and gently pull in opposite directions If the fuse link is open the insulator should stretch and break where the link has failed NOTE Failure of a fuse link is usually due to a ...

Page 354: ...ose as possible to the fuse link terminals 3 Remove 8 mm 5 16 in of insulator from the ends of the circuit wiring 4 Insert the circuit wire end in the link terminal making sure the wire end bottoms out in the center of the terminal 5 Crimp the terminal on the bare wire 6 Using a heat gun carefully heat the link ter minal until the solder ring has melted into the wiring and the terminal insulator h...

Page 355: ... BP1 Positive terminal to PF2 BP2 Positive terminal from battery BP3 Positive terminal to SM CC Ignition switch CL Cluster CRD Rear RH turn light Used on European models only CRG Rear LH turn light Used on European models only DB Diagnostic connector DC1 Accessory outlet DC2 Accessory outlet DC3 Accessory outlet ABBREVIATION DESCRIPTION DC5 Accessory outlet DC6 Accessory outlet DC7 Accessory outle...

Page 356: ...only PLG LH License plate light Used on European models only PRD Rear RH light PRG Rear LH light RBL Trailer harness Used on European models only RD1 Voltage regulator rectifier SM Starter motor SS1 Starter solenoid SS2 Starter solenoid SW1 Winch relay SW2 Winch relay SW4 Winch relay SWW Winch remote switch 2 vmr2016 133 ...

Page 357: ...Subsection 02 WIRING HARNESS AND CONNECTORS WIRING HARNESS ROUTING Main Harness Front 1 2 HIC2 HIC1 CC DC1 DC2 DPS2 PDH PDB DB SW4 SW1 SW2 DC3 BD DC5 SWW MG1 MG2 vmr2015 132 100_a vmr2016 133 3 ...

Page 358: ...Subsection 02 WIRING HARNESS AND CONNECTORS Main Harness Front 2 2 PF2 SM DPS1 DPS3 HICa CI FT PGH PGB vmr2016 133 100_a 4 vmr2016 133 ...

Page 359: ...Subsection 02 WIRING HARNESS AND CONNECTORS Main Harness Rear FRR BN PF2 DC6 SS FT PL CRD RD1 PRD BN4 BN1 BN2 SS2 SS1 BP3 BP1 vmr2016 133 101_a vmr2016 133 5 ...

Page 360: ...RING HARNESS SPLICE LOCATION Main Harness Rear Part DB DC6 Jt WH BE JT WH BK D2 JT WH OR JT RD JT BK2 JT RD PK PF2 FL FRR vmr2016 133 102_a Main Harness Front Part 1 2 JT RD GN JT RD GY DPS2 Diode 5 Diode 6 SW4 DPS1 vmr2015 132 105_a 6 vmr2016 133 ...

Page 361: ...Harness Front Part 2 2 DC2 DC1 PF1 FT HICa JT BU Diode 11 JT RD OR JT RD WH JT BK1 JT RD VI JT BK3 JT RD BK JT GN JT VI BE JT VI GY JT RD BR JT BK BR JT RD BU JT OR BK JT BK WH JT BE JT BU GY JT RD BE JT VI RD JT RD YL vmr2015 132 106_a vmr2016 133 7 ...

Page 362: ...k 4 Sealing cap NOTICE Do not apply dielectric grease on ter minal inside connector Terminal Removal To remove terminals from connector proceed as follows 1 Using long nose pliers pull out the secondary plastic lock from between the terminals 1 V01G0OA TYPICAL FEMALE CONNECTOR 1 Female lock V01G0PA 1 TYPICAL MALE CONNECTOR 1 Male lock NOTE Before pin extraction push wire forward to relieve pressur...

Page 363: ...ust be installed F04H6LA 1 1 TYPICAL CONNECTOR PIN OUT 1 Terminal position identification numbers PACKARD CONNECTORS Packard Connector Application Packard connectors are used to connect Electrical harnesses Gauges 3 Pin Packard Connector F04H45A 1 A B C VIEW OF A 3 PIN PACKARD CONNECTOR 1 Identification letters NOTE This type of connector also comes in other pin configurations To remove a terminal...

Page 364: ...o remove retainer 1 A33Z01A 2 TYPICAL 1 Retainer 2 Tab one on each side Open housing by lifting 4 tabs 1 A33Z02A TYPICAL 1 Tabs 2 on each side Lift the top plastic lock of the female terminal to be removed and hold in position Lift the female terminal to unlock from the housing and push out of housing 10 vmr2016 133 ...

Page 365: ...nector Application Molex connectors are used on the following sys tem ECM Molex Connector Removal Push and hold the locking tab vmr2008 022 013_a Rotate connector lock until it stops vmr2008 022 014_a Pull out connector vmr2008 022 015_a Molex Connector Installation Fully open connector lock vmr2008 022 015_b Install connector to ECM vmr2016 133 11 ...

Page 366: ...ate intermit tent or permanent contact problems Molex Connector Inspection Before replacing an ECM always check electrical connections 1 Ensure connector locking mechanism is func tioning properly 2 Ensure all wire terminals pins are properly locked in the connector 3 Ensure they are very tight make good contact with the pins in the ECM 4 Ensure the pins in the harness connector and the ECM connec...

Page 367: ...nnector ensure all terminals are prop erly crimped on wires After installation of wire terminals in the connectors ensure they are properly locked by gently pulling on them as if to extract them FURUKAWA CONNECTOR Furukawa Connector Application Voltage regulator rectifier Terminal Removal 1 Remove the secondary lock plastic insert smr2010 050 021_a Step 1 Remove the secondary lock 2 Carefully inse...

Page 368: ...shing on them as if to extract them BATTERY AND STARTER CABLE TERMINALS Cable Crimping Carefully strip the wire approximately to 10 mm 3 8 in in length using a wire stripping tool or sharp blade knife A32E2QA A A 10 mm 3 8 in NOTE Make sure not to cut wire strands while stripping the wire Install the appropriate terminal on the wire ac cording to the requirement Refer to appropriate PARTS CATALOG ...

Page 369: ...y some pulling force on wire and the terminal at the same time from both directions NOTICE Never weld the wire to the terminal Welding can change the property of the wire and it can become brittle and break Install the protective heat shrink rubber tube on the terminal Heat the heat shrink rubber tube us ing the heat gun so that it grasps the wire and the terminal NOTICE Make sure that the protect...

Page 370: ...t locations DIAGNOSTIC GUIDELINES The following is provided to help in diagnosing the probable cause of a problem It is a guideline and should not be assumed to list all possible causes ENGINE WILL NOT START ENGINE TURNS OVER 1 Fouled or defective spark plug Replace 2 Defective CPS Check operation of CPS and replace if necessary Refer to ELECTRONIC FUEL INJECTION EFI subsection 3 Defective trigger...

Page 371: ... subsection and remove the LH side panel vmr2012 031 001_a TYPICAL 1 Ignition key 2 Ignition switch connector 3 ECM EMERGENCY ENGINE STOP SWITCH Testing the Emergency Engine Stop Switch at ECM 1 Disconnect ECM connector and install it on the ECM adapter tool vmr2012 031 005_b TYPICAL 1 ECM 2 ECM connector cover REQUIRED TOOL ECM ADAPTER TOOL P N 529 036 166 2 Remove ignition key switch fuse F8 ref...

Page 372: ...MG1 2 Open circuit If switch tests good test continuity of wiring Re fer to WIRING DIAGRAM IGNITION COIL vmr2006 018 100 Ignition Coil Access Refer to BODY subsection and remove RH inner fender panel s for access to the ignition coil vmr2012 031 002_a TYPICAL 1 Ignition coil location Installing the Ignition Coil Install a new elastic nut and tighten to the speci fied torque TIGHTENING TORQUE Ignit...

Page 373: ... the Ignition Coil Resistance An ignition coil with good resistance measure ment can still be faulty Voltage leakage can occur at high voltage levels which is not detectable with an ohmmeter Replacing the ignition coil may be necessary as a test Primary Windings 1 Disconnect HIC2 connector vmr2012 031 005_a TYPICAL 1 ECM 2 ECM connector cover 3 HIC2 connector 2 Disconnect ECM connector and connect...

Page 374: ...park plug gap lubricating oil entering the combustion chamber or too cold spark plug The plug face of a fouled spark plug has either a wet black deposit or a black carbon fouling Such coatings form a conductive connection between the center electrode and ground Spark Plug Analysis A00E0AA 1 2 3 TYPICAL 1 Overheated light grey white 2 Normal light brown brown 3 Fouled black wet or dry dark deposits...

Page 375: ...neto has a 3 phase delta wound stator vmr2006 017 001 TYPICAL Voltage Regulator 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 Fuse links Battery The voltage regulator limits voltage to prevent any damage to electrical components COMPONENT VOLTAGE Vdc Minimum 12 5 Voltage Regulator Maximum ...

Page 376: ...e NAPA ULTRA PRO BATTERY LOAD TESTER P N 95260 3 Ensure proper test conditions TEST CONDITIONS Initial battery voltage Above 12 5 Vdc Engine OFF Load 3 times the amp hour AH rating Time 15 seconds Required for accurate testing SPECIFICATION Battery Above 9 6 Vdc If battery voltage drops below specification dur ing test replace battery and perform a CHARG ING SYSTEM LOAD TEST CHARGING SYSTEM LOAD T...

Page 377: ...tor rectifier is accessible on the RH rear side of the vehicle vmr2016 135 001_a Voltage Regulator Continuity Test Due to internal circuitry there is no static test available Voltage Regulator Power Test 1 Check voltage at RD1 1 TEST CONDITIONS RD1 1 Hot at all times BACKPROBE PROBE SPECIFICATION RD1 1 BAT2 Battery voltage 2 Connect a battery load tester such as the NAPA ULTRA PRO BATTERY LOAD TES...

Page 378: ... 002_a TYPICAL 1 Battery retaining plate 2 Retaining plate screws 3 4 Remove battery Battery Cleaning Clean the battery support cables and battery posts using a solution of baking soda and water Remove corrosion if so from battery cable ter minals and battery posts using a firm wire brush Rinse with clear water and dry well Battery Inspection Visually inspect battery casing for cracks or any other...

Page 379: ...e increases due to overcharging the valve opens to release excess pressure preventing battery damage An automatic charger is a fast and convenient way for error proof charging Always follow the battery manufacturer s charg ing instructions When using a constant current charger charge battery according to the chart below Battery Voltage Below 12 8 V and Above 11 5 V STANDARD CHARGING RECOMMENDED BA...

Page 380: ...kes applied check the following 1 Shifter rod adjustment refer to appropriate SHIFTER subsection 2 Gearbox position indicator switches or the gearbox position sensor GBPS refer to ap propriate GEARBOX AND 4X4 COUPLING UNIT subsection 3 Switches or sensor wires and connectors re fer to appropriate WIRING DIAGRAM If the Engine cranking conditions are met and the starter will not crank the engine che...

Page 381: ...r Solenoid Control Circuit F8 5 A ECM vmr2015 135 003_a TEST CONDITION Engine stop switch RUN Ignition switch ON Start button Pressed vmr2015 048 003_a SS1 IS ON THE RIGHT PROBE PROBE SPECIFICATION SS1 SS2 Battery voltage SS1 BAT Battery voltage BAT SS2 Battery voltage If voltage is as per specification replace starter so lenoid If voltage is not as per specification ver ify STARTER SOLENOID CONTR...

Page 382: ... CONDITION Start button Pressed PROBE PROBE SPECIFICATION MG2 1 MG2 6 Close to 0 If start button does not test as specified replace the multifunction switch assembly If start switch tests as specified repair wire to starter solenoid SS1 terminal Starter Power Circuit Voltage Drop NOTE Engine must be in starting condition for this test Do not perform on a No Start vehicle TEST CONDITION Fuse F5 Rem...

Page 383: ...noid power control circuit and ground con trol circuit both test good test ECM ground circuits Refer to ELECTRONIC FUEL INJECTION EFI subsection NOTE Supply a ground with a jumper wire if you suspect that the ECM is not supplying a ground to the solenoid Starter Solenoid Continuity M BAT1 BAT2 BP BP1 BP BP3 vmr2016 136 100_a 1 Disconnect the BLACK negative battery ca ble 2 Disconnect SS1 and SS2 v...

Page 384: ...as per specification replace the solenoid If starter power and ground circuits are good re fer to MAGNETO AND STARTER subsection for starter diagnosis and replacement Solenoid Diode Test SS1 SS2 vmr2015 048 013_a 1 Disconnect SS1 and SS2 from starter solenoid vmr2015 048 012_a 1 SS1 2 Use the FLUKE 115 MULTIMETER P N 529 035 868 and set it to the diode symbol as shown vmr2006 020 005 3 Probe wires...

Page 385: ...ARITY MUST BE AROUND 0 5 V vmr2015 048 010_a REVERSE POLARITY MUST BE OPEN CIRCUIT 1 SS1 If test failed replace diode Refer to WIRING HARNESS AND CONNECTORS for diode loca tion NOTE The diode is integrated in the harness near the starter solenoid 6 vmr2016 136 ...

Page 386: ...code of the ignition key Up to 10 ignition keys may be programmed in the memory of the ECM They can also be erased in dividually or all at once Note that the D E S S circuitry is already activated on all new ECM TROUBLESHOOTING DIAGNOSTIC TIPS NOTE It is a good practice to check for fault codes using B U D S as a first troubleshooting step If D E S S key is not recognized by the ECM key is defecti...

Page 387: ...gnition key to ON position 13 Click on the appropriate Add Key button 14 Repeat to program more keys if needed 15 Click on Write Data button to transfer new settings and information to the ECM vmr2006 012 100_ben WRITE DATA BUTTON When new data is written in the ECM a message that says Remove key from vehicle is displayed in the gauge When this occurs remove the key from ignition switch and wait u...

Page 388: ...isplay 5 4WD indicator lamp 6 Low fuel level indicator lamp 7 Check engine indicator lamp 8 High beam indicator lamp 9 MPH Km h indicator lamp 10 Signal lights hazard lights indicator lamp CE models 1 Selector Button The selector button is used to navigate or change settings in the multifunction gauge 2 Transmission Position Display This display will show transmission position vmr2007 050 002_d 1 ...

Page 389: ...is indicator is ON it indicates that high beam is selected on the headlights switch and that the ignition key is in the ON with lights po sition 9 KM H or MPH Indicator Lamp The applicable lamp turns on to indicate the active speedometer unit of display 10 Turn signal Hazard lights Indicator Lamp When this indicator is ON it indicates A turn signal is activated or The hazard lights are activated M...

Page 390: ...aces vsi2009 018 032 Press and HOLD the selector button for 2 seconds to reset the hour meter Engine Hour Meter EH The engine hour meter records engine running time vsi2009 018 033 Message Display Mode If an abnormal engine condition occurs a mes sage may scroll across the main screen in con junction with a pilot lamp Refer to DIAGNOSTIC AND FAULT CODES sub section Navigating the LCD Gauge WARNING...

Page 391: ... troubleshooting an electrical system fault check battery condition cables and connections first Testing the Circuit Check the related circuit fuse condition with a fuse tester or test lamp a visual inspection could lead to a wrong conclusion NOTE If the ignition switch is left ON for more than 50 minutes the accessory relay will shut down Inspecting the Electrical Connection When replacing an ele...

Page 392: ...fuse JP1 in front fuse box refer to POWER DISTRIBUTION subsection BRAKE LIGHTS WILL NOT COME ON WHEN BRAKES APPLIED 1 Defective brake relay Test brake relay R8 refer to POWER DISTRIBU TION subsection 2 Defective brake light switch es Refer to BRAKE LIGHT SWITCHES in the BRAKE subsection 3 Defective wiring connectors Test wiring continuity refer to applicable WIRING DIAGRAM TURN SIGNAL LIGHTS WILL ...

Page 393: ...tion gauge HAZARD LIGHTS INDICATOR NOT WORKING WITH IGNITION SWITCH OFF CE MODELS ONLY 1 Diode D10 open circuit Test diode refer to WIRING DIAGRAM POSITION LIGHTS WILL NOT COME ON CE MODELS ONLY 1 Accessories fuse open circuit Test fuse F12 refer to POWER DISTRIBUTION subsection 2 Power or ground circuit wiring Check wiring continuity refer to WIRING DIA GRAM 3 Defective light bulbs Test replace l...

Page 394: ...selector button NOTE The display will flash 3 Choose the 12 hour 12H or 24 hour 24H for mat by pressing button 4 If the 12 hour format was selected choose Am A or Pm P by pressing button 5 Choose hour first digit by pressing button 6 Choose hour second digit by pressing button 7 Choose minutes first digit by pressing button 8 Choose minutes second digit by pressing but ton 9 Press button to enter ...

Page 395: ...g page Cluster tab Use the Cluster Lamp Active box to monitor dif ferent indicator lights outputs vmr2016 137 003 TYPICAL CLUSTER LAMP ACTIVE BOX This function confirms that the signals are broad casting and the indicator lights should be ON in the multifunction gauge Switch Input Monitoring In B U D S select the Monitoring page Cluster tab Use the Switch Inputs box to monitor different switch inp...

Page 396: ... CAN resistors and wires TEST RESULT READING POSSIBLE CAUSE Approximately 60 ECM and CLUSTER CAN wires and resistors good Approximately 120 CAN wire to CLUSTER open CAN wire to ECM open CLUSTER CAN resistor open ECM CAN resistor open Infinite open circuit CAN wire to DB connector open circuit Removing the Multifunction Gauge 1 Remove console panel refer to BODY subsec tion 2 Pull gauge support fro...

Page 397: ...ories relay R3 HEADLIGHTS Headlight Wire Identification HEADLIGHTS RELAY R5 FUNCTION PIN COLOR 12 volt input from fuse F11 headlights power C6 YELLOW BLACK 12 volt input from ignition switch pin A relay winding input D6 YELLOW BLUE 12 volt output to headlights low beam and low high beam switch D7 RED BLUE Relay winding ground from ECM K2 C7 ORANGE BLACK HEADLIGHT LOW HIGH BEAM SWITCH FUNCTION PIN ...

Page 398: ...el surface 5 m 16 ft in front of a test surface wall or screen as in first illustration 2 Measure the distance from the center of each headlight to the ground high beam and low beam 3 Trace a line on the test surface parallel to the ground at each measured height one for high beam and one for low beam Low beam aiming is correct when the crest of the low beam is below the applicable horizontal cen ...

Page 399: ...es relay R3 activated Brake relay R8 activated Fuse 14 from Accessories relay R3 Taillight Wire Identification FUNCTION PIN CIRCUIT PROTECTION Supplied when Accessories relay R3 activated 3 RED VIOLET Ground from BK2 2 BLACK Taillight Circuit Protection CONDITION CIRCUIT PROTECTION Supplied when Accessories relay R3 activated Fuse 14 from Accessories relay R3 Replacing the Taillight Brake Light Bu...

Page 400: ...E GRAY HAZARD SWITCH FUNCTION PIN COLOR 12 volt input from fuse F10 MG3 3 RED BLACK 12 volt output to flasher module 12 volt output to wake up gauge MG3 5 BEIGE RED Turn Signal Hazard Circuit Protection TURN SIGNAL CIRCUIT CONDITION CIRCUIT PROTECTION Supplied with Accessories relay R3 activated Fuse 7 from Accessories relay R3 Battery power continuous Fuse 10 HAZARD CIRCUIT CONDITION CIRCUIT PROT...

Page 401: ...N C GREEN BLUE 12 volt output to relay winding OUT B LIGHT BLUE WARNING Before testing make sure the winch is in FREESPOOL mode Freespool clutch disen gaged tmr2011 030 003_a SIMPLIFIED WINCH WIRING DIAGRAM 1 Winch motor 2 Winch relay 3 Winch remote control 4 Winch switch 5 Battery 6 12 volt input to switch switch pin 2 from fuse 7 7 Winch motor power SW3 8 Winch motor power SW5 9 12 volt input to...

Page 402: ...cia vmr2016 410 002_a 5 Remove the front skid plate vmr2016 410 003_a 6 Disconnect both winch power cables NOTE Note the position of the power cables for reinstallation vmr2012 035 010_a 1 Winch power cables 7 Remove the four winch retaining screws from the front bumper support vmr2012 035 011_a 1 Front bumper support 2 Winch retaining screws 8 Remove winch vmr2016 410 15 ...

Page 403: ... noted at removal NOTE If the winch power cables are not con nected correctly the winch motor will operate in the reverse direction of selection TIGHTENING TORQUE Winch retaining screws 16 N m 2 N m 142 lbf in 18 lbf in Winch power cables 7 N m 5 N m 62 lbf in 4 lbf in Winch fairlead elastic nuts 4 5 N m 5 N m 40 lbf in 4 lbf in Install a NEW cotter pin on the hook pin 16 vmr2016 410 ...

Page 404: ...KLASH MEASUREMENT TOOL 529 035 665 469 CV BOOT CLAMP PLIER 529 036 120 467 CV JOINT EXTRACTOR 529 036 005 467 SPANNER SOCKET 529 035 649 471 SERVICE PRODUCTS Description Part Number Page LOCTITE 277 293 800 073 473 LOCTITE 648 GREEN 413 711 400 475 XPS SYNTHETIC GREASE 293 550 010 467 473 475 vmr2015 138 463 ...

Page 405: ...nent must be replaced when removed 205 15 N m 151 11 lbf ft XPS Synthetic grease See STEERING SYSTEM 61 9 N m 45 7 lbf ft M10 24 5 3 5 N m 18 3 lbf ft M8 Loctite 648 XPS Synthetic grease 75 5 N m 55 4 lbf ft 75 5 N m 55 4 lbf ft Loctite 648 NEW NEW NEW NEW NEW NEW NEW vmr2015 051 100_a 464 vmr2015 138 ...

Page 406: ...EW NEW NEW XPS synthetic grease XPS synthetic grease XPS synthetic grease NEW Component must be replaced when removed NEW NEW NEW NEW 180 15 N m 133 11 lbf ft Loctite 277 7 5 0 5 N m 66 4 lbf in 33 3 N m 24 2 lbf ft 22 5 2 5 N m 17 2 lbf ft 37 3 N m 27 2 lbf ft NEW vmr2015 051 101_a vmr2015 138 465 ...

Page 407: ...have to be replaced NOTE The Visco Lok shear pump is not service able If the pump is disassembled the viscous fluid contained inside will be lost and it cannot be replaced PROCEDURES WHEEL HUB Wheel Hub Removal Lift and support vehicle Select the 4WD position and place the transmis sion lever on P Remove caliper from knuckle Refer to BRAKES subsection Remove the following parts Wheel cap Cotter pi...

Page 408: ...splines should be done Front Drive Shaft Installation The installation is the reverse of the removal pro cedure However pay attention to the following Install a NEW stop ring 1 V07H0AA TYPICAL 1 Stop ring Apply XPS SYNTHETIC GREASE P N 293 550 010 on the splines Ensure that wear ring is close to the differential DRIVE SHAFT BOOT Drive Shaft Boot Removal Remove FRONT DRIVE SHAFT See procedure in th...

Page 409: ...included with the new boot kit NOTE Do not use or add other grease Install NEW drive shaft boot clamps FRONT DIFFERENTIAL Front Differential Removal 1 Drain front differential Refer to PERIODIC MAINTENANCE PROCEDURES subsection 2 Remove both front drive shafts Refer to FRONT DRIVE SHAFT in this subsection 3 Detach vent hose from front differential vmr2012 036 003_a FROM LH SIDE 1 Vent hose 4 Remov...

Page 410: ...icator and the BACKLASH MEA SUREMENT TOOL P N 529 035 665 measure the backlash Place the backlash measurement tool at the end of pinion gear From center of tool bolt measure 25 4 mm 1 in and scribe a mark on the tab 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...

Page 411: ...n Screw the propeller shaft screw in pinion gear vmr2015 051 005_a Using a needle torque wrench measure the preload vmr2015 051 006_a PRELOAD SPECIFICATION Maximum 0 50 N m 4 lbf in If preload is out of specification split front differ ential housing and check all bearings conditions Front Differential Disassembly Differential Housing Remove front differential housing screws vmr2012 036 008_a Sepa...

Page 412: ...g ring gear to Visco Lok unit vmr2015 051 009 Separate ring gear from Visco Lok unit vmr2015 051 010_a 1 Visco Lok unit 2 Ring gear Pinion Gear Remove screw retaining front propeller shaft adapter vmr2012 036 009_a 1 Retaining screw Remove and discard oil seal vmr2012 036 010_a 1 Oil seal Unscrew the pinion nut REQUIRED TOOL SPANNER SOCKET P N 529 035 649 vmr2015 138 471 ...

Page 413: ... ring 2 Pinion gear 3 Bearing Remove and discard the needle bearing Front Differential Assembly Adjustment is required when any of the following part is changed Pinion gear Ring gear Viscolok unit Housing As a preliminary setup install shim according to the following table RECOMMENDED SHIM THICKNESS BACKLASH 0 5 mm 02 in as a preliminary adjustment vmr2015 051 008 1 Backlash shim Prior to finalizi...

Page 414: ...5 N m 3 5 N m 17 lbf ft 3 lbf ft Pinion Gear Install a NEW ball bearing Install a NEW O ring Install a NEW needle bearing Apply LOCTITE 277 P N 293 800 073 to pinion nut Install and tighten the pinion nut to specification TIGHTENING TORQUE Pinion nut 180 N m 15 N m 133 lbf ft 11 lbf ft LOCTITE 277 P N 293 800 073 Apply XPS SYNTHETIC GREASE P N 293 550 010 on NEW oil seal and install Tighten front ...

Page 415: ...upport vehicle 2 Remove front wheel Refer to WHEELS AND TIRES subsection 3 Remove inner fender panel s Refer to BODY subsection 4 Remove bolts securing front differential to frame vmr2012 036 004_a 1 Bolts securing front differential to frame 5 Remove the following Oetiker clamps from front propeller shaft vmr2012 009 020_a 1 Oetiker clamps 6 Detach front propeller shaft from front differen tial b...

Page 416: ...it tle Front Propeller Shaft Installation The installation is the reverse of removal proce dure However pay attention to the following Apply XPS SYNTHETIC GREASE P N 293 550 010 on splines Tighten propeller shaft adapter screw to specifica tion TIGHTENING TORQUE Propeller shaft adapter screw differential side M10x16 75 N m 5 N m 55 lbf ft 4 lbf ft LOCTITE 648 GREEN P N 413 711 400 Propeller shaft ...

Page 417: ...CKLASH MEASUREMENT TOOL 529 035 665 620 CV BOOT CLAMP PLIER 529 036 120 616 CV JOINT EXTRACTOR 529 036 005 617 SPANNER SOCKET 529 035 649 623 SERVICE PRODUCTS Description Part Number Page LOCTITE 277 293 800 073 625 LOCTITE 648 GREEN 413 711 400 619 XPS SYNTHETIC GREASE 293 550 010 615 618 vmr2015 052 611 ...

Page 418: ...ed NEW NEW NEW NEW XPS Synthetic grease Hi temp bearing grease NLGI 2 or equivalent XPS Synthetic grease NEW NEW 90 5 N m 66 4 lbf ft NEW NEW 205 15 N m 151 11 lbf ft NEW Loctite 648 Loctite 648 75 5 N m 55 4 lbf ft XPS Synthetic grease MAX models Short models XPS Synthetic grease XPS Synthetic grease XPS Synthetic grease NEW vmr2015 052 100_a 612 vmr2015 052 ...

Page 419: ...when removed NEW NEW NEW NEW XPS Synthetic grease Hi temp bearing grease NLGI 2 or equivalent XPS Synthetic grease NEW NEW 90 5 N m 66 4 lbf ft NEW NEW 205 15 N m 151 11 lbf ft NEW Loctite 648 Loctite 648 75 5 N m 55 4 lbf ft XPS Synthetic grease MAX models Short models XPS Synthetic grease XPS Synthetic grease NEW vmr2015 052 101_a vmr2015 052 613 ...

Page 420: ...ed NEW For preload adjustment For backlash adjustment NEW NEW NEW NEW NEW NEW 180 15 N m 133 11 lbf ft LH threads XPS synthetic grease XPS synthetic grease 32 3 N m 24 2 lbf ft 5 1 N m 44 9 lbf in NEW 22 5 2 5 N m 17 2 lbf ft Loctite 277 XPS synthetic grease vmr2015 052 102_a 614 vmr2015 052 ...

Page 421: ...le washer Remove wheel hub Wheel Hub Inspection Remove disk from RH wheel hub as necessary Check wheel hub for cracks or other damages Check inner splines for wear or other damages If any damage is detected on wheel hub replace it with a new one vmr2012 037 004 Wheel Hub Installation The installation is the reverse of the removal pro cedure However pay attention to the following Apply XPS SYNTHETI...

Page 422: ...BOOT Check shaft splines Replace drive shaft if neces sary Check dust shield on drive shaft end Replace if necessary Drive Shaft Installation The installation is the reverse of the removal pro cedure However pay attention to the following Install a NEW stop ring 1 V07H0AA TYPICAL 1 NEW stop ring After drive shaft insertion in rear final drive vali date if properly locked DRIVE SHAFT BOOT Drive Sha...

Page 423: ...irclip A new one is in cluded in the boot kit Remove drive shaft boot Drive Shaft Boot Installation The installation is the reverse of the removal pro cedure However pay attention to the following Pack bearing area with grease included with the new boot kit NOTE Do not use any other grease PROPELLER SHAFT Propeller Shaft Removal vmr2012 037 014_b TYPICAL 1 Propeller shaft 1 Lift and support rear e...

Page 424: ...in this subsection 8 Remove bolts from rear retaining plate Refer to REAR FINAL DRIVE in this subsection 9 Move the rear final drive rearward to allow dis lodging the propeller shaft 10 Dislodge the propeller shaft from the gearbox 11 Remove the propeller shaft vmr2012 037 012_a 1 Pull out propeller shaft Propeller Shaft Inspection Inspect if propeller shaft is not bent or twisted Check propeller ...

Page 425: ...opeller Shaft U Joint Removal Remove internal snap ring from bearing caps 1 V01H0YA 1 Snap ring Support inner yoke in vice and drive other yoke down with a soft hammer V01H0ZA Support U joint in vice and drive inner yoke down to remove remaining bearing caps Remove U joint cross Propeller Shaft U Joint Installation Install a NEW U joint in inner yoke NOTE Position propeller shaft U joint as shown ...

Page 426: ...OPELLER SHAFT in this subsection Remove rear final drive screws 5x vmr2015 052 002_a Remove bolts from rear retaining plate vmr2015 052 003_a Unplug the vent hose from final drive vmr2012 037 015_a 1 Pull out Remove the final drive Rear Final Drive Inspection Assembled Manually turn rear final drive gear it should turn smoothly Repair if necessary Check if oil seals are brittle hard or damaged Re ...

Page 427: ...esult Rotate pinion gear 1 turn and recheck backlash BACKLASH SPECIFICATION 0 1 mm 004 in to 0 35 mm 014 in If backlash is out of specification split final drive housing and adjust shim thickness as per follow ing guideline BACKLASH ADJUSTMENT GUIDELINE BACKLASH MEASUREMENT WHAT TO DO Below 0 1 mm 004 in Add shim s and recheck backlash Above 0 35 mm 014 in Remove shim s and recheck backlash vmr201...

Page 428: ... Below 0 06 N m 5 lbf in Add shim s and recheck preload Above 0 50 N m 4 lbf in Remove shim s and recheck preload vmr2015 052 004_b 1 Preload shim Rear Final Drive Disassembly Ring Gear Remove the final drive housing screws vmr2015 052 007_a Split final drive housings NOTE Be careful to keep track of shims on ring gear vmr2015 052 004_c 1 Backlash shim 2 Preload shim 3 Ring gear Extract ring gear ...

Page 429: ...052 011_a 1 O ring 2 Ball bearing 3 Pinion gear shim 4 Pinion gear The pinion gear and bearing can be easily removed using the following suggested tool PART QTY Pipe 83 mm 3 1 4 in diameter x 127 mm 5 in 1 Threaded rod M10 x 1 25 x 178 mm 7 in 1 M10 x 1 25 nut 3 Flat bar 1 Remove and discard the needle bearing vmr2015 052 012_a Rear Final Drive Assembly Adjustment is required when any of the follo...

Page 430: ...the gear case and the shim surface of pinion 3 Measure the distance B between outside sur face of the gear case and the bearing shoulder of the gear case 4 The shim thicknesss will be A B 0 53 mm 021 in 5 Select the good combination of shim to match the thickness calculated on step 4 A B vmr2015 052 016_a vmr2015 052 015_a 1 Backlash side 2 Preload side vmr2015 052 004_a 1 Backlash shim vmr2015 05...

Page 431: ...nstall the shim s then a NEW ball bearing install a NEW O ring Apply LOCTITE 277 P N 293 800 073 to pinion nut Install and tighten the pinion nut as per specifica tion TIGHTENING TORQUE Pinion nut LH THREADS 180 N m 15 N m 133 lbf ft 11 lbf ft LOCTITE 277 P N 293 800 073 Lubricate and install a NEW oil seal Rear Final Drive Installation The installation is the reverse of the removal pro cedure How...

Page 432: ...kPa 6 PSI 41 4 kPa 6 PSI MAX Use when total load is greater than 131 5 kg 290 lb 48 3 kPa 7 PSI 68 9 kPa 10 PSI Tire Inspection Check tire for presence of slits bulges wear or other damage Replace if necessary Tire Replacement Use an automotive tire changer to replace tires WARNING Replace tires only with the same type and size as original tires For unidirectional tread pattern ensure that the tir...

Page 433: ...ll lug nuts with the taper towards the wheel Tighten wheel lug nuts to the specified torque us ing the illustrated sequence WHEEL LUG NUTS TORQUE 100 N m 10 N m 74 lbf ft 7 lbf ft vmr2012 038 004_a TYPICAL TIGHTENING SEQUENCE NOTICE Always use the recommended wheel nuts for the type of wheel Using a different nut could cause damages to the rim or studs 628 vmr2015 053 ...

Page 434: ... 036 059 3 SERVICE TOOLS OTHER SUPPLIER Description Part Number Page SMOOTHFLOW TAPERED TIP 16 ga 511 rtt b 4 SERVICE PRODUCTS Description Part Number Page LOCTITE 406 GLUE 293 800 100 4 LOCTITE 767 ANTISEIZE LUBRICANT 293 800 070 9 PULLEY FLANGE CLEANER 413 711 809 4 XPS SYNTHETIC GREASE 293 550 010 9 vmr2016 414 1 ...

Page 435: ...5 N m 53 6 lbf ft 72 5 7 5 N m 53 6 lbf ft NEW NEW NEW NEW 72 5 7 5 N m 53 6 lbf ft 24 5 3 5 N m 18 3 lbf ft NEW 72 5 7 5 N m 53 6 lbf ft NEW NEW Component must be replaced when removed NEW XPS Synthetic grease 24 5 3 5 N m 18 3 lbf ft 72 5 7 5 N m 53 6 lbf ft 31 5 3 5 N m 23 3 lbf ft Loctite 767 Antiseize 24 5 3 5 N m 18 3 lbf ft Loctite 406 Loctite 406 vmr2016 414 100_a 2 vmr2016 414 ...

Page 436: ... sure pitman arm remains centered Oth erwise repeat steps 5 and 6 8 Remove two wheel nuts on the LH rear wheel and install the steering alignment tool REQUIRED TOOL STEERING ALIGNMENT TOOL P N 529 036 059 9 Place a rope around all four tires using an elas tic link both ends together NOTE The rope must be placed at the center of the wheels 10 Rotate the front wheel to position the align ment tool l...

Page 437: ...dure for other front wheel 17 Put the vehicle back on the ground 18 Remove the handlebar securing device 19 Place the front wheels in straight ahead posi tion and adjust the handlebar in its center posi tion by loosening the 4 bolts clamping the han dlebar on the steering column PROCEDURES HANDLEBAR GRIP Removing the Handlebar Grip 1 Loosen the screw at the end of handlebar grip 2 Remove the handl...

Page 438: ... CONNECTORS Steering Connector Access 1 Remove gauge support refer to REMOVING THE MULTIFUNCTION GAUGE in LIGHTS GAUGE AND ACCESSORIES subsection Steering Connector Identification Refer to WIRING HARNESS AND CONNECTORS subsection MULTIFUNCTION SWITCH Removing the Multifunction Switch From Vehicle Remove gauge support Refer to LIGHTS GAUGE AND ACCESSORIES subsection Carry out steps in MULTIFUNCTION...

Page 439: ...or 2 Throttle cable adjuster 3 Lock nut 4 Throttle lever housing 5 Loosen lock nut and screw in the throttle cable adjuster 6 Remove inner housing protector 1 V07I0HA 1 Inner housing protector 7 Slide cable in clip slot and remove the end of the cable from clip V07I0IA 8 Remove throttle cable from housing Installing the Throttle Lever For installation reverse the removal procedure Adjust throttle ...

Page 440: ...to REMOVING THE MULTIFUNCTION GAUGE in LIGHTS GAUGE AND ACCESSORIES subsection 2 Remove the front body module refer to BODY subsection 3 Remove the air intake silencer Refer to AIR IN TAKE SYSTEM subsection 4 Remove handlebar refer to REMOVING THE HANDLEBAR in this subsection Also remove locking ties and separate wiring harnesses and hoses from the steering column 5 Disconnect the tie rods from th...

Page 441: ...the DPS unit NOTE Some parts in following illustration not shown for clarity of illustration vmr2012 039 011_a 1 Steering column 2 Steering column lower pinch bolt 3 DPS unit 6 Remove upper half bushing retaining bolts and pull retainer off of half bushings vmr2012 039 010_a TYPICAL 1 Upper steering column support 2 Half bushings 3 Half bushing retainer 4 Retainer mounting screws 2 7 Pull steering...

Page 442: ... ap plicable wheel 2 Remove tie rod end from steering knuckle by removing Cotter pin discard Retaining nut Hardened washers note position vmr2012 039 012_a TYPICAL TIE ROD AT STEERING KNUCKLE 1 Cotter pin 2 Elastic nut 3 Hardened washers 3 If completely removing tie rod from vehicle re peat previous step at pitman arm vmr2012 039 008_b TYPICAL 1 Steering column 2 Pitman arm 3 Tie rod end Inspectin...

Page 443: ...subsection 4 Remove brake caliper refer to BRAKES subsec tion 5 Remove wheel hub refer to FRONT DRIVE subsection vmr2015 141 003 6 Detach upper suspension arm from knuckle re fer to FRONT SUSPENSION 7 Detach lower suspension arm from knuckle re fer to FRONT SUSPENSION 8 Remove knuckle from vehicle Inspecting the Knuckle Check knuckle for cracks or other damages Re place if necessary Check if wheel...

Page 444: ...remove bearing WARNING Clean all grease from outside and inside of knuckle before heating it Installing the Wheel Bearing The installation is the reverse of the removal pro cedure However pay attention to the following To ease wheel bearing installation Place bearing in a freezer for 10 minutes Place knuckle in oven to 100 C 212 F for 30 minutes maximum When knuckle is cooled down install NEW circ...

Page 445: ... The slower the vehicle speed the greater the as sist will be If the electrical system is activated but the engine is not running there is no power assist provided When the handlebar is in the straight ahead posi tion there is no steering assist Steering torque may also come from the wheels due to rough terrain Steering kickback is reduced while providing feedback to the driver The greater the pow...

Page 446: ...rease and or when the ripples in the electric circuit decreases NOTE This reaction is a normal protective behav ior of the unit and it does not necessarily raise a fault in the cluster DPS SYSTEM DESCRIPTION COMPONENTS DPS Unit The DPS unit is a self contained unit that includes the steering gear the DPS module the DPS mo tor and the torque sensor vmr2010 003 003 TYPICAL DPS UNIT The DPS module pr...

Page 447: ...T When replacing the following parts or 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 half bushings Steering column Tie rod Tie rod end Knuckle Wheel bearing Ball joint Front suspension arm lower upper Pitman arm Steering alignment Reset Torque Offset in Setting DPS 1 Ensure prop...

Page 448: ...ated DPS mode will be briefly displayed in the multifunction gauge 3 Repeat previous step to toggle through the available mode NOTE The DPS mode of operation cannot be changed if the vehicle is in reverse The DPS Override switch must be released between each DPS mode selection TROUBLESHOOTING TROUBLESHOOTING FLOW CHARTS Use the troubleshooting flow charts to diagnose a problem If a problem cannot ...

Page 449: ...battery voltage min 12V and ground connections Check ground going to DPS Check all connector pins NOTE Refer to appropriate Shop Manual for proper validation Check connection from ECM to DPS unit Check for proper B U D S version Power down unit reboot B U D S then repower up DPS tab still invisible No Assistance from DPS Is it a replacement DPS Is there voltage going to both wires of the DPS power...

Page 450: ...pressure good 34 to 48 kPa 5 to 7 PSI Any active or occured faults in B U D S screen Check battery voltage and ground connections Check DPS fuses F 4 7 5 Amp F 3 40 Amp Check power source and ground going to DPS Check all connector pins Check stator connector and charging system Inspect all relevant wiring harnesses NOTE Refer to appropriate Shop Manual for proper validation Test again once pressu...

Page 451: ...d service action NOTE Refer to appropriate Shop Manual for proper validation Test again once pressure is corrected Verify steering components for any interference or dam aged parts Insure nothing limits the mov ement of steering components Inspect steering column pitman arm bushings tie rod ends and ball joints for free normal movement no obstructions Inspect front brake pads for sticking Inspect ...

Page 452: ... Felt in Steering System Is there any backlash or play in the steering system Verify that tie rods pitman arm ball joints all steering components and fasteners are tight Ensure the upper steering bushing is greased All OK and problem still present Contact the service department and have the B U D S report ready to be sent YES NO vbs2014 009 004_aen 518 vmr2015 142 ...

Page 453: ...sensor or a re occurring torque sensor fault Make sure nothing touches the steering column Verify steering column align ment as per appropriate Shop Manual Check for faults and perform required actions Ensure the latest calibration file is installed Re occurring faults or symptoms Contact the service department and have the B U D S report ready to be sent Check tire pressure and steering alignment...

Page 454: ...L 1 Rear fuse box PF2 1 Test DPS fuse PF2 F3 using a multimeter REQUIRED TOOL FLUKE 115 MULTIMETER P N 529 035 868 vmr2012 029 002_a TYPICAL 1 30 A Main 2 40 A Fan accessories 3 40 amp DPS fuse 2 Replace fuse as required DPS Unit Input Voltage Test Power Side 1 Disconnect the DPS PWR power connector vmr2010 003 013_d TYPICAL 1 DPS PWR connector motor power 2 Test for 12 Vdc DPS motor power at DPS2...

Page 455: ..._b TYPICAL 1 DPS CTRL control connector 2 Set the ignition switch to ON 3 Set the engine RUN STOP switch to RUN 4 Test for 12 Vdc power to the DPS module at DPS1 A as per following table MULTIMETER PROBE POSITIONS VOLTAGE DPS control connector pin A and battery ground Battery voltage rmr2008 028 093_a If NO voltage is measured check wires and con nector pins from DPS unit to the Relays Speedo fuse...

Page 456: ...DPS1 D MULTIMETER PROBE POSITIONS RESISTANCE 20 C 68 F DPS control connector pin C and diagnostic connector pin 1 rmr2008 028 094_a DPS control connector pin D and diagnostic connector pin 2 rmr2008 028 094_b Below 1 If resistance measured is out of specification check wires and connector pins Carry out re pairs as required and reset fault codes using B U D S software If resistance measured is goo...

Page 457: ...stops generates maximum DPS load maximum current draw on electrical system Electrical system must sustain at least 12 Vdc for proper DPS operation vmr2010 003 007 If the electrical system cannot sustain at least 12 Vdc check the following Battery Battery connections DPS unit power and ground connections Charging system Frame and engine ground studs If the previously listed items carry out the foll...

Page 458: ...k to 60 amps then drop off close to 0 amps as torque applied is nulled out by steering assist A residual torque of 2 N m 18 lbf in with a corresponding current draw is acceptable If current draw tends to remain high carry out the following Steering alignment check Steering column shim adjustment at half bush ings as described in the DPS UNIT INSTALLA TION procedure detailed in this section TORQUE ...

Page 459: ...e steering to each side and disengage each tie rod end from the pitman arm vmr2010 003 023 TYPICAL TIE ROD ENDS HARDWARE REMOVED 9 Pull up on the steering column to partly disen gage it from the DPS unit NOTE A mechanical stop on the steering column will prevent you from fully disengaging the steer ing column 10 Remove the lower half bushing retainer that secures the steering shaft to the frame vm...

Page 460: ...12 039 015_a DPS REMOVAL LEFT SIDE Step 1 Remove DPS retaining screws 2 each side Step 2 Discard conical washers under screw head 13 Pull up on DPS unit to remove the DPS unit and support bracket from the frame vmr2012 039 016_a TYPICAL LH DPS SUPPORT BRACKET 1 DPS unit 2 DPS support bracket 3 Vehicle frame 4 Slotted hole in DPS support bracket 14 If replacing DPS unit remove the following from th...

Page 461: ...ews steady using a wrench as you apply specified torque to heat shield retaining nuts TIGHTENING TORQUE Retaining nuts DPS heat shield 24 5 N m 3 5 N m 18 lbf ft 3 lbf ft 2 Install LH DPS support bracket loosely using NEW fasteners NOTE Important Install the retaining screws to the DPS support bracket loosely at this time This is required to ensure proper DPS alignment at a later step when all ste...

Page 462: ...y in the steering column vmr2010 003 031 TYPICAL STEERING COLUMN INDEXED TO DPS SHAFT SPLINES 7 Ensure the following are properly positioned on the lower steering shaft and lower steering shaft mount O rings Steering shaft half bushings vmr2012 039 020_a 1 Lower steering shaft mount 2 O rings 3 Steering shaft half bushings 8 Install the 3 remaining hexagonal forming screws that secure the DPS unit...

Page 463: ...talled loosely 10 Install steering column pinch bolt and a NEW elastic nut loosely 11 Tighten the steering and DPS fasteners to specified torque using the torque sequence specified in the following 3 illustrations TIGHTENING TORQUE DPS retaining screws DPS bracket retaining screws Steering column retainer Steering column pinch bolt 24 5 N m 3 5 N m 18 lbf ft 3 lbf ft 5 4 1 7 3 9 2 6 8 vmr2012 039 ...

Page 464: ...column pinch bolt and edge of DPS unit housing extension Secure bellows using the appropriate locking tie NOTE Ensure the locking tie is on the tube part of the steering column not on the forged end Bel lows should cover end of ring flange on DPS unit but not cover the drainage hole at the bottom of the ring flange Do not install a locking tie on the DPS end of the bellows Lower portion of bellows...

Page 465: ...l 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 latest applicable B U D S software version 2 Select the Read Data button 3 In the Module menu choose the DPS sub menu and install the latest DPS software Update file as applicable to the type ATV Out lander or Renegade vmr2010 003 0...

Page 466: ... the positioning adapter in the Pitman arm so its point rests in the DPS output shaft NOTE A countersunk hole is machined in tip of the DPS output shaft to accept and center the po sitioning adapter point REQUIRED TOOL POSITIONING ADAPTOR P N 529 036 230 vmr2012 039 024_a 1 Pitman arm 2 Positioning adapter 6 Turn the jig positioning screw until the screw tip rests snugly in the positioning adapter...

Page 467: ...ly against jig upper bar NOTE Be sure to hold the position screw steady to prevent its tip from backing off the positioning adapter vbs2011 015 008_a 1 Jig upper bar 2 Positioning screw 3 Lock nut 10 As you hold the positioning screw steady turn the extractor nut up to pull the Pitman arm off the DPS output shaft vmr2012 039 029_a 1 Positioning screw held steady 2 Extractor nut turned up 11 Remove...

Page 468: ...aft 4 Insert the DPS input shaft in the Pitman arm jig receptacle with the Pitman arm facing up vmr2012 039 025_a 1 DPS input shaft 2 Shaft receptacle in Pitman arm jig vmr2012 039 030_a 1 Spline keyway alignment here 5 Turn the jig positioning screw until the align ment point makes proper contact with the Pit man arm NOTE Ensure positioning screw is centered in Pitman arm tube vmr2012 039 031_a 1...

Page 469: ...screw and remove pusher adapter and pull out DPS unit 8 Install Pitman arm retaining washer and nut Tighten nut as specified vmr2012 039 022_a 1 DPS 2 Pitman arm 3 Pitman arm nut and washer TIGHTENING TORQUE Pitman arm retaining nut 72 5 N m 7 5 N m 53 lbf ft 6 lbf ft 9 Carry out a steering alignment as described in this subsection vmr2015 142 535 ...

Page 470: ...Subsection XX FRONT SUSPENSION FRONT SUSPENSION SERVICE TOOLS Description Part Number Page BALL JOINT REMOVAL TOOL 529 036 310 7 vmr2015 056 1 ...

Page 471: ...ase 45 5 N m 33 4 lbf ft NEW 3 0 5 N m 27 4 lbf in NEW Suspension Grease 90 from arm axis NEW NEW 3 0 5 N m 27 4 lbf in 73 7 N m 54 5 lbf ft 61 9 N m 45 7 lbf ft Component must be replaced when removed NEW NEW 24 5 3 N m 18 2 lbf ft 24 5 3 N m 18 2 lbf ft vsi2015 143 001_a 2 vmr2015 056 ...

Page 472: ...S AND COMPONENTS NEW NEW 48 6 N m 35 4 lbf ft 3 0 0 5 N m 27 4 lbf in NEW NEW 4 5 0 5 N m 40 4 lbf in NEW Suspension Grease Suspension Grease 90 from arm axis 3 0 0 5 N m 27 4 lbf in Component must be replaced when removed vmr2015 056 101 vmr2015 056 3 ...

Page 473: ...troke at mid travel Seizing or binding condition except at extreme end of either stroke Oil leakage A gurgling noise after completing one full com pression and extension stroke Replace if any faults are present Shock Absorber Installation The installation is the reverse of the removal pro cedure However pay attention to the following Install shock absorber screws from front towards rear of vehicle...

Page 474: ...IC MAINTENANCE PROCEDURES subsection Tighten ball joint nut to specification TIGHTENING TORQUE Nut securing ball joint to knuckle 48 N m 6 N m 35 lbf ft 4 lbf ft Perform steering alignment procedure Refer to STEERING ALIGNMENT subsection UPPER SUSPENSION ARM Upper Suspension Arm Removal 1 Safely lift and support the vehicle off the ground 2 Remove wheel refer to WHEELS AND TIRES subsection 3 Remov...

Page 475: ... suspension arm Upper Suspension Arm Installation The installation is the reverse of the removal pro cedure However pay attention to the following Lubricate suspension arm Refer to PERIODIC MAINTENANCE PROCEDURES subsection Install a NEW cotter pin to secure ball joint nut Both end of cotter pin must be folded Tighten shock absorber nut to specification TIGHTENING TORQUE Lower shock absorber nut 7...

Page 476: ...er to PERIODIC MAINTENANCE PROCEDURES subsection BALL JOINTS Ball Joint Removal 1 Remove suspension arm from vehicle Refer to SUSPENSION ARM REMOVAL in this subsec tion 2 Remove circlip from ball joint vmr2015 056 010 LOWER BALL JOINT vsi2015 143 010_a UPPER BALL JOINT 3 Install suspension arm on a press NOTICE Pressing on the center or on the lip of the ball joint will damage it vmr2015 056 012_a...

Page 477: ... EDGE ONLY 4 Remove ball joint from suspension arm NOTICE Make sure that suspension arm is properly supported on the press during ball joint removal Ball Joint Installation The installation is the reverse of the removal pro cedure However pay attention to the following Install a NEW circlip to secure ball joint 8 vmr2015 056 ...

Page 478: ... Subsection 05 REAR SUSPENSION REAR SUSPENSION SERVICE TOOLS Description Part Number Page SPRING COMPRESSOR 529 036 184 681 SERVICE PRODUCTS Description Part Number Page SUSPENSION GREASE 293 550 033 684 vmr2015 057 677 ...

Page 479: ... BAR Components must be replaced when removed NEW NEW 3 0 0 5 N m 27 4 lbf in Suspension Grease NEW Suspension Grease 255 10 N m 188 7 lbf ft NEW 4 5 0 5 N m 40 4 lbf in 3 0 0 5 N m 27 4 lbf in NEW NEW NEW Suspension Grease 90 from arm axis vmr2015 057 100 678 vmr2015 057 ...

Page 480: ...Section 08 CHASSIS Subsection 05 REAR SUSPENSION SHOCK ABSORBERS NEW Components must be replaced when removed NEW 61 9 N m 45 7 lbf ft vmr2015 057 101 vmr2015 057 679 ...

Page 481: ...rm resistance with its rod upward Check the following conditions that will denote a defective shock A skip or a hang back when reversing stroke at mid travel Seizing or binding condition except at extreme end of either stroke Oil leakage A gurgling noise after completing one full com pression and extension stroke Replace if any faults are present Shock Absorber Installation The installation is the...

Page 482: ...ck absorber 7 Release spring remover screw 8 Remove spring from shock absorber Spring Inspection Inspect the spring for damage Replace if necessary Spring Installation The installation is the reverse of the removal pro cedure However pay attention to the following On applicable models install spring cap opening at 180 from spring stopper opening vmr2015 057 018_a CAP OPENING AT 180 SWAY BAR Sway B...

Page 483: ...tion TIGHTENING TORQUE Screws securing sway bar to frame 24 5 N m 3 5 N m 18 lbf ft 3 lbf ft Screws securing sway bar to link arm 61 N m 9 N m 45 lbf ft 7 lbf ft Lubricate sway bar Refer to PERIODIC MAINTE NANCE PROCEDURES subsection TRAILING ARM Trailing Arm Removal 1 Safely lift and support the vehicle off the ground 2 Remove wheel hub refer to REAR DRIVE sub section 3 Remove protective plate fr...

Page 484: ...ng bearing into trailing arm vmr2015 057 012 2 Install trailing arm on a press 3 Use an appropriate bearing remover 4 Remove drive shaft bearing from trailing arm Link Arm Inner Bushing Removal Remove both bushings and sleeve from trailing arm vmr2015 057 011_a 1 Bushings 2 Sleeve Trailing Arm Pivot Bearing Removal 1 Remove both spacers and seals from trailing arm pivot vmr2015 057 014_a 1 Spacer ...

Page 485: ...ert bearing on RH side Step 2 Center inner spacer with RH side bearing using a shaft Step 3 Insert bearing on LH side Lubricate trailing arm pivot seals LUBRICATION Pivot seals SUSPENSION GREASE P N 293 550 033 Install trailing arm pivot seal with its cavity facing inwards vmr2015 057 017_a 1 Seal cavity 2 Trailing arm Center trailing arm pivot shaft Tighten trailing arm pivot nuts as per the foll...

Page 486: ...scription Part Number Page ECM ADAPTER TOOL 529 036 166 9 SERVICE PRODUCTS Description Part Number Page XPS BRAKES AND PARTS CLEANER USA 219 701 705 12 XPS BRAKES AND PARTS CLEANER 219 701 776 12 XPS SYNTHETIC GREASE 293 550 010 10 vmr2016 411 1 ...

Page 487: ... be replaced when removed NEW To rear circuit 5 5 1 5 N m 49 13 lbf in 28 5 1 5 N m 21 1 lbf ft 28 5 1 5 N m 21 1 lbf ft 61 9 N m 45 7 lbf ft 33 5 3 5 N m 25 3 lbf ft 28 5 1 5 N m 21 1 lbf ft NEW NEW NEW NEW 28 5 1 5 N m 21 1 lbf ft NEW NEW vmr2016 411 100_a 2 vmr2016 411 ...

Page 488: ...hen removed NEW To front circuit NEW 28 5 1 5 N m 21 1 lbf ft NEW 27 5 2 5 N m 20 2 lbf ft See tightening sequence XPS synthetic grease 33 5 3 5 N m 25 3 lbf ft NEW NEW 28 5 1 5 N m 21 1 lbf ft 61 9 N m 45 7 lbf ft NEW NEW NEW 0 7 0 1 N m 6 1 lbf in NEW vmr2016 411 101_a vmr2016 411 3 ...

Page 489: ...m 21 1 lbf ft NEW 5 5 1 5 N m 49 13 lbf in 5 5 1 5 N m 49 13 lbf in NEW 28 5 1 5 N m 21 1 lbf ft NEW NEW 28 5 1 5 N m 21 1 lbf ft To rear RH caliper 28 5 1 5 N m 21 1 lbf ft NEW NEW 28 5 1 5 N m 21 1 lbf ft NEW NEW 28 5 1 5 N m 21 1 lbf ft 61 9 N m 45 7 lbf ft 33 5 3 5 N m 25 3 lbf ft NEW NEW NEW vmr2016 411 102_a 4 vmr2016 411 ...

Page 490: ...ust be replaced when removed NEW NEW 27 5 2 5 N m 20 2 lbf ft See tightening sequence XPS synthetic grease 61 9 N m 45 7 lbf ft 33 5 3 5 N m 25 3 lbf ft To front RH splitter NEW NEW 0 7 0 1 N m 6 1 lbf in To front RH splitter vmr2016 411 103_a vmr2016 411 5 ...

Page 491: ...tic grease XPS synthetic grease On applicable models RH SIDE 8 5 1 5 N m 75 13 lbf in REAR 8 5 1 5 N m 75 13 lbf in Brake caliper synthetic grease 8 5 1 5 N m 75 13 lbf in Brake caliper synthetic grease 1 3 0 1 N m 12 1 lbf in 1 3 0 1 N m 12 1 lbf in Cover gasket Cover gasket vmr2013 044 100_a 6 vmr2016 411 ...

Page 492: ...ept CE models Controls rear brakes Controls front brakes Controls rear brakes CE models Controls rear brakes Controls front brakes Controls front and rear brakes INSPECTION BRAKE SYSTEM PRESSURE VALIDATION Required Tools Use an appropriate compression force gauge such as MARK 10 EG 200 and a ruler tmr2011 037 110 TYPICAL Brake Lever Verification NOTE Do not pump up the brakes repeatedly be fore do...

Page 493: ...eading must be as per the following table BRAKE PEDAL VERIFICATION MODELS DISTANCE A MINIMUM LOAD Renegade CE 55 mm 2 5 32 in 180 N 40 lbf All Renegade except CE 55 mm 2 5 32 in 220 N 49 lbf 6 If load reading is not in accordance with the specification 6 1 Perform a brake system inspection and cleaning 6 2 Bleed brake system NOTE Refer to PERIODIC MAINTENANCE PROCEDURES subsection PROCEDURES BRAKE...

Page 494: ...nect brake light switch connector Brake Light Switch Located on Master Cylinder or Manifold 1 Disconnect brake light switch connector 2 Drain brake line 3 Remove brake light switch NOTE Use shop rags to catch any spilled brake fluid 4 Install NEW sealing washers 5 Install brake light switch TIGHTENING TORQUE Brake light switch 28 5 N m 1 5 N m 21 lbf ft 1 lbf ft 6 Connect brake light switch connec...

Page 495: ...TEP 2 Brake pedal nut 27 5 N m 2 5 N m 20 lbf ft 2 lbf ft vmr2015 058 007_a TIGHTENING SEQUENCE Step 1 Tighten bolt Step 2 Hold bolt then tighten nut MASTER CYLINDER Master Cylinder Removal 1 Remove BRAKE PEDAL See procedure in this subsection 2 Remove master cylinder from support vmr2015 058 008_a 3 Remove hoses and bleeder from master cylin der Master Cylinder Inspection Check boot for crack Che...

Page 496: ...ners retaining brake hose 5 Remove screws securing caliper support vmr2015 058 002_a 1 Caliper screws 6 Place caliper assembly onto a support NOTICE Do not let caliper hangs by the hose and do not stretch or twist hose Caliper Installation The installation is the reverse of the removal pro cedure However pay attention to the following If caliper was removed for replacement Refill and bleed brake s...

Page 497: ...E To avoid damaging pistons use an old pad to push it into the caliper using a C clamp 7 Ensure brake pad spring is properly positioned onto caliper and not damaged vmr2012 042 011_a BRAKE PAD SPRING 8 Ensure pad stopper is properly aligned with caliper support protrusion vmr2012 042 012_a 1 Pad stopper 2 Caliper support protrusion NOTICE Prior to installing brake pads pad stopper must be properly...

Page 498: ...warpage of the disc MAXIMUM DISC WARPAGE FRONT REAR 0 2 mm 01 in Brake Disc Replacement 1 Remove caliper refer to CALIPER REMOVAL in this subsection 2 Remove wheel hub refer to FRONT DRIVE or REAR DRIVE subsection 3 Remove screws securing brake disc to wheel hub vmr2012 042 013_a 1 Brake disc screw 4 Replace brake disc 5 Install NEW brake disc screws 6 Tighten brake disc screws to specification TI...

Page 499: ...Subsection 08 BODY EXCEPT X MR BODY EXCEPT X MR SERVICE TOOLS Description Part Number Page OETIKER PLIERS 295 000 070 9 vmr2016 416 1 ...

Page 500: ... 6 7 8 9 11 10 vmr2016 416 001_a REAR BODY MODULE FRONT BODY MODULE 1 Gauge support 2 Console 3 Rear fender 4 Side panel 5 Footrest 6 Side panel extension LH side only 7 Inner fender panel 8 Headlight trim 9 Front bumper 10 Front fascia 11 Front fender 12 Engine panel RH side not shown 2 vmr2016 416 ...

Page 501: ...X MR BODY PARTS REAR 4 5 0 5 N m 40 4 lbf in 4 5 0 5 N m 40 4 lbf in 2 5 0 5 N m 22 4 lbf in NEW NEW NEW 4 5 0 5 N m 40 4 lbf in 4 5 0 5 N m 40 4 lbf in Component must be replaced when removed NEW vmr2016 416 002_a vmr2016 416 3 ...

Page 502: ... 4 N m 14 4 lbf in 2 5 0 5 N m 22 4 lbf in NEW 2 5 0 5 N m 22 4 lbf in 4 5 0 5 N m 40 4 lbf in 4 5 0 5 N m 40 4 lbf in NEW NEW 4 5 0 5 N m 40 4 lbf in NEW 1 6 0 4 N m 14 4 lbf in 2 5 0 5 N m 22 4 lbf in NEW 1 6 0 4 N m 14 4 lbf in Component must be replaced when removed NEW vmr2016 416 003_a 4 vmr2016 416 ...

Page 503: ... m 40 4 lbf in NEW 4 5 0 5 N m 40 4 lbf in NEW 2 5 0 5 N m 22 4 lbf in NEW 2 5 0 5 N m 22 4 lbf in 3 5 0 5 N m 31 4 lbf in 4 5 0 5 N m 40 4 lbf in NEW 4 5 0 5 N m 40 4 lbf in NEW NEW 2 5 0 5 N m 22 4 lbf in NEW 2 5 0 5 N m 22 4 lbf in 3 5 0 5 N m 31 4 lbf in 4 5 0 5 N m 40 4 lbf in 10 2 N m 89 18 lbf in vmr2016 416 004_a vmr2016 416 5 ...

Page 504: ...emoved NEW 10 2 N m 89 18 lbf in 24 5 3 5 N m 18 3 lbf ft 24 5 3 5 N m 18 3 lbf ft 10 2 N m 89 18 lbf in 24 5 3 5 N m 18 3 lbf ft NEW NEW NEW 24 5 3 5 N m 18 3 lbf ft NEW 48 6 N m 35 4 lbf ft NEW 48 6 N m 35 4 lbf ft NEW 48 6 N m 35 4 lbf ft NEW vmr2016 416 005_a 6 vmr2016 416 ...

Page 505: ... be replaced when removed NEW 24 5 3 5 N m 18 3 lbf ft NEW NEW 24 5 3 5 N m 18 3 lbf ft 4 5 0 5 N m 40 4 lbf in NEW 10 2 N m 89 18 lbf in NEW 4 5 0 5 N m 40 4 lbf in NEW NEW 24 5 3 5 N m 18 3 lbf ft 24 5 3 5 N m 18 3 lbf ft NEW vmr2016 416 006_a vmr2016 416 7 ...

Page 506: ...m 40 4 lbf in NEW 4 5 0 5 N m 40 4 lbf in NEW 4 5 0 5 N m 40 4 lbf in NEW 10 2 N m 89 18 lbf in 24 5 3 5 N m 18 3 lbf ft NEW NEW 2 5 0 5 N m 22 4 lbf in Component must be replaced when removed NEW Renegade STD Renegade X xc vmr2016 416 007_a 8 vmr2016 416 ...

Page 507: ...isopropyl alcohol clean the surface and dry thoroughly Apply liquid soap to new decal and carefully posi tion it Using a sponge or a squeegee remove the air bubbles and surplus water working from the center toward the edges Allow to air dry NOTICE Do not apply isopropyl alcohol or solvent directly on decals Use these products in a well ventilated area FRONT BODY MODULE Removing the Front Body Modu...

Page 508: ...fender to footrest panel 9 Remove bolt securing front body module to bumper vmr2012 047 005_a SOME PARTS REMOVED FOR CLARITY 1 Bolt securing front body module to bumper 10 Remove front fuse box from its support vmr2012 047 006_a SOME PARTS REMOVED FOR CLARITY 1 Front fuse box 11 Remove bolts securing front body module to frame vmr2012 047 007_a SOME PARTS REMOVED FOR CLARITY 1 Bolts securing front...

Page 509: ...t Screws securing front fender to footrest panel 2 5 N m 0 5 N m 22 lbf in 4 lbf in REAR BODY MODULE Removing the Rear Body Module 1 Remove seat 2 Remove SIDE PANELS See procedure in this subsection 3 Disconnect taillight connector on both sides vmr2012 047 008_a RH SIDE SHOWN 1 Taillight connector 4 Remove screws securing rear fender to footrest panel on both sides vmr2012 047 009_a RH SIDE SHOWN...

Page 510: ...f in Rear anchors retaining screws 4 5 N m 0 5 N m 40 lbf in 4 lbf in Bolts securing rear fender to frame 2 5 N m 0 5 N m 22 lbf in 4 lbf in CONSOLE Removing the Console 1 Remove seat 2 Pull both front pins out of their grommets 3 Pull both front hooks out of their slots vbl2012 007 005_a 1 Console 2 Pin 3 Hook 4 Slot 5 Grommet 4 Pull rear portion of the console up to pull the pins of their gromme...

Page 511: ... 014_a RH SIDE PANEL SHOWN 1 Tabs 3 Lift front portion of side panel to release lower tab from rear fender vmr2012 047 015_a RH SIDE PANEL SHOWN 1 Lower tab 4 Remove side panel by pulling it outwards Installing the Side Panel The installation is the reverse of the removal pro cedure FOOTREST PANELS Removing the Footrest Panel 1 Remove footpeg retaining screws 2 Remove footrest panel retaining scre...

Page 512: ...rom vehicle Installing the Footrest Panel The installation is the reverse of the removal pro cedure However pay attention to the following Tighten footrest panel screws to specification TIGHTENING TORQUE Footpeg retaining screws 4 5 N m 0 5 N m 40 lbf in 4 lbf in Footrest panel retaining screws 3 5 N m 0 5 N m 31 lbf in 4 lbf in Screws securing footrest panel to fenders 2 5 N m 0 5 N m 22 lbf in 4...

Page 513: ...Subsection XX FRAME FRAME SERVICE TOOLS OTHER SUPPLIER Description Part Number Page BLIND THREADED INSERT INSTALLER model 9600 3 vmr2013 047 1 ...

Page 514: ...per frame support welded Lower frame support Renegade series 24 5 3 5 N m 18 3 lbf ft 24 5 3 5 N m 18 3 lbf ft Trailer hitch Final drive protector Outlander series 24 5 3 5 N m 18 3 lbf ft Footrest bracket Rear frame extension Front bumper support 24 5 3 5 N m 18 3 lbf ft Max Models 24 5 3 5 N m 18 3 lbf ft 24 vmr2013 047 001 2 vmr2013 047 ...

Page 515: ...eir web site at www textronfasteningsystems com tmr2011 039 004 After insert installation ensure insert can hold the torque applied to the screw it retains and measure the compressed length of the frame insert Oth erwise install a new insert INSERT COMPRESSED LENGTH Insert for M6 bolt 9 mm 0 5 mm 354 in 02 in Insert for M8 bolt 11 5 mm 0 5 mm 453 in 02 in vmr2012 044 002_a INSERT FOR M6 BOLT SHOWN...

Page 516: ...75 mm 2 95 in 570 570 cm 34 8 in 850 854 cm 52 1 in Displacement 1000R 976 cm 59 6 in 570 10 3 1 850 10 5 1 Compression ratio 1000R 10 6 1 570 7500 rpm 850 7000 rpm Maximum HP RPM 1000R 7250 RPM Exhaust system Spark arrestor approved by USDA Forest Service Air filter Synthetic paper filter with foam 570 3 BTDC 850 5 BTDC Intake valve opening 1000R 8 BTDC 570 34 ABDC 850 45 ABDC Intake valve closin...

Page 517: ...mm 1 591 in Valve spring free length All Service limit 39 00 mm 1 535 in New 1 05 mm to 1 35 mm 041 in to 053 in Intake Service limit 1 8 mm 071 in New 1 25 mm to 1 55 mm 049 in to 061 in Valve seat contact width Exhaust Service limit 2 mm 079 in New 12 036 mm to 12 050 mm 4739 in to 4744 in Rocker arm bore diameter Service limit 12 060 mm 4748 in New 12 000 mm to 12 018 mm 4724 in to 4731 in Rock...

Page 518: ...15 mm 0059 in New 0 02 mm to 0 06 mm 0008 in to 0024 in Tapered face All Service limit 0 15 mm 0059 in New 0 01 mm to 0 18 mm 0004 in to 0071 in Ring piston groove clearance Oil scraper ring All Service limit 0 25 mm 0098 in 570 84 023 mm to 84 037 mm 3 308 in to 3 3085 in 850 93 993 mm to 94 007 mm 3 7005 in to 3 7011 in Cylinder bore 1000R New 90 993 mm to 91 007 mm 3 5824 in to 3 583 in Maximum...

Page 519: ... to 34 020 mm 1 3387 in to 1 3394 in Crankshaft bearing journal diameter in PTO cover Service limit 33 998 mm 1 3385 in Crankshaft radial play PTO cover bearing Service limit 0 10 mm 0039 in New 0 200 mm to 0 500 mm 0079 in to 0197 in Crankshaft axial play Service limit 0 600 mm 0236 in New 40 001 mm to 40 025 mm 1 5748 in to 1 5758 in 570 850 Service limit 39 990 mm 1 5744 in New 41 986 mm to 42 ...

Page 520: ...KE SYNTHETIC BLEND OIL P N 293 600 121 For the winter season use XPS 4 STROKE SYNTHETIC OIL P N 293 600 112 If not available use a 5W40 motor oil that meets the requirements for API service classification SG SH or SJ COOLING SYSTEM Type Ethyl glycol water mix 50 coolant 50 water Use LONG LIFE ANTIFREEZE P N 219 702 685 or coolant specifically designed for aluminum engines 570 3 4 L 9 U S gal Coola...

Page 521: ...mit 4 mm 157 in New 9 2 mm to 9 4 mm 362 in to 37 in Spring sleeve length Service limit 9 0 mm 354 in New 30 060 mm to 30 100 mm 1 183 in to 1 185 in Driven pulley sliding half bushing Service limit 30 200 mm 1 189 in New 30 060 mm to 30 100 mm 1 183 in to 1 185 in Driven pulley sliding fixed bushing Service limit 30 200 mm 1 189 in Torque gear on driven pulley Service limit 7 500 mm 295 in Cam wi...

Page 522: ... to 5 20 mm 201 in to 205 in Shift fork claw thickness low and reverse gear shift fork Service limit 5 0 mm 197 in New 6 92 mm to 6 97 mm 272 in to 274 in Shift fork pin diameter Service limit 6 85 mm 27 in New 5 30 mm to 5 40 mm 209 in to 213 in Width of shift fork engagement groove low and reverse gear Service limit 5 50 mm 217 in New 5 00 mm to 5 10 mm 197 in to 201 in Width of shift fork engag...

Page 523: ...in to 205 in Shift fork claw thickness low and reverse gear shift fork Service limit 5 0 mm 197 in New 5 30 mm to 5 40 mm 209 in to 213 in Width of shift fork engagement groove low and reverse gear Service limit 5 50 mm 217 in New 5 30 mm to 5 40 mm 209 in to 213 in Width of shift fork engagement groove high gear Service limit 5 50 mm 217 in New 29 000 mm to 29 013 mm 1 1417 in to 1 1422 in Diamet...

Page 524: ...d type NGK LMAR8D J Spark plug 850 1000R Gap 0 7 mm to 0 9 mm 028 in to 035 in Forward 8000 rpm Engine RPM limiter setting All models Reverse 15 km h 9 MPH without override Type Maintenance free Voltage 12 volts Nominal rating 18 A h Battery Power starter output 0 7 KW High 2 x 60 W HB3 Headlights Low 2 x 60 W HB3 Taillights 2 x 5 21 W Turn signal lights CE models only 4 x 10 W Position lights CE ...

Page 525: ... Fuses in fuse box 1 Fuel pump relay F15 5 A Fuse in fuse box 2 DPS motor F3 40 A FUEL SYSTEM 570 Electronic Fuel Injection EFI 46 mm throttle body 1 injector per cylinder Fuel delivery 850 1000R Electronic Fuel Injection EFI 54 mm throttle body 1 injector per cylinder Type Electrical in fuel tank Fuel pump Operating pressure 350 kPa 10 kPa 51 PSI 1 PSI Idle speed 1400 rpm 50 not adjustable Type R...

Page 526: ...toe in Camber angle vehicle on ground 0 Tie rod maximum length unengaged threads 348 5 mm 13 72 in FRONT SUSPENSION Suspension type Double suspension arm with dive control geometry Suspension travel 215 9 mm 8 5 in Qty 2 X xc Type HPG shock with piggy back reservoir and dual speed compression damping adjustments Qty 2 STD 570 Type Oil Qty 2 Shock absorber STD 850 and 1000R Type HPG shock STD 570 3...

Page 527: ...ic Minimum brake pad thickness 1 mm 04 in Minimum brake disc thickness 4 0 mm 157 in Maximum brake disc warpage 0 2 mm 01 in TIRES UP TO 164 kg 360 lb 41 4 kPa 6 PSI Front FROM 164 kg 360 lb TO 235 kg 517 lb 48 2 kPa 7 PSI UP TO 164 kg 360 lb 41 4 kPa 6 PSI Pressure Rear FROM 164 kg 360 lb TO 235 kg 517 lb 68 9 kPa 10 PSI Minimum tire thread depth 3 mm 118 in Front 635 x 203 x 305 mm 25 x 8 x 12 i...

Page 528: ... 850 engine 303 kg 668 lb Dry weight 1000R engine 314 kg 692 lb Rear cargo area capacity 16 kg 35 lb Total vehicle load allowed including driver passenger all other loads and added accessories 141 kg 311 lb Except CE version 590 kg 1 300 lb Towing capacity CE version 135 kg 300 lb Except CE version 23 kg 50 lb Tongue capacity CE version 14 kg 30 lb vmr2016 412 13 ...

Page 529: ...r and size Wiring Diagram Index The wiring diagram is separated by rows letters and columns numbers mmr2015 147 004_a WIRING DIAGRAM INDEX Connector Code The wire connects to the indicated connector Connector Pin The wire is the indicated pin in the connector NOTE Could be identified by either a number or by a letter depending on the type of connector used FOLLOWING A CIRCUIT To follow a circuit s...

Page 530: ...rform the usual tests described in ELECTRICAL SYSTEM sections before inves tigating the harness splices 2 If an electrical issue can not be found with the usual tests locate the main harness splice that is involved in the faulty circuit and repair it as per the SPLICES REPAIR PROCEDURE 3 To repair a splice we recommend the use of a tin solder meeting the followings requirements or an equivalent TI...

Page 531: ...oximately 13 mm 1 2 in each side 9 Reinstall wires into protector tube CASE 2 Wire Broken from Splice 1 Locate splice Refer to splices location dia grams 2 Remove wires from protector tube 3 Locate the shrink tube protecting the defective splice mmr2010 043 001_a 1 Shrink tube 4 Remove the shrink tube 4 1 Using a blade cut the shrink tube mmr2010 043 002 NOTICE Be careful with the blade to avoid c...

Page 532: ...a 1 Broken wire stripped 2 Splice wire stripped 8 Twist wire around stripped wire mbg2008 021 120_a 1 Twisted wire 9 Perform a tin solder on twisted wire 10 Apply electrical tape to cover splice NOTE Make sure tape overlaps on wire insula tion approximately 13 mm 1 2 in each side 11 Reinstall wires into protector tube NOTE Always perform a solder on a bigger wire lower gage 4 vmr2016 149 ...

Page 533: ... BK BR 22 VI BE 20 G 1 BK 16 BK 22 FUEL PMP RELAY R4 B11 A12 BK BU 22 BU GY 20 JT BU GY BK 16 A11 BK RD 18 JT RD BE B12 BU GY 20 HIC1_F HIC1_F E 5 HIC1_F H G A D B E S R J K P HIC2_F HIC2_F D F E H G HIC1_F M WH BE 22 N F WH BK 22 FUEL PMP FUSE F15 5A D5 D4 BU GY 20 PK 22 BK BE 22 RD BE 18 G 2 B 7 WH BK 20 BK 16 RD GY 16 WH BE 20 JT WH BE JT WH BK RELAY SPEEDO FUSE F4 5A B5 B6 RD BE 18 OR GN 20 OR...

Page 534: ...4 VT BU 16 BR BK 16 M2 BR OR 16 M1 SPK 2 1 2 3 SPK 1 SPECIFIC HARNESS OUTLANDER RENEGADE 2016 CE OUTLANDER L 2016 MAIN HARNESS SIDE CE HARNESS SIDE HANDLEBAR SW OFF LH RH OFF RUN OFF RUN INTERCONNECT HICA FROM ACC RELAY HOT AT KEY ON E FROM MAIN HOT ALL TIME D TO CLUSTER FLASHER SIGNAL B TO MAIN VEHICLE GROUND A BE 20 RD BK 20 BK 20 JT BE BE 20 JT RD BK OR 20 JT BK LFF LEFT FRONT FLASHER LFF 2 LFF...

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