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Can-Am commander 800R, Shop Manual


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Summary of Contents for commander 800R

Page 1: ......

Page 2: ...2011 Shop Manual CommanderTM 800R 1000 Series can am...

Page 3: ...Printed in Canada Technical Publications Bombardier Recreational Products Inc BRP Valcourt QC Canada TM Trademarks of Bombardier Recreational Products Inc BRP or its affiliates Trademarks of Bombardie...

Page 4: ...LT INSPECTION 20 DRIVE PULLEY DRIVEN PULLEY AND ONE WAY BEARING MAINTENANCE 20 CVT AIR INLET OUTLET CLEANING 20 GEARBOX OIL LEVEL VERIFICATION 21 GEARBOX OIL REPLACEMENT 21 THROTTLE BODY INSPECTION 22...

Page 5: ...ED OVER VEHICLE 35 SUBMERGED VEHICLE 35 02 ENGINE CVT AND GEARBOX 01 ENGINE REMOVAL AND INSTALLATION 37 GENERAL 38 PROCEDURES 38 ENGINE REMOVAL 38 ENGINE INSTALLATION 40 ENGINE MOUNTS 40 02 AIR INTAKE...

Page 6: ...UTCH GEAR 88 STARTER DRIVE GEARS 89 07 TOP END 91 GENERAL 96 INSPECTION 96 LEAK TEST 96 PROCEDURES 98 INTAKE MANIFOLD 98 VALVE COVER 99 ROCKER ARM 100 CYLINDER HEAD 102 CAMSHAFT 104 VALVE SPRINGS 106...

Page 7: ...OCEDURES 200 SHIFT LEVER 200 SHIFTER CABLE 201 SHIFT PLATE 202 03 ELECTRONIC MANAGEMENT SYSTEM 01 ENGINE MANAGEMENT SYSTEM EMS 205 GENERAL 206 SYSTEM DESCRIPTION 206 02 COMMUNICATION TOOLS AND B U D S...

Page 8: ...CTION 252 FUEL TANK LEAK TEST 252 FUEL PUMP PRESSURE TEST 252 TROUBLESHOOTING 255 FUEL SYSTEM DIAGNOSTIC FLOW CHART 255 PROCEDURES 256 FUEL HOSE AND OETIKER CLAMPS 256 FUEL TANK 256 FUEL PUMP 258 FUEL...

Page 9: ...ROCEDURES 283 KEY PROGRAMMING 283 07 LIGHTS GAUGE AND ACCESSORIES 285 GENERAL 285 TROUBLESHOOTING 285 DIAGNOSTIC TIPS 285 PROCEDURES 285 CONSOLE SWITCHES 285 MULTIFUNCTION GAUGE LCD AND ANALOG DIGITAL...

Page 10: ...INION 325 TIE ROD ENDS 325 KNUCKLES 326 WHEEL BEARINGS 326 03 FRONT SUSPENSION 329 GENERAL 330 PROCEDURES 330 SHOCK ABSORBER 330 SHOCK ABSORBER BUSHINGS 331 SPRINGS 331 LOWER SUSPENSION ARM 331 UPPER...

Page 11: ...CARGO BOX GAS SHOCK 371 CARGO BOX 371 08 FRAME 373 GENERAL 376 PROCEDURES 376 CAGE 376 FRAME 377 08 TECHNICAL SPECIFICATIONS 01 COMMANDER 800R AND 1000 379 09 WIRING DIAGRAM 01 WIRING DIAGRAM INFORMA...

Page 12: ...sought in case of doubt The engines and the corresponding components identified in this document should not be utilized on product s other than those mentioned in this document This manual emphasizes...

Page 13: ...ovement of its products without imposing upon itself any obligation to install them on products previously manufactured Due to late changes there may be some differ ences between the manufactured prod...

Page 14: ...6 Lower hydraulic lift and ensure vehicle is sup ported safely onto both jack stands HOISTING THE VEHICLE The vehicle may be lifted off the ground by the cage using a hoist and a lifting strap NOTICE...

Page 15: ...aps 6 Pass a tie down strap inside each rear wheel 7 Firmly attach the rear wheels tie down straps to both sides of the rear of the trailer with ratch ets 8 Ensure that both the front and rear wheels...

Page 16: ...h the procedure is contained A number of procedures throughout the book re quire the use of special tools Before starting any procedure be sure that you have on hand all re quired tools or their appro...

Page 17: ...d with a new one Illustration number for publishing process Document number for publishing process 1 r Specific torque applicable to this installation CAUTION Pay attention to torque specifications So...

Page 18: ...al cleaner CAUTION Clean magneto flywheel using only Indicates specific a clean cloth procedure to be Magneto Flywheel Removal carried out Remove muffler refer to the EXHAUST SYSTEM section Remove aco...

Page 19: ...eners are used to secure a part eg a cylinder head Some parts must be torqued according to a specific sequence and torque pattern as detailed in the installation procedure Property class and head mark...

Page 20: ...cking the fas tener LOCTITE APPLICATION PROCEDURE The following describes common procedures used when working with Loctite products NOTE Always use proper strength Loctite prod uct as recommended in t...

Page 21: ...tall stud 6 Install cover part etc 7 Apply a few drops of proper strength Loctite on uncovered stud threads 8 Install and tighten retaining nut s as required Threadlocker Application for Pre Assembled...

Page 22: ...d 3 Follow Standard Thread Repair procedure 4 Allow 30 minutes for Loctite FORM A THREAD to cure 5 Complete part assembly Gasket Compound Application 1 Proper strength Loctite 2 Loctite Primer N P N 2...

Page 23: ...installed 2 Continue parts assembly as per previous illus tration Threadlocker Application for Case In Components Metallic Gaskets 1 Proper strength Loctite 1 Clean inner housing diameter and outer g...

Page 24: ...Ela PLL 9E0 6Z9 N d 1001 103NNODSICI 60E 66Z abed S00 9E0 6ZS N d 801DVEL1X3 1N10r AD no sco 6Z9 N d 90103101dd 1JVHS INVEID LW 9E0 6M N d 1109 9N1 1001 1JVHSNNVHD OEL 9E0 6Z9 N d 39IM 3onvo AAV3H 100...

Page 25: ...661 9E0 6Z9 N d SSANHVH 311SONDVIG 013N9VV J ZZO 9E0 6Z9 N d 1001 DNIldll 3NIDN3 6Z0 9E0 6Z9 N d H01D310Hd 1V S 110 IdVHS 3A1EIG KO 9E0 6Z9 N d H311V1SN1 1V3S 110 1JVHS 3A1HG 17L1 9E0 6Z9 N d 9E E H3...

Page 26: ...N d XOEILIV3D E1311V1SN1 1V3S 110 EE0 9E0 6Z9 N d d311V1SNI 1V3S 110 E13 00 Old 616 9E0 6z9 N d 10SS31 1d1A100 91 111 1 NO1SId Egl 9E0 669 N d E1311V1SNI d1101 110 NO1S1d 1Z6 SE0 6zs N d 1 1311VISN1 d...

Page 27: ...3A1VA 0t7L 9E0 6zg N d 3A1VA 008 LZO 6Z9 N d dIAInd 31 InssaidivvrinDeA LEE abed 19U 9E0 6Z9 N d HOSS38dV 100 9NIEldS 3 V1VA X3CINI S1001 331AE3S a 690 9E0 6Z9 N d 1001 INTAINDITV DNIH331S 01 I 96 ed...

Page 28: ...INSPECTION CHART Replace Adjust lighten Lubricate Clean I Inspect ENGINE Engine oil and filter X Valve clearance X X Cylinder head screws Air filter X Engine seals X Engine mounting fasteners X Exhau...

Page 29: ...ART Replace Adjust Tighten Lubricate Clean I Inspect STEERING SYSTEM Steering system column bearing etc X Front wheel alignment BRAKES Brake fluid OCCUPANT RESTRAINT SYSTEM Seat belts X Side nets _ X...

Page 30: ...l Inspect the drive shaft joints condition Inspect the front rear propeller shaft joint condition Grease the front rear propeller shaft joints Inspect the tie rod ends Inspect shock absorbers for any...

Page 31: ......

Page 32: ...Maintenance procedures The following systems should be serviced accord ing to the PERIODIC MAINTENANCE SCHED ULE PROCEDURES AIR FILTER REPLACEMENT NOTICE Never modify the air intake system Otherwise...

Page 33: ...d in air filter housing clean it using a vacuum cleaner Install air filter Install air filter housing cover and latch all clamps Install service cover MUFFLER SPARK ARRESTER CLEANING AND INSPECTION A...

Page 34: ...arrester for any damage Replace as required For installation reverse the removal procedure However pay attention to the following Install new gasket and retaining screws PART TORQUE Tail pipe retainin...

Page 35: ...ft 1 lbf ft Replace oil filter Refer to ENGINE OIL FILTER RE PLACEMENT in this subsection Refill engine with recommended engine oil ENGINE OIL CAPACITY 2 2 L 23 25qt U S fig RECOMMENDED ENGINE OIL SEA...

Page 36: ...Install the filter into the cover Apply engine oil on 0 ring and grease on the end of filter OIL FILTER COVER SCREWS TIGHTENING TORQUE 10 N m 1 N rn 891bf in 9 lbf in RECOMMENDED ENGINE COOLANT COOLAN...

Page 37: ...e coolant expansion tank under the RH front fender COOLANT EXPANSION TANK 1 MAX level 2 MIN level 3 Operating range 8 Add coolant if level is below MIN mark Use a funnel to avoid spillage Do not overf...

Page 38: ...nt into a suitable container NOTE Take note of the position of the hose clamp on the lower radiator hose at the radiator Section 01 MAINTENANCE Subsection 03 PERIODIC MAINTENANCE PROCEDURES 1 Hose cla...

Page 39: ...Remove the pressure cap 4 Fill the cooling system until coolant comes out of the bleed screw s 5 Install the bleed screw s using NEW gasket ring s and torque as per following chart BLEED SCREW INSTALL...

Page 40: ...sure cap 16 Check coolant level in the coolant expansion tank and fill to the MIN level as required 17 Run engine at idle with the pressure cap ON until the cooling fan cycles on for a second time 18...

Page 41: ...COOLANT SPECIFIC GRAVITY CHECKas detailed in this subsection 5 Carry out a PRESSURE CAP TESTas detailed in this subsection 6 Replace engine coolant if contaminated NOTE Engine coolant should be replac...

Page 42: ...checking or adjusting the valve clearance turn crankshaft to TDC ignition of the respective cylinder refer to CAMSHAFT TIMING GEARin the TIMING CHAIN subsection Using feeler gauge check the valve clea...

Page 43: ...cracks fraying or abnormal wear Replace if necessary Check drive belt width at cord level Replace if it is out of specification see table below DRIVE BELT WIDTH SERVICE LIMIT I 30 mm 1 181 in 1 Drive...

Page 44: ...arbox 7 Magnetic drain plug 2 Seaiing ring 3 Oil filler screw 4 0 ring Dispose gearbox oil as per your local environmen tal regulations Inspection Oil condition gives information about the teeth condi...

Page 45: ...m leaks must be repaired Dam aged worn or leaking fuel system com ponents should be replaced to ensure fuel system tightness FUEL PUMP PRESSURE TEST Refer to FUEL TANK AND FUEL PUMP subsec tion for pr...

Page 46: ...NG Remove the VSS Refer to VSS REMOVAL in GEARBOX AND 4X4 COUPLING UNIT subsec tion Remove all metal particles and oil from the VSS magnet NOTE A dirty VSS will cause erratic speedometer readings FRON...

Page 47: ...n plug 2 Filler plug Install drain plug Refill the rear final drive RECOMMENDED OIL QUANTITY XPS SYNTHETIC GEAR OIL 75W 140 P N 293 600 140 or a 75W 140 API GL 5 gear oil 350 ml 12 U S oz It is possib...

Page 48: ...for any play 3 If there is any loose replace wheel bearing re fer to STEERING SYSTEM subsection NOTE To properly locate play during this inspec tion be sure to check other components for wear or loos...

Page 49: ...ustrated 5 Install 0 rings then shock sleeves 6 Install shock absorber FRONT SUSPENSION ARM LUBRICATION Lubricate suspension arm at grease fittings SUSPENSION ARM LUBRICATION SUSPENSION GREASE P N 293...

Page 50: ...r for cleaning them 3 Lubricate caliper sliders and pins using an appropriate BRAKE CALIPER SYNTHETIC GREASE Brake Disc 1 Check brake disc as follows Check disc thickness Check disc surfaces Check dis...

Page 51: ...t 2 Install the VACUUM PRESSURE PUMP P N 529 021 800 onto caliper bleeder 3 Place pump to vacuum position 4 Pump vacuum pump a few times 5 Loosen bleeder 6 Continue to pump until no more air bubbles a...

Page 52: ...ure for the other caliper bleeders 9 Check brake pedal operation If brake pedal feels spongy bleed system again then carry out the BRAKE SYSTEM PRESSURE VALIDATION as detailed in BRAKES subsection PAS...

Page 53: ......

Page 54: ...re found replace them Remove rags that were installed for storage CVT outlet hose and muffler Disconnect air inlet hose from the air filter housing and inspect for animal nests etc Reinstall hose Drai...

Page 55: ..._...

Page 56: ...ABILIZER P N 413 408 600 or an equiv alent to prevent fuel deterioration and fuel system gumming Follow the manufacturer s instructions for proper use NOTICE Fuel stabilizer should be added prior to e...

Page 57: ...or plastic parts use only flan nel clothes with XPS MULTI PURPOSE CLEANER P N 219 701 709 NOTICE It is necessary to use flannel cloths on plastic parts to avoid damaging surfaces Never clean plastic...

Page 58: ...s a t engine Drain the entire air intake sys em Inspect the throttle body Remove parts as required Replace the air filter tmr2011 006 Drain inspect and clean the CVT Empty muffler removal required Unp...

Page 59: ......

Page 60: ...5 9 lbf n 4 9 0 4 N rn 43 4 lbf in Section 02 ENGINE CVT AND GEARBOX Subsection 01 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION SERVICE TOOLS Description Part Number Page ENGINE LIF...

Page 61: ...N TRODUCTIONsubsection 3 Unplug the BLACK cable from battery then the RED cable NOTICE Always unplug battery cables ex actly in the specified order the BLACK cable first 4 Remove the front section of...

Page 62: ...S 2 Coolant plastic housing 22 Detach the shifter cable from its bracket and remove it 23 Remove the upper engine support with its rub ber isolator 7 Rubber isolator is located between frame and engin...

Page 63: ...he reverse of the removal pro cedure However pay attention to the following Prior to install engine inspect condition of engine mounts Install the rear propeller shaft onto engine output shaft Connect...

Page 64: ...Section 02 ENGINE CVT AND GEARBOX Subsection 02 AIR INTAKE SYSTEM AIR INTAKE SYSTEM SERVICE PRODUCTS Description Part Number Page LOCTITE 5910 293 800 081 44 tmr2011 008 41...

Page 65: ...1 N rn ky L 53 9 lbf in 2 5 0 5 1 l rn 22 4 lbf in Section 02 ENGINE CVT AND GEARBOX Subsection 02 AIR INTAKE SYSTEM AIR FILTER HOUSING To Throttle Body To PTO cover tm r2011 008 001 _a 42 tmr2011 00...

Page 66: ...a procedure must be reinstalled as per factory stan dards NOTICE Never modify the air intake system Otherwise engine performance degradation or damage can occur The engine is calibrated to operate spe...

Page 67: ...lation reverse the removal procedure but pay attention to the following If the intake adapter is removed reseal it with LOCTITE 5910 P N 293 800 081 and align its recess with the notch on air filter h...

Page 68: ...1 N rn 155 9 lbf in 13 1 N rn 155 9 lbf in 11 1 N m 97 9 lbf in 1 7 0 L ME Component must be replaced when removed Section 02 ENGINE CVT AND GEARBOX Subsection 03 EXHAUST SYSTEM EXHAUST SYSTEM tmr2011...

Page 69: ...pecifications must strictly be adhered to Locking devices when removed e g locking tabs elastic stop nuts self locking fasteners cotter pin etc must be replaced Hoses cables or locking ties removed du...

Page 70: ...ment 2 Remove the following parts Springs from Y exhaust pipe Imr2011 009 Rubber support Head pipe nuts 3 Remove front head pipe from vehicle according to following sub steps NOTE The space to remove...

Page 71: ...pipe LH lateral console panel refer to BODYsub section Head pipe nuts 2 Remove head pipe from the vehicle 3 Remove and discard exhaust gaskets Rear Head Pipe Inspection Check head pipe for cracks ben...

Page 72: ...TION SYSTEM LUBRICATION SYSTEM SERVICE TOOLS Description Part Number Page ADAPTER HOSE 529 035 652 52 DISCONNECT TOOL 529 035 714 52 PRESSURE GAUGE 529 035 709 52 SERVICE PRODUCTS Description Part Num...

Page 73: ...f ft Loctite 24 3 6 0 7 N rn 53 6 lbf iin 10 1 N rn 89 9 lbf in Engine oil Engine oil 4ite 0 Loctite 243 7 0 5 N rn 62 4 lbf in gpyi Component must be replaced when removed 12 1 N m 106 9 lbf in 8 1 N...

Page 74: ...BRICATION SYSTEM ENGINE LUBRICATION CIRCUIT 1 Camshaft bearings 2 Oil pressure switch 3 Oil filter Oil pressure regulator valve 5 Oil strainer 6 Oil pump 7 Crankshaft main bearings 8 Crankshaft suppor...

Page 75: ...cations check the points described in TROUBLESHOOT ING section Remove oil pressure gauge and adapter hose NOTE To remove adapter hose from oil pressure gauge use the DISCONNECT TOOL P N 529 035 714 Re...

Page 76: ...ce valve stem seals 3 Worn piston rings blue exhaust smoke Replace piston rings PROCEDURES OIL COOLER Oil Cooler Removal Drain engine oil Refer to ENGINE OIL CHANGE in the PERIODIC MAINTENANCE PROCEDU...

Page 77: ...e resistance be tween as shown OPS CONNECTOR ENGINE NOT RUNNING ENGINE RUNNING PIN RESISTANCE S2 4 Engine ground Close to 0 52 normally closed switch Infinite open when pressure reaches 20 kPa to 40 k...

Page 78: ...ring for free length NOTE Replace worn or damaged components Clean bore and thread in the magneto housing from metal shavings and other contaminations Oil Pressure Regulator Installation For installat...

Page 79: ...her damages Check for scratches in crankcase between outer rotor and oil pump bore If so replace damaged parts Check oil pump cover for damages and for surface straightness with a straightedge 1 Oil p...

Page 80: ...E When the axial clearance of the oil pump shaft assembly increases the oil pressure de creases tmr2011 010 Oil Pump Installation For installation reverse the removal procedure Pay attention to the fo...

Page 81: ...r for cracks or other dam age Replace if damaged Oil Strainer Installation The installation is the reverse of the removal pro cedure REED VALVE The engine is equipped with a reed valve which prevents...

Page 82: ...KIT 529 036 056 76 FLUKE 115 MULTIMETER 529 035 868 68 HANDLE 420 877 650 78 LARGE HOSE PINCHER 529 032 500 64 66 OIL SEAL PUSHER 529 035 757 78 ROTARY SEAL PUSHER PLATE 529 036 130 74 SEAL PUSHER 529...

Page 83: ...2 10 2 N m 88 18 lbf in 3 0 5 N rn 27 4 lbf in Engine 3 0 5 N rn 27 4 lbf in Section 02 ENGINE CVT AND GEARBOX Subsection 05 COOLING SYSTEM RADIATOR 8008 Engine IZE3 Component must be replaced when r...

Page 84: ...4 lbf in Engine 3 0 5 Wm 27 4 lbf in j 10 2 N m 10 8 I 8 18 lbf in 1 _ 4 tr _ 3 0 5 N rn 27 4 lbf in Engine Imm Component must be replaced when removed I 2011011 101_a Section 02 ENGINE CVT AND GEARB...

Page 85: ...e 111 5 _t 0 6 N rn 44 5 lbf in 411111 Loctite 243 5 0 6 N rn 44 5 lbf in 6 0 7 N rn 53 6 lbf in 6 0 7 NI rn 53 6 lbf in 0 111 16 2 N rn 142 18 lbfqn Loctite 243 CTS See EFI Section 02 ENGINE CVT AND...

Page 86: ...f in 0 Loctite 243 6 0 7 N m 53 6 lbf in Loctite 243 5 0 6 Nem 44 5 lbf in 20 2 Nem 15 1 lbf ft 10 1 N m 89 9 lbf in Engine oil 2 5 0 3 N m 22 3 lbf in CZ Molycote 111 Section 02 ENGINE CVT AND GEARBO...

Page 87: ...ocking fasteners etc PROCEDURES THERMOSTAT The thermostat is a single action type Thermostat Location 8008 Models The thermostat is located in the thermostat hous ing at the top of the front cylinder...

Page 88: ...hose lower hose RH side similar 2 Drain remainder of cooling system refer to PERIODIC MAINTENANCE PROCEDURES subsection 1000 Models with Thermostat Access thru LH Front Wheel Well 3 Remove service co...

Page 89: ...N rn 0 6 N rn 531bf in 5Ibf in 1000 Models Reverse removal procedures All Models Refill cooling system Bleed cooling system refer to PERIODIC MAIN TENANCE PROCEDURES subsection NOTICE The cooling sys...

Page 90: ...ubber bushings between bottom of radiator and radiator support 3 Ensure the vent hose on the cooling fan motor is properly rooted as prior to removal NOTE Cooling fan vent hose must pass over the top...

Page 91: ...Test Radiator Cooling Fan 1 Remove relay 2 Use the FLUKE 115 MULTIMETER P N 529 035 868 and select the 52 position 3 Probe relay as follows TERMINAL RESISTANCE 30 87 Open circuit OL 4 Connect battery...

Page 92: ...nderneath the dashboard on the driver s side 1 Cooling fan fuse Fuel Pump Enabled Disabled Activate Fuel Pump ooling Fan 1 Accesory Relay 1 Cooling Fan activation button If fan turns on check CTS wiri...

Page 93: ...arness and connectors good NO Repair or replace defective part s YES 4 Try a new ECM I Is fan working Radiator Cooling Fan Removal 1 Disconnect fan motor electrical connector 2 Remove fan motor vent t...

Page 94: ...ads Remove by turning coun terclockwise and install by turning clockwise Water Pump Impeller Inspection Check impeller for cracks or other damage Re place impeller if damaged Water Pump Impeller Insta...

Page 95: ...E Be careful not to damage the crankcase while removing outer part of the rotary seal 4 Thoroughly remove carefully sealing residue and burr of rotary seal using a scraper NOTICE Be careful not to dam...

Page 96: ...TALLATION 4 Ensure that the oil seal is properly seated in wa ter pump cavity TYPICAL 1 Oil seal properly seated Rotary Seal NOTICE Read and thoroughly understand the entire procedure of installing th...

Page 97: ...urface If required grind the pusher bolt 1 4 x tubes 70mm 2 75in length 2 4 x screws M6 x 85 3 Plane surface on pusher bolt 8 Apply a little grease at the end of tool pusher bolt 9 Ensure that the pus...

Page 98: ...flat washer P N 420 227 935 onto water pump shaft 17 Install M8 x 1 25 nut P N 233 281 414 onto water pum p shaft 1 M8 robust flat washer P N 420 227 935 2 M8 x 1 25 nut P N 233 281 414 Repeat the st...

Page 99: ...mediate driven gear on water pump shaft 1 Circlip 2 Water pump gear 3 Remove the Water pump intermediate driven gear Needle pin Thrust washer 1 Water pump intermediate driven gear removed 2 Needle pin...

Page 100: ...ifices for oil seal removal Water Pump Shaft Seal Inspection Disassembled Engine Inspect water pump gear for wear and damage on the snap mechanism to the needle pin Replace if damaged Check water pump...

Page 101: ...sher When installing the oil seal on the pusher make sure the sealing lip points outwards Push NEW oil seal in place 1 Oil seal 2 Installer handle with oil seal pusher Apply DOW CORNING 111 P N 413 70...

Page 102: ...ump shaft with rotary seal must rotate freely NOTICE A missing thrust washer will cause a Tighten screws of the water pump housing cross leaking rotary seal wise 1 Water pump intermediate driven gear...

Page 103: ......

Page 104: ...FT PROTECTOR 529 036 034 86 MAGNETO DIAGNOSTIC HARNESS 529 036 199 84 85 MAGNETO PULLER 529 035 748 86 SERVICE PRODUCTS Description Part Number Page DREI BOND SEALING COMPOUND 420 297 906 83 LOCTITE 6...

Page 105: ...lubricant 25 3 N m 18 2 lbf ft tmr2011 012 001_a 10 1 N m 89 9 lbf in 11 1 N m 97 9 lbf in 150 10 N m 111 7 lbf ft See ELECTRONIC FUEL INJECTION EFI 6 0 7 N m 53 6 lbf in Drei Bond sealing compound Lo...

Page 106: ...ie raps Disconnect magneto connector Remove dipstick and oil level tube with 0 rings 1 Dipstick 2 Oil level tube 3 Crank position sensor CPS 4 0 rings Remove magneto cover retaining screws 1 Magneto c...

Page 107: ...Access Refer to BODYand remove upper console Stator Static Test Continuity 1 Disconnect the magneto connector 2 Install the MAGNETO DIAGNOSTIC HARNESS P N 529 036 199 on magneto connector mag neto si...

Page 108: ...ge as per following table TEST ENGINE SPEED TERMINAL VOLTAGE 4000 RPM 1 and 2 10 25 Vac 1 and 3 2 and 3 tmr2011 012 7 If voltage is lower than specification replace stator 8 Re plug connectors properl...

Page 109: ...t clogged 1 Rotor 2 Oil bore Check keyway of the rotor for wear or damages Check if trigger wheel teeth are bent or otherwise damaged Check woodruff key and keyway on the crank shaft for wear or damag...

Page 110: ...lutch gear 1 Starter double gear 2 Sprag clutch gear 3 Intermediate gear SPRAG CLUTCH Sprag Clutch Removal Remove MAGNETO COVER See procedure in this subsection Heat screws in order to break the Locti...

Page 111: ...installation reverse the removal procedure Pay attention to the following details Apply LOCTITE 648 GREEN P N 413 711 400 on threads of sprag clutch housing screws Install screws but do not torque yet...

Page 112: ...tarter double gear 3 Starter gear 4 Location Ins Starter Drive Gear Removal Remove MAGNETO COVER See procedure in this subsection Remove location pins starter double gear and in termediate gear Starte...

Page 113: ...f...

Page 114: ...PISTON RING COMPRESSOR 529 035 919 112 TDC DIAL INDICATOR 414 104 700 97 VALVE GUIDE INSTALLER 529 036 140 110 VALVE GUIDE REMOVER 5 MM 529 035 924 110 VALVE SPRING COMPRESSOR CUP 529 035 764 106 VALV...

Page 115: ...9 lbf in 10 1 N m 89 9 lbf in 6 0 7 Nom 53 6 lbf in Loctite 243 Engine i oil 10 1 N m 89 9 lbf in Loctite 243 6 0 7 N m 53 6 lbf in Engine oil See ELECTRONIC FUEL INJECTION EFI Engine oil 20 2 5 Nem...

Page 116: ...n 12 1 N m 106 9 lbf in See tightening procedure Engine oil 12 1 N m 106 9 lbf in Component must be replaced 6 Engine oil Loctite 648 when removed 10 1 N rn 89 9 lbf in Section 02 ENGINE CVT AND GEARB...

Page 117: ...See tightening procedure 20 2 N m 5 1 5 lbf ft See Ignition System Engine oil 6 Engine oil 10 1 N rin 89 9 lbf in Engine oil 6 6 Loctite 648 Component must be replaced when removed 0 Section 02 ENGIN...

Page 118: ...Section 02 ENGINE CVT AND GEARBOX Subsection 07 TOP END CYLINDERS AND PISTONS Imr2011 013 95...

Page 119: ...ts cotter pin etc must be replaced When disassembling parts that are duplicated in the engine e g valves it is a strongly rec ommended to note their position PTO MAG side front rear cylinder and to ke...

Page 120: ...is at ignition TDC To turn crankshaft there are two possible proce dures First Procedure Turn the drive pulley Second Procedure 1 Remove plug screw with 0 ring from magneto cover 2 Use a 14 mm Allen...

Page 121: ...ews Air escaping into crankcase area means exces sively worn cylinder and or broken piston rings Air oil escaping from crankcase means dam aged gasket and or loosened screws refer to BOTTOM END subsec...

Page 122: ...NG SCREWS TIGHTENING TORQUE 20 N rn 2 5 N m 15 lbfeft 2 lbf ft Enable fuel pump using B U D S VALVE COVER Valve Cover Removal To remove cylinder 1 valve cover remove plenum Remove valve cover screws o...

Page 123: ...TIMING CHAIN subsection Remove timing chain tensioner and camshaft tim ing gear refer to TIMING CHAIN subsection Remove pan head screw and camshaft retaining plate 1 Rocker arm shaft 2 Rocker arm exh...

Page 124: ...eck adjustment screws for free movement cracks and or excessive play 1 Free movement of adjustment screw top Rocker Arm Shaft Check for scored friction surfaces if so replace parts Measure rocker arm...

Page 125: ...l the remaining coolant in cylin der head could overflow into the engine and a little quantity of coolant could drop into the engine In this case the engine oil will be contaminated Disconnect spark p...

Page 126: ...haft bearing journal spark plug side Cylinder Head Installation NOTE Never invert front and rear cylinder heads On the 800R cylinder heads are not identical For installation reverse the removal proced...

Page 127: ...equipped with two different camshafts 1 Intake cam 2 Exhaust cam 3 Camshaft of cylinder 1 4 Camshaft of cylinder 2 5 Flat spot Camshaft Removal The removal procedure is the same for both camshafts Eac...

Page 128: ...EW 32 950 mm to 33 150 mm 1 2972 in to 1 3051 in SERVICE LIMIT 32 930 mm 1 2965 in CAMSHAFT LOBE INTAKE NEW 32 890 mm to 33 090 mm 1 2949 in to 1 3028 in SERVICE LIMIT 32 870 mm 1 2941 in 1000 CAMSHAF...

Page 129: ...he following details NOTICE The camshafts are not identical in design Do not invert the camshafts during assembly Any mix up of the components will lead to engine damage Place the camshaft retaining p...

Page 130: ...00 mm 1 535 in Replace valves springs if not within specifications Valve Spring Installation For installation reverse the removal procedure Pay attention to the following details Colored area of the...

Page 131: ...ls whenever valves are re moved Valve Inspect valve surface check for abnormal stem wear and bending If out of specification replace by a new one VALVE OUT OF ROUND INTAKE AND EXHAUST VALVES NEW 0 005...

Page 132: ...Ensure to seat valves properly Apply some lap ping compound to valve face and work valve on its seat with a lapping tool see VALVE GUIDE PRO CEDURE in this subsection Measure valve face contact width...

Page 133: ...ee CYLINDER HEAD in this subsection Remove valves see VALVES in this subsection NOTE Clean valve guide area from contamination before removal Using the VALVE GUIDE REMOVER 5 MM P N 529 035 924 and a h...

Page 134: ...sure to seat valves properly Apply marking paste to ease checking contact pattern Repeat procedure until valve seat valve face fits together CYLINDER Cylinder Removal Remove chain tensioner see CHAIN...

Page 135: ...ake the same measuring points like de scribed in CYLINDER TAPER above A Perpendicular to crankshaft axis B Parallel to crankshaft axis Cylinder Installation For installation reverse the removal proced...

Page 136: ...ve one piston circlip and discard it 1 Piston circlip NOTE The removal of both piston circlips is not necessary to remove piston pin Push piston pin out of piston 1 Piston 2 Piston pin Detach piston f...

Page 137: ...sed piston is not worn If clearance exceeds specified tolerance replace piston by a new one and measure piston cylinder clearance again NOTE Make sure the cylinder bore gauge indica tor is set exactly...

Page 138: ...piston pin Insert piston pin into piston and connecting rod For each cylinder install piston with the punched arrow on piston dome is pointing toward the rear side of the engine Front cylinder Mark on...

Page 139: ...properly CORRECT POSITION OF THE PISTON CIRCLIP PISTON RINGS Ring Removal Remove the piston see PISTON in this subsec tion Ring Inspection Ring Piston Groove Clearance Using a feeler gauge measure eac...

Page 140: ...eeler gauge check ring end gap Replace ring if gap exceeds above described specified tol erance Ring Installation For installation reverse the removal procedure Pay attention to the following details...

Page 141: ......

Page 142: ...ING CHAIN TIMING CHAIN SERVICE TOOLS Description Part Number Page CAMSHAFT TIMING TOOL CRANKSHAFT TDC POSITION TOOL 529 529 036 036 201 200 123 124 126 128 SERVICE PRODUCTS Description Part Number Pag...

Page 143: ...N rn 53 6 lbf in Loctite 243 6 0 7 N rn 53 6 lbf in Loctite 243 4 5 0 5 N m 40 4 lbf in Engine oil 0 1 N rn 0 89 lbf in Loctite 243 10 1 N m 89 9 lbf in Loctite 243 10 1 N rn 89 9 lbf in Section 02 E...

Page 144: ...chain tensioner 3 WORN OUT TIMING CHAIN GUIDE S Replace timing chain guide s 4 STRETCHED TIMING CHAIN OR WORN OUT TIMING GEARS Replace timing chain and timing gears 5 LOOSE TIMING GEAR RETAINING SCREW...

Page 145: ...e sure that the camshaft timing gear can be moved back and forth MOVE GEAR BACK AND FORTH Apply engine oil on the plunger before installation Slightly turn the camshaft timing gear in order to get the...

Page 146: ...r Remove the camshaft timing gear NOTE Secure timing chain with a piece of wire Camshaft Timing Gear Inspection Check camshaft timing gear for wear or deteriora tion If gear is worn or damaged replace...

Page 147: ...NG CHAIN TENSIONER in this subsection Apply LOCTITE 243 BLUE P N 293 800 060 on the camshaft timing gear retaining screw threads Install and tighten camshaft timing gear retaining screws to specified...

Page 148: ...covers of both cylinders Remove the plug and 0 ring of magneto cover 1 CPS 2 Screw Use a 14 mm Allen key to turn crankshaft until piston 2 rear is at TDC ignition 1 Allen key 14 mm When rear piston is...

Page 149: ...r 2 Cylinder head base To lock crankshaft at TDC ignition proceed as fol lows Insert CRANKSHAFT TDC POSITION TOOL P N 529 036 200 in CPS orifice to lock crankshaft in posi tion Make sure to match the...

Page 150: ...280 counterclockwise until marks on magneto fly wheel 1 and magneto cover are aligned CYLINDER 1 AT TDC IGNITION 1 Mark 1 on magneto flywheel 2 Notch on magneto cover 3 Location of crankshaft positio...

Page 151: ...PTO side behind the PTO cover Timing Chain Removal Magneto Side Refer to MAGNETO SYSTEM subsection and re move following parts Magneto cover Rotor Sprag clutch gear Refer to TOP END subsection and rem...

Page 152: ...excessive radial play CHECKING TIMING CHAIN RADIAL PLAY Check chain condition for wear and teeth condi tion 1 Timing chain If chain is excessively worn or damaged replace it as a set camshaft timing g...

Page 153: ...sioner Side Refer to TIMING CHAINin this subsection Timing Chain Guide Inspection Tensioner Side Check timing chain guide for wear cracks or de forming Replace if necessary Timing Chain Guide Installa...

Page 154: ...5 617 146 DRIVE SHAFT OIL SEAL INSTALLER 529 036 028 135 DRIVE SHAFT OIL SEAL PROTECTOR 529 036 029 137 PLAIN BEARING REMOVER INSTALLER 529 036 032 139 PLAIN BEARING REMOVER INSTALLER 529 035 917 143...

Page 155: ...ntiseize lubricant 4 Super Lube grease 4 Loctite 5910 4 Section 02 ENGINE CVT AND GEARBOX Subsection 09 BOTTOM END ENGINE DRIVE SHAFT Engine oil Loctite 5910 10 1 N m 6 89 9 lbf in 4 Super Lube grease...

Page 156: ...10 1 N rrl Super 89 9 lbf ri Lube grease 5 0 6 N rn 44 5 lbf in 25 3 Nl rn 18 8 lbf ft 0 Engine oil 0J Engine oil 10 1 NI rri 89 9 lbf in Loctite 243 Engine oil Super Lube grease Section 02 ENGINE CV...

Page 157: ...Loctite 243 Engine oil See torquing procedure inside See torquing procedure inside Engine oil 1141111110 1 11 rn 89 9 lbf in it Section 02 ENGINE CVT AND GEARBOX Subsection 09 BOTTOM END CRANKSHAFT L...

Page 158: ...ve the engine Refer to ENGINE REMOVAL AND INSTALLATIONsubsection To remove the rear oil seal the gearbox has to be removed from the engine Refer to GEARBOX AND 4X4 COUPLING UN Tsubsection To replace d...

Page 159: ...Engine Drive Shaft Installation The installation is the reverse of removal proce dure Pay attention to the following details Clean all metal components in solvent Crankcase surfaces and bearing cover...

Page 160: ...for axial play of the drive shaft PTO COVER OIL SEAL To replace oil seal it is not necessary to remove engine from vehicle PTO Oil Seal Removal Refer to CONTINUOUSLY VARIABLE TRANSMIS SION CVT subsect...

Page 161: ...Driven pulley CVT air guide Disconnect vent hose Remove PTO cover screws and pull PTO cover PTO Cover Inspection Check the PTO cover for cracks or other damage Replace PTO cover if damaged Clean oil b...

Page 162: ...arings Use a press only Carefully remove the PTO oil seal with a screw driver without damaging the PTO cover Push out the plain bearings from the outside towards the inside using the PLAIN BEARING RE...

Page 163: ...n bearings must be positioned near to oil bore in counter clockwise direction 1 Partition 2 PTO cover inside 3 Oil bore PTO Cover Installation For installation reverse the removal procedure Pay attent...

Page 164: ...ipped with a breather gear which prevents engine oil coming out through the breathing system into the air intake system Check if oil seal is brittle hard or damaged Re place if necessary Drive Gear In...

Page 165: ...sing 11 Refer to LUBRICATION SYSTEMsection to re move following parts Oil filter Oil cooler Oil pump drive gear NOTE Oil pump removal from crankcase is not necessary but recommended to see condition o...

Page 166: ...SERVICE LIMIT I 42 100 mm 1 6575 in Clean crankcase using a part cleaner Dry crankcase using compressed air Blow the oil supply lines Oil Strainer Clean the engine oil strainer same procedure as for...

Page 167: ...rankcase support sleeve under crankcase halves before installing the plain bearings refer to BEARING REMOVAL PROCE DURE Carefully press in the plain bearings in the same di rection as during disassemb...

Page 168: ...Oil the plain bearings before mounting the crank shaft NOTICE Correctly reinstall crankshaft refer to CRANKSHAFT Properly reinstall engine oil strainer and screws Reinstall water pump shaft shafts gea...

Page 169: ...rankcase PTO side front side Use a 14 mm Allen key to turn crankshaft until piston 2 rear is at TDC When rear piston is at TDC marks on magneto fly wheel 2 and on the magneto cover are aligned 1 Mark...

Page 170: ...otherwise damaged 1 Crankshaft timing gears Crankshaft Axial Play NOTE Axial play needs to be measured before splitting the crankcase Measure play on PTO end using a dial indicator CRANKSHAFT AXIAL P...

Page 171: ...ed initially Carry out the tightening procedure described in CRANKSHAFT ASSEMBL Yin this subsection A Connecting rod big end plain bearing BOOR Engine CRANKSHAFT PIN DIAMETER NEW 40 009 mm to 40 025 m...

Page 172: ...over Refer to PTO COVER in this sub section 1 Micrometer 2 Crankshaft journal PTO support bearing CRANKSHAFT JOURNAL DIAMETER PTO COVER BEARING NEW 34 016 mm to 34 040 mm 1 339 in to 1 34 in SERVICE L...

Page 173: ...y They are not reusable 800R Engine Tighten screws in the following sequence CONNECTING RODS SCREWS TIGHTENING SEQUENCE 1 Tighten to 1 2 of specified torque 2 Tighten to 20 N rn 2 Nom 15 lbf ft 1 lbf...

Page 174: ...wrench NOTE Do not apply any thread locker 1 Angle torque wrench NOTICE Failure to strictly follow this proce dure may cause screw to loosen and lead to se vere engine damage Crankshaft Installation...

Page 175: ...Section 02 ENGINE CVT AND GEARBOX Subsection 09 BOTTOM END 1 Crankcase half MAG side 2 Connecting rod cylinder 1 3 Connecting rod cylinder 2 152 tmr2011 014...

Page 176: ...SERVICE TOOLS Description Part Number Page CLUTCH PULLER 529 035 746 159 DRIVE PULLEY HOLDER CVT 529 006 400 158 DRIVEN CLUTCH HOLDER 529 035 771 166 GEAR LOCK PIN 529 035 747 157 SERVICE PRODUCTS Des...

Page 177: ...N CVT Loctite 243 10 1 N rn 89 9 lbf in Isoflex grease Topas NB 52 60 7 N rn 44 5 lbf ft Isoflex grease Topas NB 52 Pulley flange cleaner 00 5 0 6 N rn 44 5 lbf in 120 8 N m 89 6 lbf ft 7 0 8 N rn 62...

Page 178: ...Section 02 ENGINE CVT AND GEARBOX Subsection 10 CONTINUOUSLY VARIABLE TRANSMISSION CVT tmr2011 015 155...

Page 179: ...med by an authorized Can Am dealer Subcompo nent installation and assembly tolerances re quire strict adherence to procedures detailed NOTICE Never use any type of impact wrench at drive pulley remova...

Page 180: ...IGHTENING SEQUENCE CVT COVER SCREWS TIGHTENING TORQUE 7 N m 0 8 Nom 62 lbf in 7 lbf in DRIVE BELT Drive Belt Removal CVT cover and air outlet must be cleaned Remove CVT COVER TYPICAL 1 Driven pulley e...

Page 181: ...liding sheave and governor cup to ensure correct index ation at reinstallation 1 Mark on drive pulley sliding sheave 2 Mark on governor cup Block the drive pulley using one of the following methods Fi...

Page 182: ...Sliding sheave of drive pulley is spring loaded 1 Thrust washer 2 Conical spring washer 3 Drive pulley screw 4 Sliding sheave with governor cup Step 1 Push Slowly release and remove sliding sheave Sc...

Page 183: ...Use a flat screwdriver if necessary 1 Slider shoe Put governor cup on a vice to push out bearing sleeve of roller in the foreseen direction against arrow Use an appropriate punch diameter of punch mus...

Page 184: ...rankshaft tapered end and the taper inside the fixed sheave of the drive pulley crankshaft threads and threads of drive pulley screw NOTICE Avoid contact between cleaner and crankshaft seal because da...

Page 185: ...slider shoes at the same time Check slider shoes for visible wear and replace if damaged NOTE If necessary use a screwdriver to remove slider shoes ROLLER OUTER DIAMETER NEW 13 70 mm to 13 80 mm 539 i...

Page 186: ...pulley will oc cur because of levers difference Sliding Sheave Check sliding sheave for cracks and sliding con tact surface for excessive wear Replace sliding sheave if necessary Measure centrifugal...

Page 187: ...w one CLUTCH SPRING SQUARENESS SERVICE LIMIT I 4 mm 157 in One Way Clutch Check bearings for excessive play and smooth op eration Replace one way clutch if necessary NOTICE Be careful not to damage th...

Page 188: ...bearing sleeve 2 Mating surface of slider shoes 3 Vice Each time when replacing the bearing sleeves sign the foreseen box with a punch NOTICE Do not tap too hard Violent damage of the governor cup ma...

Page 189: ...ew with jobber ones Always use BRP genuine parts for this particular case Section 02 ENGINE CVT AND GEARBOX Subsection 10 CONTINUOUSLY VARIABLE TRANSMISSION CVT To tighten the drive pulley screw lock...

Page 190: ...of driven pulley 3 Spring 4 Cam Driven Pulley Disassembly Fixed Sheave Remove retaining ring and lift torque gear 1 Retaining ring 2 Torque gear 3 Fixed sheave of driven pulley Section 02 ENGINE CVT...

Page 191: ...wool and dry cloth Use PULLEY FLANGE CLEANER P N 413 711 809 to clean driven pulley Clean the CVT air guide area from contamination Using a paper towel with PULLEY FLANGE CLEANER P N 413 711 809 to c...

Page 192: ...NOMINAL 30 060 mm to 30 100 mm 1 183 in to 1 185 in SERVICE LIMIT 30 200 mm 1 189 in Fixed Sheave Check fixed sheave for cracks and excessive wear Replace fixed sheave if necessary Check ball bearing...

Page 193: ...SPRING FREE LENGTH SERVICE LIMIT I 125 mm 4 921 in CLUTCH SPRING SQUARENESS SERVICE LIMIT I 3 8 mm 15 in Driven Pulley Assembly For installation reverse the removal procedure Pay attention to followin...

Page 194: ...ance sleeve must face gearbox side 1 0 ring 2 Distance sleeve 3 Chamfered area of distance sleeve Install cam on countershaft end the right way on the countershaft splines 1 Countershaft splines 2 Cam...

Page 195: ...bf ft Bend the locking washer in order to lock the driven pulley screw 1 Bent locking washer CVT AIR GUIDE CVT Air Guide Removal Remove the DRIVE PULLEY and the DRIVEN PULLEY Unscrew the clamps retain...

Page 196: ...M ADAPTER TOOL 529 036 166 178 FLUKE 115 MULTIMETER 529 035 868 176 180 HANDLE 420 877 650 182 OIL SEAL INSTALLER GEARBOX 529 035 758 182 OIL SEAL INSTALLER 529 036 204 183 SERVICE TOOLS OTHER SUPPLIE...

Page 197: ...octite 5910 3 0 3 N m 27_ 3 lbf in Loctite 243 28 3 N m 21 2 lbf ft 6 0 7 N rn 53 6 lbf in Loctite 243 6 Engine oil 25 3 N m 18 8 lbf ft EWA Engine oil Super Lube grease 6 Loctite 243 10 1 N m 89 9 lb...

Page 198: ...sensor VSS 4 Actuator 5 4WD indicator switch 1 Center housing 2 Left cover 3 Countershaft 4 Output shaft 5 Shift shaft TROUBLESHOOTING UNUSUAL GEARBOX NOISE AND OR VIBRATIONS 1 Low oil level in gearb...

Page 199: ...1 from main relay R2 VSS Input Voltage Test 1 Use the FLUKE 115 MULTIMETER P N 529 035 868 and select Vdc 2 Turn ignition switch ON 3 Back probe the VSS connector using FLUKE RIGID BACK PROBE P N TP8...

Page 200: ...its values for proper operation A reset must be carried out each time any of the following parts has been replaced Gearbox assembly Shift drum GBPS ECM 1 Connect vehicle to the latest applicable vers...

Page 201: ...Select an other position P R H or L Re peat substeps 8 2 and 8 3 until all position are verified NOTE The vehicle must be in movement to complete the procedure on R H and L posi tion GBPS Access To re...

Page 202: ...sition Sensor GBPS GBPS Installation For installation reverse the removal procedure Pay attention to the following details Shift lever must be in the NEUTRAL position Align GBPS with the flat on the s...

Page 203: ...nd connector from fuel pump Actuator Test Using the FLUKE 115 MULTIMETER P N 529 035 868 check if the 2WD 4WD selector works prop erly Unplug actuator connector Turn ignition key ON Measure vo tage as...

Page 204: ...led correctly Remove actuator and reinstall it Place ignition switch to ON position and select the 2WD position Turn front wheel again The front propeller shaft should turn easily If the front propell...

Page 205: ...n Shift plate from shift shaft The shift shaft oil seal can be removed without removing the gearbox from the vehicle Use a suitable tube with the proper diameter to install the oil seal If gearbox hou...

Page 206: ...re beginning the installation ensure gearbox is set to PARK position Apply SUPER LUBE GREASE P N 293 550 030 on sealing lips Apply engine oil on outer diameter of oil seal to avoid damaging it during...

Page 207: ...e it from engine Gearbox Disassembly NOTE During gearbox disassembly inspect the condition of each part closely Gearbox Left Cover Set gearbox to NEUTRAL position Unscrew all bolts retaining the gearb...

Page 208: ...clockwise and remove index washer 1 Index lever 2 Index washer 3 Shift drum Remove the index lever with washer step ring and spring 1 Washer 2 Index lever 3 Step ring 4 Index spring Main Shaft and Sh...

Page 209: ...fting sleeve HIGH range gear 2 Shift fork Section 02 ENGINE CVT AND GEARBOX Subsection 11 GEARBOX AND 4X4 COUPLING UNIT Remove shifting sleeve HIGH range gear and shift fork 1 Snap ring 2 Free pinion...

Page 210: ...aft assembly Gearbox Right Cover Remove ACTUATOR and GBPS GEARBOX PO SITION SENSOR see procedures in this subsec tion Unscrew all bolts retaining the gearbox right cover 1 5 screws M8 x 55 2 2 screws...

Page 211: ...AND 4X4 COUPLING UNIT 1 Screw 2 Washer 3 Intermediate gear 4 Dowel pin Remove shift fork shaft Disengage shift forks from shift drum 1 Shift drum 2 Thrust washer Output Shaft and 4x4 Coupling Mechanis...

Page 212: ...G Clean oil outside and inside from housing before heating NOTICE Always support gearbox housings properly when ball bearings are removed Housing damages may occur if this procedure is not performed c...

Page 213: ...dogs and slots Worn shift fork engagement groove Worn splines on shafts and shifting sleeves Bearings Check if ball bearings turn freely and smoothly Check all bearings bearing points tooth flanks an...

Page 214: ...1 Bearing pin A Outer diameter BEARING PIN OUTER DIAMETER NEW 24 987 mm to 25 000 mm 984 in to 984 in SERVICE LIMIT 24 977 mm 9833 in Check countershaft bearing journals for wear A MAG side B Bearing...

Page 215: ...s Shift Forks Check both shift forks for visible damage wear or bent shift fork claws Check engagement rollers for wear and smooth movement Measure the shift fork claw thickness I Micrometer A Shift f...

Page 216: ...ss machine only If necessary heat housings up to 100 C 212 F before installing ball bearings A WARNING Clean oil outside and inside from housing before heating Place new bearing in freezer for 10 minu...

Page 217: ...ft assembly with shift fork LOW REVERSE range gear into inner splines of shifting sleeve HIGH range gear Install reverse intermediate gear Finally engage shift forks in shift drum and install shift fo...

Page 218: ...s in their corresponding groove on the shift drum Install shift fork shaft NOTE Turn gears to validate proper operation Sealing Compound Application NOTE Unless otherwise specify the procedure to appl...

Page 219: ...ngage parking lock lever slot onto index washer pin 1 Left cover 2 Parking lock lever slot 3 Index washer pin Install all screws on left cover and tighten them as per following sequence nstall 0 ring...

Page 220: ...rbox Installation For installation reverse the removal procedure Pay attention to following Before gearbox installation check 0 ring in bearing cover if brittle hard or damaged Replace if nec essary 7...

Page 221: ......

Page 222: ...5 1 5 N rn 137 13 lbf in 24 5 3 5 N rn 18 3 lbfqt 24 5 3 5 N rn 18 3 lbf t CE Model 9 1 N rn 80 9 lbf in Section 02 ENGINE CVT AND GEARBOX Subsection 12 SHIFTER SHIFTER trnr2011 017 100a tmr201 1 017...

Page 223: ...pins etc NOTICE Hoses cables and locking ties re moved during a procedure must be reinstalled as per factory standards PROCEDURES SHIFT LEVER Shift Lever Access 1 Refer to BODYsubsection and remove t...

Page 224: ...Tighten shift lever handle nut to specification SHIFT LEVER HANDLE NUT TORQUE 15 5 N m 1 5 N m 137 lbf in 13Ibf in Adjust shifter cable refer to SHIFTER CABLE AD JUSTMEIVTin this subsection Check if...

Page 225: ...Readjust as required NOTE To properly check shift lever alignment into notch move shift lever toward the RH side then let it return to position SHIFT PLATE Shift Plate Removal NOTE Do not remove shift...

Page 226: ...f the removal pro cedure However pay attention to the following Place gearbox in NEUTRAL position before shift plate installation Install and align shift plate using marks previously traced If shift p...

Page 227: ...204...

Page 228: ...8 100_a COOLING FAN CPS Crankshaft Position Sensor CTS Cooling Temperature Sensor ECM Engine Control Module ETA Electric Throttle Actuator FRONT FUEL PUMP GBPS GearBox Position Sensor IGN COIL Ignitio...

Page 229: ...es a permanent memory that will store the information on the various ignition keys programmed to the vehicle fault codes cus tomer information and other engine information even when the battery is rem...

Page 230: ...Section 03 ELECTRONIC MANAGEMENT SYSTEM Subsection 01 ENGINE MANAGEMENT SYSTEM EMS under certain fault conditions For more informa tion refer to DIAGNOSTIC SYSTEM AND FAULT CODES tmr2011 018 207...

Page 231: ......

Page 232: ...status lights that indicate the connection condition USB and CAN Both lights must be GREEN for the MPI 2 to function prop erly Otherwise refer to the following charts Prerequisite for USB Communicati...

Page 233: ...d remove the connec tor from the module and test for the following Proper input voltage to the module Ground circuit continuity CAN bus continuity Refer to the applicable WIRING DIAGRAM or appropriate...

Page 234: ...in its protective cap on the lower RH side of the bat tery rack 1 Diagnostic connector NOTE Do not mismatch the diagnostic connector with the one on the LH side of the battery rack This connector has...

Page 235: ...rry out setting changes For more information pertaining to the use of the B U D S software use its Help menu which con tains detailed information on its functions Always use the latest applicable B U...

Page 236: ...file is avail able in B U D S to update at least one of the elec tronic modules NOTE If an update file is available on BOSSWeb but the B U D S software being used is not up to date the update icon wi...

Page 237: ...tic connector in its protective cap TYPICAL 1 File description Writing Changes Saving to a Module 1 When making a data or setting change in a mod ule using B U D S save the new data or set ting in the...

Page 238: ...ll turn on or blink 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 v...

Page 239: ...s may be viewed in the Faults page of B U D S Only fault codes in an active state may be viewed in the multifunction gauge Active Fault Codes An active fault code is an indication of a fault that is p...

Page 240: ...gital Gauge Proceed as follows to view the active fault codes 1 Turn ignition key to ON with lights position GNITION SWITCH POSITION 1 OFF 2 ON with lights turn key to this selection 3 ON 2 Wait for t...

Page 241: ...re to view all active fault codes To exit the fault code display function press both the M and S buttons simultaneously LCD Gauge 1 Turn ignition key to ON with lights position GNITION SWITCH POSITION...

Page 242: ...battery voltage is low when the engine is running at idle RPM the ECM will command an increase in RPM to a set value thereby increasing the charging system output in order to prevent the battery from...

Page 243: ......

Page 244: ...he accelerator pedal demand less if normal mode is selected Vehicle speed is limited to 70 km h 43 MPH Performance Key When a performance key is used engine delivers 100 of the accelerator pedal deman...

Page 245: ...e Mode When certain faults are occurring the ECM will enter the limp home mode In this mode the en gine will deliver less than the accelerator pedal de mand PROCEDURES SPORT NORMAL SWITCH Sport Normal...

Page 246: ...g on the pedal position which confirms the TAS signal reaches the ECM ACCELERATOR PEDAL RETAINING NUTS TIGHTENING TORQUE 13 Nom 1 Nom 1151bf in 9Ibf in Carry out the ECM FIRST INITIALIZATION refer to...

Page 247: ......

Page 248: ...ectronic fuel injection system EFI is com prised of various sensors used for detecting ongo ing operating conditions of the engine and vehicle and includes all the components that perform the required...

Page 249: ...ails which are used to secure the injectors to the manifold also provide to the injectors the fuel pressure that they receive from the fuel pump The fuel pressure applied to the fuel rails is regu lat...

Page 250: ...ated Problems It is important to check the following in the elec trical system Battery voltage Fuses Ground connections Wiring and connectors Ensure that all electronic components are genuine OEM Any...

Page 251: ...If the operation is successful a message will be displayed stating that the reset was successful If an error occurred or a component is out of range a message may be displayed Follow the instructions...

Page 252: ...following Main relay Wiring and connections refer to the WIRING DIAGRAM Continuity Test of ECM Ground Circuits 1 Disconnect connector B from ECM 2 Install the ECM ADAPTER TOOL P N 529 036 166 on ECM...

Page 253: ...owing methods If the faulty ECM can be read with B U D S refer to ECM AUTOMATED DATA TRANSFER If the faulty ECM cannot be read with B U D S refer to ECM MANUAL DATA ENTRY ECM Automated Data Transfer T...

Page 254: ...rts ECM Manual Data Entry There are 2 possible methods to collect the re quired information The 1st being the easiest 1 Use B U D S to obtain the data from a saved mpem file on your PC computer 2 Coll...

Page 255: ...2 Record the following numbers using BOSSWeb Look in Service menu and choose Unit history 1 Vehicle serial number 2 Vehicle model number 3 Customer name 3 Enter the recorded data in the new ECM as de...

Page 256: ...not enter the M at the beginning of the engine number 3 Customer name VEHICLE TAB 6 Click on the following tabs History Part Replacement Add Part in History 7 Enter the old ECM serial number in the Ad...

Page 257: ...ION SYSTEM subsection Engine condition Fuel Injector Balance Test Using B U D S NOTICE After fuel injector activation using B U D S always crank engine in drowned mode to ventilate engine and prevent...

Page 258: ...e fuel injector to be tested TYPICAL 1 Click on injector to activate You should hear the injector functioning This will validate the injector mechanical and elec trical operation If the injector does...

Page 259: ...d 12 Vdc REAR TYPICAL If supply voltage is not good check continuity between fuse F5 and injector see WIRING DIA GRAMS NOTE Probe fuse exactly as shown This vali dates fuse at the same time Use a mult...

Page 260: ...gine oil to 0 rings to ease insertion in rail Install fuel injector with your hand Do not use any tool Position the manifold 0 ring on injector as in fol lowing illustration TYPICAL MANIFOLD 0 RING PO...

Page 261: ...Installation For installation reverse the removal process how ever pay attention to the following Install new clamps using pliers as per removal if fuel rail was replaced Install fuel rail and evenly...

Page 262: ...CAUTION Ensure ignition key is removed so that nobody can activate the electrical sys tem otherwise the ECM would turn on and the throttle actuator ETA would cycle This could cause serious finger inj...

Page 263: ...y set TPS may lead to improper idle speed too low or too high poor engine performance poor engine starting and engine stop on deceleration fault codes and possible engine damage Emission compli ance m...

Page 264: ...the throttle body using a blunt tool without sharp tip A CAUTION Do not move throttle plate with your fingers Otherwise if ECM should turn off it would quickly close the throttle plate which could ca...

Page 265: ...tion NOTE Take into account that a CPS fault can be triggered by bent or missing encoder wheel teeth First check fault codes using B U D S then check the encoder wheel teeth condition if necessary ref...

Page 266: ...ance value is incorrect repair the connec tors or replace the wiring harness between ECM connector and the CPS CPS Replacement Disconnect CPS connector and cut harness lock ing tie Remove CPS retainin...

Page 267: ...ure reading while the engine is stopped 4 Perform the same test with a new MAPTS and compare both readings Values have to be within 3 4 kPa 0 5 PSI MAPTS PRESSURE FUNCTION QUICK TEST RESULT SERVICE AC...

Page 268: ...el same ambient air temperature If there is no reading carry out a MAPTS RESIS TANCE TEST TEMPERATURE FUNCTION MAPTS Resistance Test Temperature Function Disconnect the connector from the MAPTS Using...

Page 269: ...f in LOCTITE 243 BLUE P N 293 800 060 CTS COOLANT TEMPERATURE SENSOR CTS Access The CTS is located on the LH of the engine aft cylinder To access it remove the Driver s seat LH lateral console panel T...

Page 270: ...value is correct refer to ECM RE PLACEMENT If resistance value is incorrect repair the connec tors or replace the wiring harness between ECM connector and the CTS CTS Replacement 1 Disconnect CTS conn...

Page 271: ......

Page 272: ...er Page ECM ADAPTER TOOL 529 036 166 259 FLUKE 115 MULTIMETER 529 035 868 258 FUEL HOSE ADAPTER 529 036 023 253 OETIKER PLIERS 295 000 070 256 PRESSURE GAUGE 529 035 709 253 VACUUM PRESSURE PUMP 529 0...

Page 273: ...Section 04 FUEL SYSTEM Subsection 03 FUEL TANK AND FUEL PUMP CE Model 6 Component must be replaced when removed 250 tmr2011 023...

Page 274: ...disconnect the fuel pump electrical connector to disable fuel pump and crank engine to release fuel pressure prior to disconnecting any fuel hose Cover the fuel hose connections with an ab sorbent sho...

Page 275: ...bsection and remove the fol lowing RH passenger seat RH lateral console panel Fuel tank cover panel 3 Remove the vent hose from the fuel tank vent valve 4 Using the VACUUM PRESSURE PUMP P N 529 021 80...

Page 276: ...ER P N 529 036 023 be tween disconnected hose and fuel rail in line installation PRESSURE GAUGE T FITTING 9 Using B U D S reactivate fuel pump by select ing Enabled 1 Click here to disable the fuel pu...

Page 277: ...FUEL TANK AND FUEL PUMP A slow pressure drop after the engine is stopped indicates leakage either from a fuel injector or from the fuel pressure regulator Check fuel injectors for leaks If not leakin...

Page 278: ...Fuel pump runs Replace fuel pump module Repair or replace Fuel pressure less than specifications Fuel pressure within specifications Fuel pressure more than specifications A Fails A Fails Check fuel...

Page 279: ...en validate fuel system tightness by performing a fuel pressure test Oetiker Clamp Replacement To secure or cut Oetiker clamps on fuel lines use OETIKER PLIERS P N 295 000 070 1 Securing clamp 1 Secur...

Page 280: ...12 Pull fuel tank out from the RH side of vehicle Fuel Tank Inspection Inspect fuel tank for any damages or cracks which may result in fuel leaks Inspect tank and protector attachment points for damag...

Page 281: ...Fuel pump should come ON for a few seconds then stop If fuel pump does operate as in previous steps carry out the following Check fuel pump fuse Check in B U D S for applicable fault codes Refer to CO...

Page 282: ...he fuel pump fuse 2 Remove connector B from the ECM and con nect it to the ECM ADAPTER TOOL P N 529 036 166 3 Set multimeter to Q 4 Measure fuel pump resistance as follows FUEL PUMP RESISTANCE TEST AT...

Page 283: ...l pump locking ring A WARNING Fuel vapors are flammable and explosive un der certain conditions Use only non spark ing tools FUEL PUMP LOCKING RING REMOVAL 1 Notch in fuel pump locking ring 7 Carefull...

Page 284: ...ng ring until it is fully engaged FUEL PUMP LOCKING RING INSTALLATION 1 Notch in locking ring 2 Raised portion in locking ring 5 places 3 Lock position on tank flange 5 places 7 Using B U D S enable t...

Page 285: ...d replace fuel pump 6 Insert the new strainer on fuel pump making sure to press it in tightly against pump face 7 Press in a NEW push nut to secure strainer 8 Reinstall remaining removed parts FUEL LE...

Page 286: ...oltage If battery voltage is not read test wiring continuity between sender and multifunction gauge If wiring continuity is good replace multifunction gauge If continuity is not obtained repair or rep...

Page 287: ...ws freely through the valve when upside down and the vacuum indication does not increase on the pump gauge Fuel Tank Vent Valve Removal and Installation 1 When removing or installing the fuel tank ven...

Page 288: ...AGE REGULATOR RECTIFIER ACCESSORIES RELAY R3 0 0 0 0 0 52 F7 5A SWITCHES ILLUMINATION 2WD 4WD SWITCH WINCH SWITCH STARTER RELAY GAUGE F8 5A IGNITION SWITCH WINCH RELAY COMMUNICATION CONNECTOR 000000 F...

Page 289: ...A 11 30 A 12 15 A 13 5 A 14 15 A 15 5 A RELAY IDENTIFICATION Relays 1 Cooling fan 2 Main 3 Accessories 4 Headlights 8 Brake lights FUSE BOX 2 FUSE IDENTIFICATION Fuse 1 Main 30 A 2 Fan accessories 40...

Page 290: ...ation with each other at a rate of about every 20 milliseconds CAN lines consist of a pair of wires WHITE BEIGE and BEIGE GREEN If a component or system malfunction is detected a module ECM or multifu...

Page 291: ......

Page 292: ...AND FAULT CODES subsection Always refer to the WIRING DIAGRAM when troubleshooting an electrical circuit Refer to POWER DISTRIBUTION for fuse and re lay information DIAGNOSTIC GUIDELINES The following...

Page 293: ...ORANGE D E S S signal E ORANGE RED 12 Vdc output ECM starter solenoid and start switch F BLACK YELLOW Ignition Coil Access Refer to BODYand remove upper console Ignition Coil Installation Install a n...

Page 294: ...ngs Disconnect ECM A connector and connect it to the ECM ADAPTER TOOL P N 529 036 166 Using a multimeter check resistance in primary windings as follows PRIMARY CIRCUIT ENGINE NE CONCTOR HIC ECM CONN...

Page 295: ...is TYPICAL 1 Overheated light grey white 2 Normal light brown brown 3 Fouled black wet or dry dark deposits grey melted coating The plug face reveals the condition of the engine operating condition me...

Page 296: ...eceives AC current from the mag neto and transforms it into direct current DC The voltage regulator included in the same unit limits voltage to prevent any damage to electrical components TYPICAL VOLT...

Page 297: ...O SYSTEM subsection TROUBLESHOOTING It is good practice to check for fault codes using the B U D S software as a first troubleshooting step Refer to DIAGNOSTIC SYSTEM AND FAULT CODES subsection BATTER...

Page 298: ...into the test check battery voltage TIME TO MEASURE INTO TEST VOLTAGE 14 seconds Min 10 5 Vdc 20 C 68 F Battery Removal 1 Disconnect BLACK cable first then the RED cable NOTICE Always respect this or...

Page 299: ...he reverse of removal procedure however pay attention to the following Install the battery with the positive post down Tighten battery strap retaining nut to the speci fied torque BATTERY STRAP RETAIN...

Page 300: ...he ignition switch is left ON for more than 15 minutes engine will not start unless igni tion switch is turned OFF then ON again TROUBLESHOOTING It is good practice to check for fault codes using the...

Page 301: ...itch is OFF 2 Disconnect pins SS1 and SS2 from starter sole noid 3 Disconnect ECM connector B 4 Connect ECM ADAPTER TOOL P N 529 036 166 to the ECM connector B 5 Set multimeter to diode check 6 Test d...

Page 302: ...attery terminal 3 Momentarily connect SS2 to the chassis ground If starter runs carry out the STARTER SOLENOID INPUT VOLTAGE TEST If starter does not run carry out the STARTER SO LENOID WINDING RESIST...

Page 303: ...ns test other starting system compo nents Starter Removal Turn OFF ignition switch Disconnect BLACK cable from battery A WARNING Always disconnect BLACK cable first and reconnect last Disconnect RED c...

Page 304: ...E NUT TIGHTENING TORQUE PRODUCT 6 Nom 53Ibfoin DIELECTRIC GREASE P N 293 550 004 First connect RED cable to battery then con nect the BLACK cable Connect battery cables A WARNING Always connect RED ca...

Page 305: ......

Page 306: ...also be erased in dividually or all at once Note that the D E S S circuitry is already activated on all new ECM TROUBLESHOOTING DIAGNOSTIC TIPS NOTE It is a good practice to check for fault codes usi...

Page 307: ...ing 5m2011 079 001 1913011 001 052_ a Modtie Tools Help vrer 2006 012 100_50r Section 05 ELECTRICAL SYSTEM Subsection 06 DIGITALLY ENCODED SECURITY SYSTEM D E S S 0 Grime Ft Free roe frce 1 2 ea r7 r...

Page 308: ...al connections Make sure they are tight make good contact and are corrosion free Dirty loose or corroded contacts are poor conductors and are often the source of a system or component malfunction Pay...

Page 309: ...m fuse 1 of fuse block 2 Supplied with main relay activated Fuse 4 of fuse block 1 from main relay R2 Multifunction Gauge Removal 1 Remove gauge cover 2 Disconnect gauge connector 3 Release retaining...

Page 310: ...011 030 007_a Imr2011 030 006_b Custer Language lEnglistt 1m12011 030 006_c Section 05 ELECTRICAL SYSTEM Subsection 07 LIGHTS GAUGE AND ACCESSORIES Click on the Reset Service button 7 Reset Service bu...

Page 311: ...Activation and Cluster tabs Click on the WOW Test button TYPICAL 1 WOW Test button Indicator Lights Monitoring Select Monitoring and Cluster tabs Use the Cluster Lamp Active box to monitor dif ferent...

Page 312: ...t to high beam headlights 3 BLUE HEADLIGHT LOW HIGH BEAM SWITCH EUROPE IN MULTIFUNCTION SWITCH FUNCTION PIN COLOR 12 volt input from headlights relay MGC 4 GREEN 12 volt output to high beam headlights...

Page 313: ...n below the headlight horizontal center line scribed on a test surface 5m 16 ft away NOTE Load vehicle as per normal use Measure headlight center distance from the ground Scribe a line at this height...

Page 314: ...from brake light switch relay winding input 1 1B RED ORANGE 12 volt output to LH brake light 11A WHITE ORANGE Relay winding ground to ground terminal BK2 12A BLACK BRAKE LIGHT SWITCH FUNCTION PIN COL...

Page 315: ...al BN4 is connected to the diodes used to prevent electric arcs in the switch WINCH SWITCH FUNCTION PIN COLOR 12 volt input from fuse 7 2 RED BLACK 12 volt output to relay winding IN 1 GREEN BLUE 12 v...

Page 316: ...ires the yellow wire at rear and the blue one at front Install a new cotter pin on the hook pin TURN SIGNALS HAZARD EC MODELS ONLY Turn Signal Wire Identification FLASHER MODULE FUNCTION PIN COLOR 12...

Page 317: ...e block 1 from fuse 2 of fuse box 2 HORN EC MODELS ONLY Horn Wire Identification HORN SWITCH IN MULTIFUNCTION SWITCH FUNCTION PIN COLOR 12 volt input from fuse F10 MGB 1 ORANGE GREEN 12 volt output to...

Page 318: ...REMENT TOOL 529 035 665 301 CV JOINT EXTRACTOR 529 036 005 299 OETIKER PLIERS 295 000 069 299 OETIKER PLIERS 295 000 070 299 SPANNER SOCKET 529 035 649 301 SERVICE PRODUCTS Description Part Number Pag...

Page 319: ...lbf ft 70 5 N rn 52 4 lbf in XPS Synthetic grease See STEERING SYSTEM To Engine 75 5 N rn 2_41 55 4 lbf in See BRAKES Loctite 271 225 15 N rn 166 11 lbf ft Component must be replaced when removed nlri...

Page 320: ...24 2 lbf ft 12 11 1 33 3 N m 24 2 lbf ft 10 11 12 0 4I Mira 8 13 r T r 14 7 5 0 5 N rn 66 4 lbf in _J NEW Loctite 277 XPS Synthetic grease 180 15 N rn 133 11 lbf ft LEFT HAND THREADED MEI Component mu...

Page 321: ...s a pressure proportional to wheel speed differential meaning the difference in rotational speed be tween the two wheels This pressure engages the friction clutch via a piston to transmit the torque I...

Page 322: ...inner splines should be done Front Drive Shaft Installation The installation is the reverse of the removal pro cedure However pay attention to the following Install a NEW stop ring 1 Stop ring Apply...

Page 323: ...front fascia Remove the radiator Refer to COOLING SYSTEM subsection Remove bolts that attach winch bracket to the frame XT models Remove front screw and rear nut securing the LH lower differential su...

Page 324: ...o Lok carrier pinion gear or housing is are changed Install recommended shims accordingly with the following table RECOMMENDED SHIMS PINION GEAR 1 67 mm 0 04 mm 066 in 002 in BACKLASH 0 5 mm 02 in for...

Page 325: ...se preload shim by 0 05 mm 002 in and check drag torque again Front Differential Assembly Visco Lok Carrier Ring Gear To assemble reverse the removal procedure Pay attention to the following Check con...

Page 326: ...ove the differential forwards Dislodge the propeller shaft from the engine and differential Remove front propeller shaft Front Propeller Shaft Inspection Inspect if propeller shaft is not bent or twis...

Page 327: ...shaft U joint as shown for proper grease fitting location Install bearing caps Use a vise to insert bearing caps Using a suitable pusher fully seat bearing cap on one side Install snap ring Grease U j...

Page 328: ...EMENT TOOL 529 035 665 313 CV JOINT EXTRACTOR 529 036 005 309 OETIKER PLIERS 295 000 069 309 OETIKER PLIERS 295 000 070 309 SPANNER SOCKET 529 035 649 312 SERVICE PRODUCTS Description Part Number Page...

Page 329: ...grease 70 5 N rn 52 4 lb in 79 22 5 2 5 N rn 17 2 lbf ft 70 5 Nom 52 4 lbf in 75 5 Nom 55 4 lbf in Loctite 271 trn r2011 032 001_a XPS Synthetic grease 225 15 N rn 166 11 lbf4 Component must be repla...

Page 330: ...XPS Synthetic grease Component must be replaced when removed 32 5 3 5 N m 24 3 lbf ft 1 12 11 10 1 32 5 3 5 N rn 24 3 lbf ft 12 Loctite 7 5 0 5 N rn 277 66 4 lbf in 1 180 15 N rn 133 11 lbf ft LEFT H...

Page 331: ...NTRODUC TION section for proper procedure Remove the wheel Remove the following parts Cotter pin Wheel hub nut Belleville washer 1 Cotter pin 2 Wheel hub nut 3 Belleville washer NOTE On RH side remove...

Page 332: ...n The installation is the reverse of the removal pro cedure However pay attention to the following Install a NEW stop ring 1 Stop ring After drive shaft insertion in rear final drive vali date if prop...

Page 333: ...inal drive yoke 5 Remove rear final drive bolts Refer to REAR FINAL DRIVE in this subsection 6 Move the rear final drive rearward to dislodge the propeller shaft 7 Dislodge the propeller shaft from th...

Page 334: ...pusher fully seat bearing cap on one side nstall snap ring Complete installation for the other bearing caps Grease U joint Refer to PERIODIC MAINTE NANCE PROCEDURES subsection REAR FINAL DRIVE Rear Fi...

Page 335: ...o keep track of shims no 2 on ring gear no 3 Extract ring gear out of half housing NOTE The pinion nut is left hand threaded Un screw by turning clockwise Remove the bearing no 6 at the same time as t...

Page 336: ...k on tab A 25 4mm 1 in Position the dial indicator tip against the tab at a 90 angle and right on the previously scribed mark Gently move the tab back and forth Note the re sult Rotate pinion gear 1 2...

Page 337: ...n 24 lbf ft 3 lbf ft Pinion Gear To install reverse the removal procedure Pay at tention to the following Replace the 0 ring no 13 Install the shim s no 8 then the ball bearing no 6 Install a new need...

Page 338: ...e us ing the vehicle Tire pressure changes with tem perature and altitude Recheck pressure if one of these conditions has changed TIRE PRESSURE FRONT REAR MIN 69 kPa 10 PSI 83 kPa 12 PSI MAX USE WHEN...

Page 339: ...st to 3 N rn 1 N m 27 lbf in 91bf in following the illustrated sequence NOTE To ensure even pressure on the beadlock clamp ring tighten screws a few turns at a time FIRST AND SECOND TIGHTENING SEQUENC...

Page 340: ...just enough to be able to unscrew them once the vehicle will be off the ground Lift and support the vehicle Refer to INTRODUC TION subsection Remove nuts then remove wheel Wheel Inspection Inspect whe...

Page 341: ...07 CHASSIS Subsection 01 WHEELS AND TIRES TIGHTENING SEQUENCE NOTICE Always use the recommended wheel nuts for the type of wheel Using a different nut could cause damages to the rim or studs 318 tmr2...

Page 342: ...ection 02 STEERING SYSTEM STEERING SYSTEM SERVICE TOOLS Description Part Number Page STEERING ALIGNMENT TOOL 529 036 059 321 SERVICE PRODUCTS Description Part Number Page XPS SYNTHETIC GREASE 293 550...

Page 343: ...fty XPS synthetic grease o m fi 1 eV v 0 0 31 3 N rn 23 2 lbf ft ff at 48 6 Nl rn 35 4 lbf ft 34 2 N m 25 1 lbf ft 72 7 Nl m 53 5 lbf ft 5 1 Nl rn 44 9 lbf in See tightening sequence 24 5 3 5 Nl rn 18...

Page 344: ...TEERING ALIGNMENT 1 Place vehicle on a level surface 2 Inflate tires to recommended pressure 3 Find rack and pinion center to center as follows 3 1 Calculate the total steering wheel rota tions from s...

Page 345: ...not touch the first spacer of tool TYPICAL 14 Slowly move rope back until it makes contact with spacer TYPICAL 15 Keep rope in this position 16 Measure distance of the front wheel between rope and ri...

Page 346: ...C TIPS Turning Radius Unequal If vehicle turns more on one side than the other check rack and pinion center to center Refer to STEERING ALIGNMENTin this subsection PROCEDURES 50 Nom 5 Nom 37 lbf ft 4...

Page 347: ...on The installation is the reverse of the removal pro cedure However pay attention to the following Prior to installing the steering column place front wheels parallel with longitudinal plane of vehic...

Page 348: ...frame SOME PARTS REMOVED FOR CLARITY PURPOSE 6 From the LH side remove rack and pinion from vehicle Rack and Pinion Installation The installation is the reverse of the removal pro cedure However pay a...

Page 349: ...all NEW cotter pin Both ends of cotter pins must be folded 11 Install front wheel 12 Check the steering alignment refer to STEER ING ALIGNMENTin this subsection KNUCKLES Knuckle Removal 1 Safely lift...

Page 350: ...ve circlip 1 Seal 2 Circlip 4 Install knuckle on a press 5 Use an appropriate bearing remover 6 Remove bearing from knuckle NOTE It may be necessary to heat the knuckle to remove bearing A WARNING Cle...

Page 351: ......

Page 352: ...5 4 lbf ft Suspension ____6 grease matu cLI 48 6 Nem 35 4 lbf ft ME D All except X I model I X model Cl Suspension grease 1 1 1 1 I233 Component must be replaced when removed tn 2011 075 100_a Section...

Page 353: ...d Refer to INTRODUCTION subsection 2 Remove bolts and nuts retaining shock ab sorber 1 Upper bolt 7 Lower bolt 3 Remove shock absorber Shock Absorber Inspection Remove spring from shock absorber Refer...

Page 354: ...cedures LOWER SUSPENSION ARM Lower Suspension Arm Removal 1 Safely lift and support the vehicle off the ground Refer to INTRODUCTION subsection 2 Remove wheel refer to WHEELS AND TIRES subsection NOTE...

Page 355: ...scard cotter pin retaining ball joint 1 Ball joint cotter pin 5 Remove ball joint nut and washer 1 Ball joint nut 2 Ball joint hardened washer 6 Carefully move brake hose aside 7 Using a plastic hamme...

Page 356: ...RIODIC MAINTENANCE PROCEDURES subsection Install a NEW cotter pin to secure ball joint nut Both end of cotter pin must be folded SHOCK ABSORBER NUTS TORQUE 48 NI rn 6 Nom 35 lbf ft 4 lbf ft SUSPENSION...

Page 357: ...appropriate ball joint remover 5 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 ins...

Page 358: ...ft 1 i i 1 I 3 w 3 111 I iI 110 10 Nom f N _ 48 6 Nom 35 4 lbf ft 4 I 35 4Ibf ft 48 6 Nom re tit 110 10 N m 81 7 Ib t Suspension grease Section 07 CHASSIS Subsection 04 REAR SUSPENSION REAR SUSPENSIO...

Page 359: ...ground Refer to INTRODUCTION subsection 2 Open cargo box 3 Remove bolts and nuts retaining shock ab sorber 1 Upper bolt 1 Lower bolt 4 Remove shock absorber Shock Absorber Inspection Remove spring fro...

Page 360: ...YPICAL 5 Install a NEW bushing as the reverse of re moval 6 Install shock absorber on vehicle SPRINGS Spring Removal 1 Remove shock absorber from vehicle Refer to SHOCK ABSORBERS in this subsection 2...

Page 361: ...installation is the reverse of the removal pro cedure However pay attention to the following Install all retaining screws of anti sway bar loosely first Torque retaining screws of anti sway bar accor...

Page 362: ...10 Remove trailing arm from vehicle Trailing Arm Disassembly Drive Shaft Bearing Removal 1 Remove circlip securing bearing into trailing arm 1 Circlip 2 Install trailing arm on a press 3 Use an appro...

Page 363: ...f each pivot bearing with your finger Bearings should turn smoothly and quietly Replace all damaged parts Trailing Arm Assembly and Installation The installation is the reverse of the removal pro cedu...

Page 364: ...RVICE TOOLS Description Part Number Page ECM ADAPTER TOOL 529 036 166 344 SERVICE PRODUCTS Description Part Number Page COSMO RUBBER GREASE 293 550 055 346 LOCTITE 243 BLUE 293 800 060 347 XPS PARTS A...

Page 365: ...6 G3 XPS Synthetic Grease T1 5 0 11 l rn 44 9 Ib n T2 5 5 1 5 Nl rn 49 13 lbf in T3 15 5 Nl rn 133 44 lbf in T4 19 3 NJ m 168 27 IbMn T5 25 5 NI m 18 4 lbf ft T6 28 5 1 5 NJ m 21 1 lbf ft T7 48 6 N r...

Page 366: ...d NOTICE Avoid spilling brake fluid on plastic rubber or painted parts Protect these parts with a rag when servicing brake system NOTICE Sealing washers must be discarded and replaced with new ones ev...

Page 367: ...nnector 2 Check switch operation as follows BRAKE LIGHT SWITCH POSITION PIN RESISTANCE Firmly pushed 1 2 Close to 0 52 Released Infinite 01_ If switch is defective replace with a new one If the switch...

Page 368: ...light switch retaining rear brake hose SOME PARTS REMOVED FOR CLARITY PURPOSE 1 Brake light switch 2 Rear brake hose 3 Sealing washers 4 Unscrew front brake hoses from master cylin der tmr2011 037 SO...

Page 369: ...d down to check if there is a free play MASTER CYLINDER ROD REMOVED 3 Remove master cylinder retaining bolts and nuts 1 Master cylinder retaining bolts 4 Remove master cylinder from vehicle Master Cyl...

Page 370: ...is the reverse of the removal pro cedure However pay attention to the following If caliper was removed for replacement Refill and bleed brake system refer to PERI ODIC MAINTENANCE PROCEDURES subsec t...

Page 371: ...SC MINIMUM THICKNESS FRONT 4 1 mm 161 in REAR 4 1 mm 161 in NOTICE Brake discs must never be ma chined 3 Check warpage of the disc MAXIMUM DISC WARPAGE FRONT 0 2 mm 01 in REAR Brake Disc Replacement 1...

Page 372: ...000 070 359 BODY Parts Nomenclature 1 Driver seat 2 CVT air inlet cover 3 LH front fender 4 LH headlight trim 5 Hood 6 Front fascia 7 Service cover 8 RH headlight trim 9 RH front fender 10 Front late...

Page 373: ...COCKPIT PASSENGER SIDE Parts Nomenclature 1 Lower console 2 Upper console 3 RH inner kick panel 4 Glove box 5 Right front bulkhead 6 Right floor panel 7 Right lateral console panel 8 Fuel tank cowl 9...

Page 374: ...R SIDE Parts Nomenclature 1 Lower console 2 Upper console 3 LH inner kick panel 4 Bulkhead access panel 5 Left front bulkhead 6 Dash 7 Left floor panel 8 Left lateral console panel 9 Under seat storag...

Page 375: ...n 2 5 0 5 N rn 22 4 lbf in 2 5 0 5 N rn 22 4 lbf in 41 4 5 0 5 N m 40 4 lbf in trnr2011 038 004_a 1 6 0 4 N rn 14 4 lbf in 1 1 6 0 4 N m 14 4 lbf in 44 9 Ibf in 5 1 N m L 1 6 0 4 N rn 14 4 lbf in Sect...

Page 376: ...m 18 4 lbf in T2 2 5 0 5 N m 22 4 Ib n T3 3 5 0 5 N m 31 4 lbf in T4 6 5 0 5 N m 58 4 lbf in tmr2011 038 005ra Section 07 CHASSIS Subsection 06 BODY SIDE BODY PARTS Torques and Service Products tmr20...

Page 377: ...2 0 5 N m 18 4 lbf in 4 5 0 5 N rn 40 4 lbf in II C 1 4 1 i CE Model 2 5 0 5 N m 22 4 lbf in Section 07 CHASSIS Subsection 06 BODY COCKPIT TRIMS DRIVER SIDE Torques and Service Products tmr2011 038 0...

Page 378: ...8 4 Ib n 2 0 5 N rri 18 4 lbf in 2 5 0 5 Ni m 22 4 lbf in 2 5 0 5 f I m 22 4 lbf in Section 07 CHASSIS Subsection 06 BODY COCKPIT TRIMS PASSENGER SIDE Torques and Service Products tmr2011 038 016_a tm...

Page 379: ...lbf in 4 5 0 5 N m 40 4 lbf in 2 0 5 N m 18 4 lbf in 5 5 0 5 N m 49 4 lbf in 2 0 5 N m 18 4 lbf In 2 5 0 5 N m 22 4 lbf in Section 07 CHASSIS Subsection 06 BODY COCKPIT STRUCTURE PANELS PASSENGER SIDE...

Page 380: ...m oy 18 411g in 5 5 0 5 N rri 49 4 lbf in 2 5 0 5 N rn 22 4 lbf in 43 2 0 5 N m 18 4 lbf in 2 5 0 5 N m 22 4 lbf in 5 5 0 5 N rn 49 4 lbf in Section 07 CHASSIS Subsection 06 BODY COCKPIT STRUCTURE PA...

Page 381: ...Section 07 CHASSIS Subsection 06 BODY SEATS 358 tmr2011 038...

Page 382: ...decal can roll off when rubbing with your finger Pull decal slowly and when necessary apply more heat to ease removal on the area that has to be peeled off If decal tears while pulling off it has to...

Page 383: ...ower console The installation is the reverse of the removal pro cedure LATERAL CONSOLE PANELS Lateral Console Panels Removal and Installation 1 Remove seat 2 Remove plastic rivets securing the lateral...

Page 384: ...erse of the removal procedure GLOVE BOX REMOVAL AND INSTALLATION 1 Remove the glove box trim 1 Glove box trim 2 Remove glove box retaining screws 1 Glove box retaining screws 3 Pull glove box to remov...

Page 385: ......

Page 386: ...OX CARGO BOX TRIMS 1mr2011 043 001a 5 1 N rn 2 0 5 N m 44 9 lbf in 18 4 lbf in 411111 44 9 lbf in 5 1 N m c le wow lip itikomikii f Iiillilitt 0 i 18 4 Ibf in 7 2 0 5 N m 4111 alai tr 0 1 V 47 5 1 N r...

Page 387: ...Loctite 406 14 glue 6 5 1 N rn 44 9 lb n 5 1 f l rn 44 9 lbf in 6 Loctite 406 glue Section 07 CHASSIS Subsection 07 CARGO BOX CARGO BOX TILT RELEASE MECHANISM 1mr2011 043 002_a 364 tmr2011 043...

Page 388: ...11 1 N rn 97 9 lbf in 11 1 N ni 97 9 lbf in 4 0 5 N ni 35 4 lbf in Section 07 CHASSIS Subsection 07 CARGO BOX CARGO BOX SUPPORT tm r201 1 043 003_a tmr2011 043 365...

Page 389: ...lbf in 5 1 N m 44 9 lbf in 2 2 0 2 N m 19 2 Ibf in 7 1 N m 62 9 lbf in 2 2 0 2 Nom 19 2 lbf in 5 1 N m 44 9 Ibf in 5 1 N m 44 9 lbf in Section 07 CHASSIS Subsection 07 CARGO BOX UPPER TAIL GATE tmr20...

Page 390: ...5 0 5 N rn 22 4 lbf in 7 1 N rn 62 9 lbf n 5 1 N rri 44 9 lbf in 41 11 2 5 0 5 NI m 22 4 lbf in 2 2 0 2 N rn 5 1 N rn 19 2 lbf in 44 9 lbf in 5 1 N rn 44 9 lbf in 2 5 0 5 N rn 22 4 lbf n 7 1 N rn 62...

Page 391: ...4 9 lbf in 5 1 N m 44 9 lbf in 2 0 5 N rn 18 4 lbf in T 1 5 1 N rn 44 9 lbf in 2 0 5 N rn 18 4 lbf in Section 07 CHASSIS Subsection 07 CARGO BOX CARGO BOX ACCESSORIES XT model tmr2011 043 006_a 368 tm...

Page 392: ...ligned when The gap between the cargo box and rear lat eral panel is equalled on each side 19 mm 3 4 in Cargo box side and rear lateral panel are flushed The top of cargo box side may be raised for a...

Page 393: ...o box retainer 3 2 Using a small hammer reposition the cargo box retainer Temporarily retighten bolts 3 3 Close the cargo box and check the cargo box retainer gap CARGO BOX RETAINER GAP 1 Cargo box re...

Page 394: ...new one 5 Remove supports and lower cargo box CARGO BOX Cargo Box Removal 1 Unlock and raise the cargo box 2 Unplug the cargo box harness connector 1 Cargo box harness connector 3 From the LH of vehic...

Page 395: ...Section 07 CHASSIS Subsection 07 CARGO BOX If any parts of the locking mechanism have been replaced or loosen check cargo box adjustments Refer to CARGO BOX ADJUSTMENTS 372 tmr2011 043...

Page 396: ...section 08 FRAME FRAME SERVICE TOOLS OTHER SUPPLIER Description Part Number Page BLIND THREADED INSERT INSTALLER model 9600 377 SERVICE PRODUCTS Description Part Number Page LOCTITE 243 BLUE 293 800 0...

Page 397: ...RAME T1 10 2 N rn 89 18 lbf in T2 5 0 5 N m 44 4 lbf in T3 25 3 N ni 18 2 lbf ft T4 48 6 N m 35 4 lbf ft T5 21 3 N rn 15 2 lbf ft T4 6 Loctite 243 6 Loctite 243 T1 T4 XT Model T3 l7 7Ni CE Models only...

Page 398: ...ion 07 CHASSIS Subsection 08 FRAME 10 2 IN41 m 89 18 lbf in 25 3 N m 18 2 lbf ft 25 3 N ni 18 2 lbf ft 25 3 N rn 18 2 lbf ft 25 3 N m 18 2 lbf ft op 13 1 N m 115 9 lbf in unr20114 39 002_a tmr2011 039...

Page 399: ...Cage Inspection Check cage for bending cracks weld damages or any other damage A WARNING Any damaged cage components must be re placed Cage Installation A WARNING When the cage mounting bolts are remo...

Page 400: ...of cage Front attachment points FRAME Frame Inspection Check frame for bending cracks weld damages or any other damage Replace frame as neces sary Frame Welding No welding should be done on frame exc...

Page 401: ......

Page 402: ...ameter Intake New 4 966 mm to 4 980 mm 1955 in to 1961 in Service limit 4 930 mm 1941 in Exhaust New 4 956 mm to 4 970 mm 1951 in to 1957 in Service limit 4 930 mm 1941 in Valve out of round Intake an...

Page 403: ...ide New 34 959 mm to 34 975 mm 1 3763 in to 1 377 in Service limit 34 950 mm 1 376 in Spark plug side New 21 959 mm to 21 980 mm 8645 in to 8654 in Service limit 21 950 mm 8642 in Camshaft main bearin...

Page 404: ...7898 in 22 050 mm 8681 in Piston pin diameter New 19 996 mm to 20 000 mm 7872 in to 7874 in 21 996 mm to 22 000 mm 865 984 in to 866 142 in Service limit 19 980 mm 786 614 in 21 980 mm 8654 in Connect...

Page 405: ...ng free length Service limit 85 mm 3 346 in I 105 mm 4 134 in Drive pulley spring free squareness Service limit 4mm 157 in Spring sleeve length New 9 2 mm to 9 4 mm 362 in to 37 in Service limit 9 0 m...

Page 406: ...25 000 mm 9837 in to 9843 in Service limit 24 984 mm 9836 in Bearing journal MAG CVT side New 16 980 mm to 16 991 mm 6685 in to 6689 in Service limit 16 976 mm 6683 in ELECTRICAL SYSTEM Magneto gener...

Page 407: ...onnectors DC3 and DC4 12 V power outlet Communication connector F12 15 A Relays coils R1 and R3 F13 5 A Connector DC6 F14 15 A Fuel pump F15 5 A FUEL SYSTEM Fuel delivery Type Electronic Fuel Injectio...

Page 408: ...grease Hi temp bearing grease NLGI 2 or an equivalent STEERING Steering wheel Adjustable tilt steering Turning radius 240 cm 94 5 in Total toe vehicle on ground 0 mm 4 mm 0 in 157 in Camber angle veh...

Page 409: ...m X Threaded spring retainer BRAKES Front brake Qty 2 Type 214 mm ventilated disc brakes with hydraulic twin piston calipers Rear brake Qty 1 Type 214 mm ventilated disc brake with hydraulic twin pist...

Page 410: ...n Overall width 148 9 cm 58 6 in Overall height 182 9 cm 72 in Wheel base 192 4 cm 75 7 in Wheel track Front 125 7 cm 49 5 in Rear 121 9 cm 48 in Ground clearance 27 9 cm 11 in WEIGHT AND LOADING CAPA...

Page 411: ......

Page 412: ...BK is a YELLOW wire with a BLACK stripe Connector Housing Area The first number in the connector pin contact number represents the area in the vehicle where the connector is located AREA LOCATION 1 St...

Page 413: ...and INJ2 Fuel injector MAPTS Manifold air pressure and temperature sensor MD 2WD 4WD actuator MG multifunction switch OPS Oil pressure switch OV Override button PD RH headlight PF1 Fuse Holder main P...

Page 414: ...rs are used on var ious systems Engine connector Magneto connector The following procedures may be used on each as they are similar in construction Deutsch Connector Removal from its Support 1 Insert...

Page 415: ...1 Flat screwdriver 2 Deutsch connector TYPICAL DEUTSCH CONNECTOR 7 Male connector 2 Female connector 3 Secondary lock 4 Sealing cap NOTICE Do not apply dielectric grease on ter minal inside connector...

Page 416: ...is removed 2 Insert terminal through the back of the connec tor in the appropriate position and push it in as far as it will go You should feel or hear the ter minal lock engage 3 Pull back on the te...

Page 417: ...Packard connec tor use the SNAP ON TERMINAL REMOVER TOOL P N TT600 4 a WARNING Ensure all terminals are properly crimped on wires and connectors are properly fastened PACKARD CONNECTOR MULTIFUNCTION...

Page 418: ...on the ECM The engine wiring harness connector is con nected to ECM connector A The vehicle wiring harness connector is connected to ECM connec tor B Each ECM connector has 48 pins ECM CONNECTORS Do...

Page 419: ...roperly locked in the connector 3 Ensure they are very tight make good contact with the pins in the ECM 4 Ensure the pins in the harness connector and the ECM connector are clean shiny and corrosion f...

Page 420: ...the shape or enlarge the terminals and create in termittent or permanent contact problems Connector Terminal Removal Harness Connector To remove a signal terminal from the ECM har ness connector use t...

Page 421: ...GM TERMINAL EXTRACTOR P N 12094430 between the lock and the pin to release the pin GM TERMINAL EXTRACTOR P N 12094430 Step 2 Insert GM extractor tool P N 12094430 3 Gently pull on the wire to extract...

Page 422: ...N 529 035 730 to select the proper position of the tool NOTE Different wires require different crimping pliers settings POSITIONING THE CRIMPING PLIERS Step 1 Step 1 Press Step 2 Step 2 Rotate After...

Page 423: ...ctive heat shrink rubber tube on the terminal Heat the heat shrink rubber tube us ing the heat gun so that it grasps the wire and the terminal NOTICE Make sure that the protective heat shrink rubber t...

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