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Can-Am Renegade 570 2016, Service Manual


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Section 07 CHASSIS

Subsection 03 (DYNAMIC POWER STEERING (DPS))

Flow Chart D

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Summary of Contents for Renegade 570 2016

Page 1: ...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 int...

Page 2: ...ting 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 coul...

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 Identificat...

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 an...

Page 5: ...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 fastene...

Page 6: ...hing 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 b...

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...

Page 8: ...o 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 Pro...

Page 9: ...ADLOCKER 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 Thr...

Page 10: ...eads 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...

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...

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 d...

Page 13: ...DULE 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...

Page 14: ...ition 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...

Page 15: ...and output shaft seals gearbox differential and final drive Clean vehicle speed sensor Clean and lubricate lower and upper steering column half bushings The following must be performed every 2 years...

Page 16: ...ction 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...

Page 17: ...iness 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 I...

Page 18: ...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 Follo...

Page 19: ...sh 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 s...

Page 20: ...eat 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 en...

Page 21: ...nkcase 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 Engin...

Page 22: ...evel 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 vmr2...

Page 23: ...r 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...

Page 24: ...NG 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 Cooli...

Page 25: ...AD 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...

Page 26: ...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 it...

Page 27: ...r 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 TRANSMIS...

Page 28: ...tion 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...

Page 29: ...ese 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...

Page 30: ...ystem 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...

Page 31: ...ntiseize 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 pl...

Page 32: ...red 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 o...

Page 33: ...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...

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...

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 Stabil...

Page 36: ...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...

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 mov...

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 M...

Page 39: ...UEL 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 Lubricati...

Page 40: ...ry 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 recommende...

Page 41: ...TS 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 CLEANE...

Page 42: ...spection 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 st...

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...

Page 44: ...rain 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 conn...

Page 45: ...tion 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...

Page 46: ...AKE 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 Discon...

Page 47: ...CAL 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 FRO...

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 ea...

Page 49: ...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...

Page 50: ...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_...

Page 51: ...ining 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...

Page 52: ...EM 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 si...

Page 53: ...G 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 m...

Page 54: ...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...

Page 55: ...9_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 ho...

Page 56: ...y 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...

Page 57: ...e 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...

Page 58: ...ve 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 Replac...

Page 59: ...14 512_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 speci...

Page 60: ...emoval 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 ve...

Page 61: ...tening 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...

Page 62: ...ICATION 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 24...

Page 63: ...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 lb...

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...

Page 65: ...RICATION 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 beari...

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 CONSUMPTI...

Page 67: ...e 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 t...

Page 68: ...ector 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 ENGIN...

Page 69: ...ng 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...

Page 70: ...or 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 roto...

Page 71: ...or 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 OI...

Page 72: ...ate 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 a...

Page 73: ...rom 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 Replac...

Page 74: ...r 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...

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: ...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...

Page 78: ...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 mu...

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 PE...

Page 80: ...er 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 Oet...

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 a...

Page 82: ...he 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 fu...

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 Loca...

Page 84: ...cting 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 Howeve...

Page 85: ...y 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 Scre...

Page 86: ...s 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 o...

Page 87: ...e 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 r...

Page 88: ...6 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...

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...

Page 90: ...ry 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 out...

Page 91: ...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 BOTT...

Page 92: ...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 discar...

Page 93: ...er 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...

Page 94: ...ULTIMETER 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 06...

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 64...

Page 96: ...TOR 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...

Page 97: ...ENING 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 vol...

Page 98: ...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...

Page 99: ...QUIRED 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...

Page 100: ...ts 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 si...

Page 101: ...ing 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 lo...

Page 102: ...utch 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 Col...

Page 103: ...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...

Page 104: ...rfaces 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...

Page 105: ...e 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...

Page 106: ...om 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 Disco...

Page 107: ...ks 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...

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 SPRI...

Page 109: ...emoved 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...

Page 110: ...emoved 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...

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: ...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 disass...

Page 113: ...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 read...

Page 114: ...et 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...

Page 115: ...m 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 assemb...

Page 116: ...fered 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...

Page 117: ...s 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 plat...

Page 118: ...02_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...

Page 119: ...wing 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...

Page 120: ...der 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...

Page 121: ...UE 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 VALV...

Page 122: ...NGINES 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 pro...

Page 123: ...lves 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 c...

Page 124: ...rly 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 sho...

Page 125: ...T 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...

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...

Page 127: ...0 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 perpendicula...

Page 128: ...er 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 procedure...

Page 129: ...08A 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...

Page 130: ...r 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 2...

Page 131: ...ON 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 slee...

Page 132: ...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...

Page 133: ...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 smoothl...

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...

Page 135: ...ents 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_...

Page 136: ...ner 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 MO...

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 move...

Page 138: ...g 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...

Page 139: ...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 prod...

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...

Page 141: ...k 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...

Page 142: ...ver 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 behi...

Page 143: ...efer 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 01...

Page 144: ...ear 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 tmr201...

Page 145: ...R 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 2...

Page 146: ...tite 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 oi...

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...

Page 149: ...he 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 roll...

Page 150: ...ove 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 subsec...

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 remai...

Page 152: ...D 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 su...

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...

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 remo...

Page 155: ...e 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 Interme...

Page 156: ...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 E...

Page 157: ...t 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 reco...

Page 158: ...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...

Page 159: ...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 ins...

Page 160: ...16 035 002_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 O...

Page 161: ...rs 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 p...

Page 162: ...he 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...

Page 163: ...00 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...

Page 164: ...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...

Page 165: ...y 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 su...

Page 166: ...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 ro...

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: ...cription 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...

Page 169: ...lley 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...

Page 170: ...ARIABLE 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 vmr...

Page 171: ...ove 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...

Page 172: ...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 re...

Page 173: ...t 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 Slidin...

Page 174: ...overnor 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 m...

Page 175: ...h 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 gl...

Page 176: ...E 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 sheav...

Page 177: ...entrifugal 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...

Page 178: ...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...

Page 179: ...e 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 O...

Page 180: ...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 mou...

Page 181: ...der 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...

Page 182: ...se 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...

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...

Page 184: ...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 Slid...

Page 185: ...st 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 sheav...

Page 186: ...e 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 N...

Page 187: ...e 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...

Page 188: ...ER 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 shea...

Page 189: ...tly 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 ST...

Page 190: ...RIABLE 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...

Page 191: ...ER 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 Des...

Page 192: ...PLING 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 Loctit...

Page 193: ...ND 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...

Page 194: ...untershaft 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...

Page 195: ...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...

Page 196: ...y 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...

Page 197: ...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 cor...

Page 198: ...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 le...

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 co...

Page 200: ...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 wheel...

Page 201: ...il 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 vmr...

Page 202: ...eal 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 mu...

Page 203: ...sure 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 01...

Page 204: ...IMIT 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...

Page 205: ...her 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...

Page 206: ...tion 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 s...

Page 207: ...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 rol...

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 re...

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 shaf...

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...

Page 211: ...wise 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 vmr20...

Page 212: ...mages 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 bear...

Page 213: ...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 shi...

Page 214: ...006 022 080_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...

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...

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 t...

Page 217: ...heoretical 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 THICKN...

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...

Page 219: ...le 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...

Page 220: ...g 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 CV...

Page 221: ...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 i...

Page 222: ...ng 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...

Page 223: ...ng 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 withou...

Page 224: ...earing 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 f...

Page 225: ...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...

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 Loctit...

Page 227: ...emoved 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...

Page 228: ...n 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 Cen...

Page 229: ...cle 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 betw...

Page 230: ...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 V...

Page 231: ...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 sto...

Page 232: ...ts 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 RESIS...

Page 233: ...icator 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...

Page 234: ...D 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 0...

Page 235: ...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 Sea...

Page 236: ...nel 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 installa...

Page 237: ...uring 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...

Page 238: ...spect 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...

Page 239: ...sher 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...

Page 240: ...rk 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...

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 b...

Page 242: ...t 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...

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...

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 Microm...

Page 245: ...86 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...

Page 246: ...traight 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 o...

Page 247: ...nstalling 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...

Page 248: ...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 cl...

Page 249: ...h 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...

Page 250: ...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...

Page 251: ...place 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...

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 N...

Page 253: ...reads 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...

Page 254: ...ure 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 i...

Page 255: ...hift 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...

Page 256: ...015 037 005_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 plat...

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 Shi...

Page 258: ...CTS 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 NE...

Page 259: ...ccess 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 Pl...

Page 260: ...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...

Page 261: ...ce 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 Pl...

Page 262: ...e 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 specific...

Page 263: ...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 EC...

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: ...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...

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: ...on 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 po...

Page 268: ...rottle 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 ref...

Page 269: ...ir 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...

Page 270: ...51 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...

Page 271: ...d 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...

Page 272: ...omputer 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 veh...

Page 273: ...dule 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 indic...

Page 274: ...e 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 des...

Page 275: ...r 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 secu...

Page 276: ...k 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 r...

Page 277: ...d 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...

Page 278: ...st 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 f...

Page 279: ...s 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 tim...

Page 280: ...ropriate 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...

Page 281: ...s 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 c...

Page 282: ...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 parame...

Page 283: ...ms 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...

Page 284: ...ons 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 obstructio...

Page 285: ...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 a...

Page 286: ...r 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 b...

Page 287: ...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...

Page 288: ...r 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 b...

Page 289: ...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...

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 res...

Page 291: ...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 conn...

Page 292: ...r 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 va...

Page 293: ...es 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...

Page 294: ...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 bet...

Page 295: ...hms 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 f...

Page 296: ...sible 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 i...

Page 297: ...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 da...

Page 298: ...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 M...

Page 299: ...se 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 co...

Page 300: ...tance 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 dama...

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 magnet...

Page 302: ...le 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...

Page 303: ...it 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 fro...

Page 304: ...f 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 c...

Page 305: ...ssor 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...

Page 306: ...nformation 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 elect...

Page 307: ...us 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 Meas...

Page 308: ...mmobilizer 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 con...

Page 309: ...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...

Page 310: ...RIPTION 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...

Page 311: ...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...

Page 312: ...en 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 THROTTL...

Page 313: ...ar 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...

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 P...

Page 315: ...ables 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 pro...

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 fil...

Page 317: ...lso 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...

Page 318: ...2 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 co...

Page 319: ...il 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 f...

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 caus...

Page 321: ...ew 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 surf...

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 c...

Page 323: ...ection 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...

Page 324: ...rottle 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...

Page 325: ...ews 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 applicabl...

Page 326: ...mpressed 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...

Page 327: ...ing 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 T...

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 engin...

Page 329: ...pecification 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 va...

Page 330: ...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 fe...

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 t...

Page 332: ...METER 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...

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: ...ovides 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 F...

Page 335: ...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 bee...

Page 336: ...12 028 009_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 RE...

Page 337: ...e 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...

Page 338: ...lace 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...

Page 339: ...ker 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...

Page 340: ...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 fina...

Page 341: ...nspect 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 p...

Page 342: ...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 00...

Page 343: ...on 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 conta...

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 fue...

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...

Page 346: ...erforming 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 En...

Page 347: ...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...

Page 348: ...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 t...

Page 349: ...e 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 0...

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 Fue...

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...

Page 352: ...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 k...

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...

Page 354: ...se 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...

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 Use...

Page 356: ...nly 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 St...

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: ...ING 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 Di...

Page 361: ...arness 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...

Page 362: ...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 secondar...

Page 363: ...st 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 harn...

Page 364: ...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 rem...

Page 365: ...ector 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...

Page 366: ...te 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 En...

Page 367: ...nector 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 FURUKA...

Page 368: ...hing 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...

Page 369: ...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...

Page 370: ...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...

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 Discon...

Page 372: ...G1 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...

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...

Page 374: ...ark 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 c...

Page 375: ...eto 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...

Page 376: ...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 Requ...

Page 377: ...or 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 Te...

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...

Page 379: ...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...

Page 380: ...es 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...

Page 381: ...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...

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...

Page 383: ...oid 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 t...

Page 384: ...s 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 vmr201...

Page 385: ...RITY 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 integr...

Page 386: ...ode 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 a...

Page 387: ...nition 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...

Page 388: ...splay 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...

Page 389: ...s 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 o...

Page 390: ...ces 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...

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 in...

Page 392: ...use 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...

Page 393: ...ion 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 Acce...

Page 394: ...elector 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...

Page 395: ...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 casti...

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 res...

Page 397: ...ries 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 rela...

Page 398: ...l 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 t...

Page 399: ...s 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...

Page 400: ...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 Protectio...

Page 401: ...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 DI...

Page 402: ...ia 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...

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 14...

Page 404: ...LASH 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 29...

Page 405: ...ent 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...

Page 406: ...W 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...

Page 407: ...ave 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 Hu...

Page 408: ...plines 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 r...

Page 409: ...ncluded 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 MAINTEN...

Page 410: ...cator 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 m...

Page 411: ...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 o...

Page 412: ...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 vmr2...

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 Hous...

Page 414: ...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...

Page 415: ...pport 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 B...

Page 416: ...t 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 prop...

Page 417: ...KLASH 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 2...

Page 418: ...d 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...

Page 419: ...hen 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...

Page 420: ...d 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...

Page 421: ...e 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 det...

Page 422: ...OOT 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 H...

Page 423: ...rclip 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...

Page 424: ...n 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 pr...

Page 425: ...peller 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 a...

Page 426: ...PELLER 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 P...

Page 427: ...sult 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 pe...

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 fina...

Page 429: ...52 011_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...

Page 430: ...he 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 i...

Page 431: ...stall 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 T...

Page 432: ...Pa 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 n...

Page 433: ...l 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 TYP...

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 AN...

Page 435: ...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 Synthet...

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...

Page 437: ...ure 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 pos...

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 HARNE...

Page 439: ...r 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...

Page 440: ...o 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 subse...

Page 441: ...he 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 bushin...

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...

Page 443: ...ubsection 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...

Page 444: ...emove 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...

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...

Page 446: ...ease 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 DESCR...

Page 447: ...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 co...

Page 448: ...ted 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 reve...

Page 449: ...attery 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...

Page 450: ...ressure 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 go...

Page 451: ...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 limit...

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 bushi...

Page 453: ...ensor 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...

Page 454: ...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 Repla...

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 PRO...

Page 456: ...PS1 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 02...

Page 457: ...tops 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 sustai...

Page 458: ...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...

Page 459: ...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 un...

Page 460: ...2 039 015_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...

Page 461: ...ws 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 brack...

Page 462: ...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...

Page 463: ...alled 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 i...

Page 464: ...olumn 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 Be...

Page 465: ...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 softwar...

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 po...

Page 467: ...y 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 A...

Page 468: ...ft 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 keywa...

Page 469: ...crew 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...

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: ...se 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...

Page 472: ...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...

Page 473: ...roke 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 ar...

Page 474: ...C 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 Re...

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...

Page 476: ...r 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...

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 reve...

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 6...

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...

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: ...m 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 extr...

Page 482: ...k 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 o...

Page 483: ...ion 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 MA...

Page 484: ...g 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...

Page 485: ...rt 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 29...

Page 486: ...cription 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 S...

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 N...

Page 488: ...en 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...

Page 489: ...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 l...

Page 490: ...st 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...

Page 491: ...ic 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 greas...

Page 492: ...pt 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 VALIDA...

Page 493: ...ading 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...

Page 494: ...ect 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 t...

Page 495: ...EP 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 BR...

Page 496: ...ers 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 stre...

Page 497: ...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...

Page 498: ...arpage 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 DRIV...

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...

Page 501: ...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 vmr2...

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 i...

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 l...

Page 504: ...moved 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...

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...

Page 506: ...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 Rene...

Page 507: ...sopropyl 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 c...

Page 508: ...ender 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 it...

Page 509: ...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...

Page 510: ...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...

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 I...

Page 512: ...om 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 TORQ...

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: ...er 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 bra...

Page 515: ...ir 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 fram...

Page 516: ...5 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 Exhaus...

Page 517: ...m 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 co...

Page 518: ...5 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 Servic...

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...

Page 520: ...E 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 classificat...

Page 521: ...it 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...

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...

Page 523: ...n 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 Ser...

Page 524: ...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 Voltag...

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 Elect...

Page 526: ...oe 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 21...

Page 527: ...c 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...

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 3...

Page 529: ...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 Co...

Page 530: ...form 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 tha...

Page 531: ...ximately 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...

Page 532: ...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 M...

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 H...

Page 534: ...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 H...

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