Can-Am 2019 Maverick x3 Turbo Service Manual Electronic Version

SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to NOTE: Indicates supplementary information re-
correctly service and repair all vehicles of the quired to fully complete an instruction.
Can-Am™ Maverick™ Series. Although the mere reading of such information
This edition was primarily published to be used by does not eliminate the hazard, your understand-
mechanical technicians who are already familiar ing of the information provided will promote its
with all service procedures relating to BRP prod- correct use.
ucts. Mechanical technicians should attend train- Always observe common shop safety practice.
ing courses given by BRPTI.
Unless otherwise noted, the engine must be
Please note that the instructions in this manual stopped and the tether cord must be removed
will apply only if proper hand tools and special ser- prior to perform any services.
vice tools are used.
Torque wrench tightening specifications must be
The contents of this manual depicts parts and/or strictly adhered to. Use the torque values and ser-
procedures applicable to a particular product at vice products as in the exploded views or in the
the time of writing. Service and warranty bulletins procedures when noted.
may be published to update the content of this
manual. Dealer modifications that were carried Locking devices when removed must be replaced
out after manufacturing of the product, whether (e.g.: locking tabs, elastic stop nuts, self-locking
or not authorized by BRP, are not included. fasteners, cotter pins, etc.).
In addition, the sole purpose of the illustrations Hoses, cables and locking ties removed during a
throughout the manual, is to assist identification procedure must be reinstalled as per factory stan-
of the general configuration of the parts. They are dards.
not to be interpreted as technical drawings or ex- When ordering parts always refer to the specific
act replicas of the parts. model PARTS CATALOGS.
The use of BRP parts is most strongly recom- We strongly recommend that any services be car-
mended when considering replacement of any ried out and/or verified by a highly skilled profes-
component. Dealer and/or distributor assistance sional mechanic.
should be sought in case of doubt. It is understood that this manual may be trans-
The engines and the corresponding components lated into another language. In the event of any
identified in this document should not be utilized discrepancy, the English version shall prevail.
on product(s) other than those mentioned in this BRP disclaims liability for all damages and/or in-
document. juries resulting from the improper use of the con-
It is understood that certain modifications may tents of this publication.
render use of the vehicle illegal under existing
federal, provincial and state regulations. IMPORTANT SAFETY
This manual emphasizes particular information PRECAUTIONS
which, is denoted by the following wording and
symbols: We do not provide warnings about many basic
shop safety practices (e.g.: Use Grinding Wheel
WARNING – wear safety glasses). If you have not received
shop safety training or do not feel confident about
Indicates a potential hazard that, if not
your knowledge of safe servicing practices, we
avoided, could result in serious injury or
recommend that you do not attempt to perform
death.
the procedures described in BRP shop manuals.
CAUTION Indicates a hazardous situation You should have a clear understanding of all ba-
which, if not avoided, could result in minor or sic shop safety practices. You should be wearing
moderate injury. the appropriate clothing, using appropriate safety
NOTICE Indicates an instruction which, if not

followed, could result in severe damage to ve-
hicle components or other property.
219100971-005 I
SAFETY NOTICE
equipment and taking all necessary safety precau-

tions. Please be especially careful of the follow-
ing:
– Read and understand all instructions before you
begin a procedure or repair.
– Ensure you have the proper tools, any neces-
sary replacement parts and the skills to perform
the tasks safely and completely.
– Protect your eyes by using approved and prop-
erly fitted safety glasses.
– Use other protective wear when necessary, for
example safety shoes and gloves.
– Unless the service procedure requires that the
engine remain running, make sure the engine is
off before beginning service.
– Be sure there is adequate ventilation whenever
you run the engine, to avoid the risk of Carbon
Monoxide poisoning.
– To avoid injury from moving parts, make sure
your hands, fingers and clothing are out of the
way when the engine is running.
– Gasoline vapors and hydrogen gases from
batteries are explosive. Keep all cigarettes,
sparks and flames away from the battery,
fuel-related components and other enclosed
compartments.
– Never use gasoline to clean parts, always use
an approved non-flammable solvent.
– Never drain or store gasoline in an open con-
tainer.
WARNING
The foregoing list represents general safety
practices. For details on workplace health
and safety requirements in your area, con-
sult your local workplace health and safety
agency or association.
We have provided you with some of the most

important general service safety precautions,
above. We cannot, however, warn you of every
conceivable hazard that can arise in performing
the service and repair procedures depicted in
BRP manuals. Only you can decide whether or
not you should perform a given task.
II 219100971-005
INTRODUCTION
INTRODUCTION
The information and component/system descrip- ENGINE IDENTIFICATION
tions contained in this manual are correct at time NUMBER (EIN)
of writing. BRP however, maintains a policy of
continuous improvement 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 product and the
description and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.
VEHICLE INFORMATION
VEHICLE IDENTIFICATION 219001761-140_a
NUMBER (VIN) TYPICAL — ENGINE SERIAL NUMBER LABEL

1. EIN (Engine Identification Number)
The VIN (Vehicle Identification Number) decal is lo-
cated behind the passenger seat on the rear lower LIFTING AND SUPPORTING THE
bulkhead.
VEHICLE
VIN Decal Description Front of Vehicle
Place vehicle on a flat non slippery ground.
Ensure vehicle shift lever is set to PARK.
Install an hydraulic jack under front skid plate.
tmr2011-002-005_a
TYPICAL — VEHICLE IDENTIFICATION NUMBER LABEL

1. VIN (Vehicle Identification Number)
2. Model number
3. Manufacturing date
219001761-079_a
FRONT OF VEHICLE
1. Hydraulic jack position
Lift front of vehicle and install a jack stand on each

side under frame as shown below:
219100971-005 III
INTRODUCTION
LIFTING THE VEHICLE WITH A

LIFTING TABLE
Roll vehicle above lifting table.
Install two 4 x 4 horizontally across vehicle as
close as possible to lifting points.
NOTICE Ensure 4 x 4 are as close to lifting
points as possible.
219001761-129_b
Lift vehicle using table.
FRONT OF VEHICLE
NOTE: If repositioning of vehicle is needed, lift ei-
Lower hydraulic lift and ensure vehicle is sup- ther front or rear of vehicle using the lower portion
ported safely onto both jack stands. of applicable bumper.
Rear of Vehicle WARNING
Place vehicle on a flat non slippery ground. Do not allow anyone in the vehicle while it is
Activate 4WD mode. being lifted.
Ensure vehicle shift lever is set to PARK.
Install an hydraulic jack under the vehicle. HOISTING THE VEHICLE
The vehicle may be lifted off the ground by the
cage using a hoist and lifting straps.
NOTICE Never use the central portion of the
cage to lift the vehicle.
219001761-080_a
REAR OF VEHICLE
1. Hydraulic jack position
tmr2017-005-201_a
Lift rear of vehicle and install a jack stand on each
side under frame as shown below: WARNING
– Ensure hoist and lifting straps are rated for
lifting the total vehicle weight. Refer to ap-
plicable manufactures instructions.
– Ensure lifting straps are in good condition
before lifting vehicle.
– Do not allow anyone in the vehicle or under
any portion of the vehicle while it is sus-
pended by a hoist.
– Do not perform any work on the vehicle
219001761-129_a while it is suspended by a hoist.
REAR OF VEHICLE
Lower hydraulic lift and ensure vehicle is sup-

ported safely onto both jack stands.
IV 219100971-005
INTRODUCTION
TRANSPORTING THE VEHICLE 4. Strap the front tires by using tire towing straps.
If your vehicle needs to be transported, it should 5. Put a strap around the central arm of each rear
be carried on a flatbed trailer of the proper size and suspension.
capacity.
NOTICE Do not tow this vehicle — towing
can seriously damage the vehicle's drive sys-
tem.
When contacting a towing or transporting service,
be sure to ask if they have a flatbed trailer, load-
ing ramp or power ramp to safely lift the vehicle
and tie-down straps. Ensure the vehicle is prop-
erly transported as specified in this section.
NOTICE Avoid using chains to tie the vehicle
— they may damage the surface finish or plas-
tic components. 219001761-122_a
WARNING 6. Strap the rear tires by using tire towing straps.

If the vehicle is equipped with a windshield, 7. Firmly attach the rear suspension tie-down
transport it facing forward to avoid damaging straps to both sides of the rear of the trailer
the windshield. with ratchets.
8. Ensure that both the front and rear wheels are
To load the vehicle on a platform for transport, pro- firmly attached to the trailer.
ceed as follow:
1. Shift the vehicle into NEUTRAL (N). WARNING
2. Then proceed as follows: Make sure no loose objects are present inside
vehicle during vehicle transportation.
2.1 Put a strap around the lower arm of each
front suspension.
ENGINE EMISSIONS
INFORMATION
MANUFACTURER'S
RESPONSIBILITY
Manufacturers of engines must determine the
exhaust emission levels for each engine horse-
power family and certify these engines with
the United States of America Environmental
Protection Agency (EPA). An emissions control
information label, showing emission levels and
engine specifications, must be placed on each
vehicle at the time of manufacture.
219001761-124_a
DEALER RESPONSIBILITY
1. Lower arm of each front suspension When servicing any vehicle that carry an emis-
sions control information label, adjustments must
2.2 Attach the straps to the winch cable of the
be kept within published factory specifications.
towing vehicle.
Replacement or repair of any emission related
2.3 Pull the vehicle on the flatbed trailer with
component must be executed in a manner that
the winch.
maintains emission levels within the prescribed
3. Remove the key from the D.E.S.S. post. certification standards.
219100971-005 V
INTRODUCTION
Dealers are not to modify the engine in any man- RADIO FREQUENCY
ner that would alter the horsepower or allow emis- DIGITALLY ENCODED
sion levels to exceed their predetermined factory
specifications. SECURITY SYSTEM (RF
Exceptions include manufacturer's prescribed
D.E.S.S. KEY)
changes. This device complies with FCC Part 15 and Indus-
try Canada license exempt RSS standard(s). Op-
OWNER RESPONSIBILITY eration is subject to the following two conditions:
(1) this device may not cause interference, and (2)
The owner/operator is required to have engine this device must accept any interference, includ-
maintenance performed to maintain emission ing interference that may cause undesired opera-
levels within prescribed certification standards. tion of the device.
The owner/operator is not to, and should not al- Changes or modifications not expressly approved
low anyone else to modify the engine in any man- by the party responsible for compliance could void
ner that would alter the horsepower or allow emis- the user’s authority to operate the equipment.
sions levels to exceed their predetermined factory
specifications. IC Registration Number: 12006A-M01456
FCC ID: 2ACERM01456
EMISSION REGULATIONS We, the party responsible for compliance, declare
under our sole responsibility that the device is in
The vehicle you are servicing may have been conformity with the provisions of the following
certified to applicable emission regulations in Council Directive: 2014/53/EU. To which this dec-
your country or state. Not as an exhaustive list; laration relates is in conformity with the essential
this may include standards for engine exhaust requirements and other relevant requirements.
emissions, crankcase emissions, permeation The product is in conformity with the following
emissions and evaporative emissions. Servic- directives, harmonized standards and regulations:
ing procedures in this manual must be strictly Radio Equipment Directive (RED) 2014/53/EU
followed in order to keep the vehicle within the and Harmonized Standards: EN 300 330-2, EN
factory specifications. Failure to follow servicing 60950-1.
procedures in this manual may lead a vehicle to
be out of compliance with applicable emission
regulations. NOISE EMISSION CONTROL
When servicing any vehicle; adjustments must be SYSTEM REGULATION
kept within published factory specifications. Re- USA and Canada Only
placement or repair of any emission related com-
Tampering with Noise Control System Is Pro-
ponent must be executed in a manner that main-
hibited!
tains emission levels within the applicable certifi-
cation standards. Nobody is allowed to modify the U.S. Federal law and Canadian provincial laws may
engine in any manner that would alter the horse- prohibit the following acts or the causing there of:
power or allow emission levels to exceed their 1. The removal or rendering inoperative by any
predetermined factory specifications. Exceptions person other than for purposes of mainte-
include manufacturer’s prescribed changes. nance, repair or replacement of any device or
The owner/operator is required to have engine element of design incorporated into any new
maintenance performed to maintain emission lev- vehicle for the purpose of noise control prior
els within the prescribed certification standards. to its sale or delivery to the ultimate purchaser
The owner/operator is allowed and should not or while it is in use or
allow anyone else to modify the engine in any 2. The use of the vehicle after such device or ele-
manner that would alter the horsepower or allow ment of design has been removed or rendered
emissions levels to exceed their predetermined inoperative by any person.
factory specifications. Among those Acts Presumed to Constitute
Tampering Are the Acts Listed Below:
1. Removal or alteration or the puncturing of the
mufflers or any engine component which con-
ducts removal of engine exhaust gases.
VI 219100971-005
INTRODUCTION
2. Removal or alteration or the puncturing of any NOTICE Most fasteners are metric, and most
part of the intake system. components are built with parts dimensioned
3. Replacing any moving parts of the vehicle or using the metric system. Consult the appropri-
parts of the exhaust or intake system, with ate PARTS CATALOG to obtain and use the cor-
parts other than those specified by the manu- rect parts and fasteners. Mismatched or incor-
facturer. rect fasteners could cause damage to the vehi-
4. Lack of proper maintenance. cle.
MANUAL INFORMATION MANUAL LAYOUT

This manual is divided into many major sections as
MANUAL PROCEDURES can be seen in the main table of contents at the
beginning of the manual.
Many of the procedures in this manual are inter-
related. Before undertaking any task, you should Each section is divided into various subsections,
read and thoroughly understand the entire section and again, each subsection has one or more divi-
or subsection in which the procedure is contained. sions.
Illustrations and photos show the typical construc-
WARNING tion of various assemblies and, in all cases, may
Unless otherwise specified, the engine not reproduce the full detail or exact shape of the
should be turned OFF and cold for all main- parts used in a particular model vehicle. However,
tenance and repair procedures. they represent parts which have the same or a
similar function.
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 approved equivalents.
The use of RIGHT and LEFT indications in the text
are always referenced to the driving position (sit-
ting on the vehicle).
tmr2017-005-200_a
TYPICAL
1. Left
2. Right
This manual uses technical terms which may be

different from the ones of the PARTS CATALOGS.
When ordering parts always refer to the specific
model PARTS CATALOGS.
219100971-005 VII
INTRODUCTION
TYPICAL PAGE
Section 06 ENGINE Page heading

Subsection 01 (MAGNETO) indicates section
and subsection.
Subsection title MAGNETO

Indicates applicable Models
models.
Loctite 243 Drop represents a

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

1 is used to identify
a part referred to
the text.
NEW indicates that the
part must be replaced NEW
with a new one.
5 Nm
(44 lbfin)
Illustration number
for publishing process. XXX0000
Document number for 55 Page number

publishing process.
mmr2008-001
NOTICE Pay attention to torque specifications.

Some of these are in lbf in instead of lbf ft.
Use appropriate torque wrench.
Typical_iso_2008_en
VIII 219100971-005
INTRODUCTION
TYPICAL PAGE
Section 03 ENGINE
Subsection 09 (MAGNETO SYSTEM)
Tittle in bold
indicates category
of information to be GENERAL
carried out. NOTE: The following procedures can be done
without removing the engine.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Reference to a Clean threads before applying a threadlocker. Re-
specific section fer to the SELF-LOCKING FASTENERS and LOC-
or subsection. TITE APPLICATION sections at the beginning of
this manual for complete procedure. TYPICAL
WARNING indicates a general
Torque wrench tightening specifications
view which may
must be strictly adhered to. not represent exact
Locking devices (e.g.: locking tabs, elastic 1 details.
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones. TYPICAL
1. Starting pulley
PROCEDURES NOTE: To remove starting pulley bolts, hold mag- Call-outs pertaining
Indicates component neto flywheel with a socket as shown. to above illustration.
procedures apply to. MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean magneto flywheel using only
Indicates specific a clean cloth. Illustration always
procedure to be Magneto Flywheel Removal follows text to which
carried out. Remove muffler, refer to the EXHAUST SYSTEM it applies.
section.
Remove acoustic panel.
Remove rewind starter. mmr2007-016-002
Remove starting pulley no. 2. TYPICAL Italic bold face type-

Models
setting indicates a
Remove the connecting flange retaining the
procedure applicable
rewind starter to the engine housing. to a specific
model(s).
mmr2008-001 57
Bold face number following part

name refers to exploded view
at beginning of subsection.
typical_txt_2008_en
219100971-005 IX
INTRODUCTION
TIGHTENING TORQUE
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When
a torque is not specified, refer to the following table.
WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices when removed (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter
pins, etc.) must be replaced.
In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following proce-
dure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
3. Tighten fastener to the recommended torque value.
NOTICE Be sure to use the recommended tightening torque for the specified fastener used.
NOTE: When possible, always apply torque on the nut.
NOTE: Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners 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.
4.8 8.8 9.8 10.9 12.9

Property
class and
head 4.8 8.8 9.8 10.9 12.9
markings
4.8 8.8 9.8 10.9 12.9 12.9
5 8 10 12
Property
class and
12
10
nut
5
markings
A00A8BS
FASTENER FASTENER GRADE/TORQUE

SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
1.5 – 2 N•m 2.5 – 3 N•m 3.5 N•m - 4 N•m 4 N•m - 5 N•m
M4
(13 – 18 lbf•in) (22 – 27 lbf•in) (31 lbf•in - 35 lbf•in) (35 lbf•in - 44 lbf•in)
3 N•m - 3.5 N•m 4.5 N•m - 5.5 N•m 7 N•m - 8.5 N•m 8 N•m - 10 N•m
M5
(27 lbf•in - 31 lbf•in) (40 lbf•in - 49 lbf•in) (62 lbf•in - 75 lbf•in) (71 lbf•in - 89 lbf•in)
6.5 N•m - 8.5 N•m 8 N•m - 12 N•m 10.5 – 15 N•m
M6 16 N•m (142 lbf•in)
(58 lbf•in - 75 lbf•in) (71 lbf•in - 106 lbf•in) (93 – 133 lbf•in)
M8 15 N•m (133 lbf•in) 25 N•m (18 lbf•ft) 32 N•m (24 lbf•ft) 40 N•m (30 lbf•ft)
M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 73 N•m (54 lbf•ft)
X 219100971-005
INTRODUCTION
FASTENER INFORMATION Threadlocker Application for

Uncovered Holes (Bolts and Nuts)
NOTICE Most components in the vehicles
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or
vice-versa. Mismatched or incorrect fasteners 1
could cause damage to the vehicle or possible
personal injury.
SELF-LOCKING FASTENERS
PROCEDURE
2
A00A3LA
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.

2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041)
A00A6LA on threads and allow to dry.
TYPICAL — SELF-LOCKING FASTENER 3. Choose proper strength Loctite threadlocker.
The following describes common procedures 4. Fit bolt in the hole.
used when working with self-locking fasteners. 5. Apply a few drops of threadlocker at proposed
Use a metal brush or a tap to properly clean a tightened nut engagement area.
threaded hole, then use a solvent. Allow the sol- 6. Position nut and tighten as required.
vent time to act, approximately 30 minutes, then
wipe off. Solvent utilization is to ensure proper Threadlocker Application for Blind
adhesion of the product used for locking the fas- Holes
tener.
LOCTITE® APPLICATION 1
PROCEDURE
The following describes common procedures 2
used when working with Loctite products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this shop manual.
lmr2007-040-004_a
1. On fastener threads
2. On threads and at the bottom of hole
1. Clean threads (bolt and hole) with solvent.

2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041)
on threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
219100971-005 XI
INTRODUCTION
4. Apply several drops along the threaded hole Threadlocker Application for
and at the bottom of the hole. Pre-Assembled Parts
5. Apply several drops on bolt threads.
6. Tighten as required.
Threadlocker Application for Stud

Installation in Blind Holes 1
1 3
2
A00A3OA
1. Apply here
lmr2007-040-005_a 2. Do not apply
1. On stud threads
2. On threads and in the hole 1. Clean bolts and nuts with solvent.
3. On retaining nut threads
2. Assemble components.
1. Clean threads (stud and hole) with solvent. 3. Tighten nuts.
2. Apply LOCTITE 7649 (PRIMER) (P/N 293 800 041) 4. Apply a few drops of proper strength Loctite on
on threads and allow to dry. bolt/nut contact surfaces.
3. Put 2 or 3 drops of proper strength Loctite 5. Avoid touching metal with tip of flask.
threadlocker on female threads and in hole.
NOTE: For preventive maintenance on exist-
NOTE: To avoid a hydro lock situation, do not ap- ing equipment, retighten nuts and apply proper
ply too much Loctite. strength Loctite on bolt/nut contact surfaces.
4. Apply several drops of proper strength Loctite
on stud threads. Threadlocker Application for an
5. Install stud. Adjustment Screw
6. Install cover, part, etc.
7. Apply a few drops of proper strength Loctite on 2
1
uncovered stud threads.
8. Install and tighten retaining nut(s) as required.
A00A3PA
1. Apply here
2. Plunger
1. Adjust screw to proper setting.

2. Apply a few drops of proper strength Loctite
threadlocker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
XII 219100971-005
INTRODUCTION
NOTE: If it is difficult to readjust, heat screw with Gasket Compound Application

a soldering iron (232°C (450°F)).
Application for Stripped Thread Repair 1 2
5
1
6
8
2
1
A00A3QA 4 7
1. Release agent
2. Stripped threads 1 3
3. Form-A-Thread
lmr2007-040-006_a
4. Tapes
5. Cleaned bolt 1. Proper strength Loctite
6. Plate 2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518
7. New threads (P/N 293 800 038) on both sides of gasket
8. Threadlocker 3. Loctite Primer N only
Standard Thread Repair 1. Remove old gasket and other contaminants us-
Follow instructions on Loctite FORM-A-THREAD ing LOCTITE CHISEL (GASKET REMOVER) (P/N 413
81668 package. 708 500). Use a mechanical means only if nec-
essary.
If a plate is used to align bolt:
NOTE: Avoid grinding.
1. Apply release agent on mating surfaces.
2. Clean both mating surfaces with solvent.
2. Put waxed paper or similar film on the surfaces.
3. Spray Loctite Primer N on both mating surfaces
3. Twist bolt when inserting it to improve thread and on both sides of gasket and allow to dry 1
conformation. or 2 minutes.
NOTE: NOT intended for engine stud repairs. 4. Apply LOCTITE 518 (P/N 293 800 038) on both
Repair of Small Holes/Fine Threads sides of gasket, using a clean applicator.
Option 1: Enlarge damaged hole, then follow 5. Place gasket on mating surfaces and assemble
STANDARD THREAD REPAIR procedure. parts immediately.
Option 2: Apply FORM-A-THREAD on the screw NOTE: If the cover is bolted to blind holes, apply
and insert in damaged hole. proper strength Loctite in the hole and on threads.
Permanent Stud Installation (Light Duty) Tighten fastener.
1. Use a stud of the desired thread length. If holes are sunken, apply proper strength Loctite
on bolt threads.
2. DO NOT apply release agent on stud.
6. Tighten as usual.
3. Follow Standard Thread Repair procedure.
4. Allow 30 minutes for Loctite FORM-A-THREAD Threadlocker Application for Mounting
to cure. on a Shaft
5. Complete part assembly. Mounting with a Press
219100971-005 XIII
INTRODUCTION
3. Apply a strip of proper strength Loctite on lead-

ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
1 strength and gap are required.
4. Install according to standard procedure.
2
5. Wipe off excess product.
3 6. Allow 30 minutes for product to cure.
A00A3UA NOTE: Normally used on worn-out housings to
prevent leaking or sliding.
1. Bearing
2. Proper strength Loctite It is generally not necessary to remove gasket
3. Shaft
compound applied on outer gasket diameter.
1. Clean shaft external contact surface.
2. Clean internal contact surface of part to be in-
stalled on shaft.
3. Apply a strip of proper strength Loctite on cir-
cumference of shaft contact surface at inser-
tion or engagement point.
NOTE: Retaining compound is always forced out
when applied on shaft.
4. DO NOT use antiseize Loctite or any similar
product.
5. No curing period is required.
Mounting in Tandem
1. Apply retaining compound on internal contact
surface (bore) of parts to be installed.
2. Continue parts assembly as per previous illus-
tration.
Threadlocker Application for Case-In

Components (Metallic Gaskets)
A00A3VA 1
1. Proper strength Loctite
1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with LOCTITE 7649
(PRIMER) (P/N 293 800 041).
XIV 219100971-005
Subsection XX (PERIODIC MAINTENANCE SCHEDULE)
PERIODIC MAINTENANCE SCHEDULE

Maintenance is very important for keeping your vehicle in safe operating condition. Proper maintenance
is the owner's responsibility. The vehicle should be serviced as per the maintenance schedule.
The following message appears in the gauge after every 100 hours of operation, to remind you of main-
tenance requirements: MAINTENANCE SOON. To erase message, use the BRP diagnostic software or
refer to ERASING THE MAINTENANCE REQUIRED MESSAGE in this subsection.
The maintenance schedule does not exempt the pre-ride inspection.
WARNING
Failure to properly maintain the vehicle according to the maintenance schedule and procedures
can make it unsafe to operate.
MAINTENANCE
ERASING THE MAINTENANCE REQUIRED MESSAGE
Maintenance message can be removed by alternately pressing the override switch and brake pedal
3 times at power up.
SEVERE DUSTY CONDITIONS

Air Filter Maintenance Guideline
NOTICE Never modify the air intake system. Otherwise, engine performance degradation or
damage can occur. The engine is calibrated to operate specifically with these components.
Air filter maintenance should be adjusted according to riding conditions as it is critical to ensure proper
engine performance and life span.
Air filter maintenance must be increased in frequency in the following dusty conditions:
– Riding on dry sand
– Riding on dry dirt covered surfaces
– Riding on dry gravel trails or similar conditions.
– Riding in areas with high concentration of seeds or crop husks.
– Riding in severe snow conditions.
NOTICE When riding in dusty conditions or sand, the air filter housing needs to be cleaned be-
fore every ride.
NOTE: Riding in a group in these conditions would increase even more the air filter maintenance.
MAINTENANCE SCHEDULE LEGEND

Operation in trail riding conditions
Operation in severe riding conditions (dusty or muddy) or carrying heavy loads condition
219100971-006 1
MAINTENANCE SCHEDULE
Make sure to perform proper maintenance at recommended intervals as indicated in the tables. Some
items of the maintenance schedule must be performed in function of the calendar, regardless of the
distance or time of operation.
EVERY YEAR OR 3 000 KM (2,000 MI) OR 100 HOURS (whichever comes first)
Check fault codes
Perform all items indicated in the pre-ride inspection
Replace engine oil and filter

Inspect gearbox oil level and look for contamination
Inspect and clean engine air filter. Replace if needed
Inspect steering system for abnormal play and damages (column, rack and pinion, bellows)
Inspect the tie rod ends and ball joints for play and inspect boots condition
Inspect wheel bearings for abnormal play
Inspect suspension arm bushing and wear plates. Replace if needed
Verify the transverse suspension arm nuts tightening torque
Inspect front and rear shock absorber spherical bearing O-rings (if damaged, clean, lubricate and reinstall O-rings)
Lubricate suspension arms and stabilizer bar bushings (Front / Rear)
Inspect CV joints and rubber boots condition (check for abnormal play in the joints and for cuts in the rubber
boots)
Inspect and clean the brake system (fluid level, pads, discs, lines, calipers)
Inspect front differential oil level and look for contamination and overall condition (vents, mount bolt torque,
seals)
Inspect battery condition and connections
Inspect propeller shaft U-joints for abnormal play
Clean exhaust pipes and muffler area
Clean muffler spark arrester
Replace fuel vent breather filter
Inspect CVT drive belt and clean CVT pulleys
Inspect and lubricate drive pulley hub needle bearing
Inspect centrifugal levers and rollers of drive pulley
Inspect input and output shaft seals (engine, gearbox, differential)
Inspect beadlock screws (if equipped)
Inspect rear wheel scrapers wear plates
Tighten cage fasteners (only if replaced - the cage installed at the factory is welded)
Inspect, clean and validate operation of seat belts retractors, buckles and semi-cinching (if applicable)
Verify coolant level and adjust if needed
2 219100971-006
PERFORM AT THE FIRST 3 000 KM (2,000 MI)AND AT 6 000 KM (4,000 MI) THEN
FOLLOW THE REGULAR SCHEDULE
PERFORM AT THE FIRST 1 500 KM (1,000 MI) AND AT 3 000 KM (2,000 MI) THEN
FOLLOW THE REGULAR SCHEDULE
Replace gearbox oil
EVERY TWO YEAR OR 6 000 KM (4,000 MI) OR 200 HOURS (whichever comes first)
EVERY TWO YEAR OR 3 000 KM (2,000 MI) OR 100 HOURS (whichever comes first)
Check fault codes
Replace front differential oil
Replace gearbox oil.
Replace brake fluid (must be performed every 2 years)
Test engine coolant strength + level
Verify fuel system for leaks (including evaporative emission system components if equipped)
Verify fuel pump pressure (idle and wide open throttle)

Replace spark plugs
Clean vehicle speed sensor
Replace canister vent pre-filter (evaporative emission system) if equipped
EVERY 5 YEAR OR 12 000 KM (8,000 MI) (whichever comes first)

EVERY 5 YEAR OR 6 000 KM (4,000 MI) (whichever comes first)
Replace engine coolant
219100971-006 3
Subsection 02 (PERIODIC MAINTENANCE PROCEDURES)
PERIODIC MAINTENANCE
PROCEDURES
SERVICE TOOLS
Description Part Number Page
TEST CAP ...................................................................................... 529 035 991 ............................................. 9
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ....................................... 9, 21
SERVICE PRODUCTS
4T 0W40 SYNTHETIC OIL (EUR) .................................................. 779286 ............................................. 4
4T 0W40 SYNTHETIC OIL............................................................. 779139 ............................................. 4
4T 10W50 SYNTHETIC OIL (EUR) ................................................ 779240 ............................................. 4
4T 10W50 SYNTHETIC OIL........................................................... 779234 ............................................. 4
4T 5W40 SYNTHETIC BLEND OIL (EUR)...................................... 779290 ............................................. 4
4T 5W40 SYNTHETIC BLEND OIL ................................................ 779133 ............................................. 4
75W140 SYNTHETIC GEAR OIL (EUR)......................................... 779215 ........................................... 12
75W140 SYNTHETIC GEAR OIL ................................................... 779160 ........................................... 12
75W90 SYNTHETIC GEAR OIL ..................................................... 779158 ........................................... 15
BRAKE FLUID DOT 4 .................................................................... 779151 ........................................... 21
COSMO RUBBER GREASE .......................................................... 715 900 399 ........................................... 20
EXTENDED LIFE PRE-MIXED COOLANT (EUR) ........................... 779223 ............................................. 6
EXTENDED LIFE PRE-MIXED COOLANT ..................................... 779150 ............................................. 6
SYNTHETIC GREASE SUSPENSION............................................. 779163 ..................................... 17–18
SYNTHETIC GREASE .................................................................... 779162 ........................................... 20
XPS BRAKES AND PARTS CLEANER (USA) ................................. 219 701 705 ........................................... 20
XPS BRAKES AND PARTS CLEANER ........................................... 219 701 776 ........................................... 20
GENERAL Removing the Air Filter

This subsection provides: Remove the air filter cover by releasing the retain-
– Fluid level verifications ing clamps
– Maintenance procedures. Release the first two from the LH rear of the ve-
hicle.
The following systems should be serviced accord-
ing to the PERIODIC MAINTENANCE SCHED-
ULE.
PROCEDURES
AIR INTAKE SYSTEM
Replacing the Air Filter
NOTICE Never modify the air intake system.
Otherwise, engine performance degradation
or damage can occur. The engine is calibrated
to operate specifically with these components.
219100916-007-001_a
LH REAR OF VEHICLE
1. Retaining clamps
219100971-007 1
Remove the seat backrest. CAUTION Never perform this operation

Remove the bulkhead cover. immediately after the engine has been running
Release the third retaining clamp. as exhaust system is very hot.
Remove retaining screws securing muffler cover
in place and remove muffler cover.
Pull out spark arrester and remove carbon de-
posits using a brush.
219100916-007-002_a
1. Retaining clamp
Remove the filter cartridge.

Cleaning the Air Filter Housing 219001761-048_a
Inspect air filter housing for cleanliness. 1. Retaining screws

2. Muffler cover
3. Spark arrester
NOTICE If sand or other particles are found
in air filter housing, clean it using a vacuum NOTICE Use a soft brush and be careful to
cleaner. avoid damaging spark arrester mesh.
Cleaning the Air Filter Inspect mesh of spark arrester for any damage.
Clean engine air filter by tapping out heavy dust Replace as needed.
from paper element, this will allow dirt and dust Inspect spark arrester chamber in muffler. Re-
to get out of the paper filter. move any debris as needed.
NOTICE It is not recommended to blow com- Reinstall the spark arrester in the reverse of the
pressed air on the paper element; this could removal procedure. Tighten retaining screws to
damage the paper fibers and reduce its filtra- specification.
tion ability when used in dusty environments. TIGHTENING TORQUE
If engine air filter is too dirty and cannot be
cleaned following the recommended proce- Muffler cover 10 N•m ± 2 N•m
dure, it should be replaced. screws (89 lbf•in ± 18 lbf•in)
Installing the Engine Air Filter X mr model

Install air filter cartridge. The mufflers must be periodically purged of accu-
Install filter cover with the "TOP" mark upwards mulated carbon.
(duckbill valve downwards). Turn cover clockwise
to secure it. CAUTION Never perform this operation
immediately after the engine has been running
Lock the cover by pushing the plastic tab inwards. because exhaust system is very hot.
Remove retaining screws securing rear fascia.
EXHAUST SYSTEM
Cleaning the Muffler Spark Arrester
All Models Except X mr
The mufflers must be periodically purged of accu-
mulated carbon.
2 219100971-007
219001951-002_a 219001951-005_a
1. Retaining screws
Remove and discard the retaining bolts and nuts. 2. Gasket (discard)
3. Spark arrester
NOTICE Use a soft brush and be careful to

avoid damaging spark arrester mesh. Clean
with fresh water.
Inspect mesh of spark arrester for any damage.
Replace as needed.
Inspect spark arrester chamber in muffler. Re-
move any debris as needed.
Reinstall the spark arrester using a new gasket
and new retaining screws in the reverse of the
removal procedure. Tighten retaining screws to
specification.
219001951-003_a
TIGHTENING TORQUE
Remove retaining springs. 32 N•m ± 2 N•m
Muffler screws
(24 lbf•ft ± 1 lbf•ft)
Rear fascia retaining 2.5 N•m ± 0.5 N•m
screws (22 lbf•in ± 4 lbf•in)
LUBRICATION SYSTEM
Verifying the Engine Oil Level
NOTICE Operating the engine with an im-
proper level may severely damage engine.
With the engine at normal operating temperature,
place vehicle on a level surface and check the oil
level as follows:
219001951-004_a
1. Start engine and let it idle for at least 20 sec-

Pull out spark arrester and remove carbon de- onds.
posits using a brush. 2. Stop engine.
3. Unscrew dipstick then remove it and wipe
clean.
219100971-007 3
Scandinavia Countries
XPS™ RECOMMENDED ENGINE OIL
General 4T 5W40 SYNTHETIC BLEND
purpose OIL (EUR) (P/N 779290)
Cold 4T 0W40 SYNTHETIC OIL
temperature (EUR) (P/N 779286)
Warm 4T 10W50 SYNTHETIC OIL
temperature (EUR) (P/N 779240)
IF THE RECOMMENDED XPS ENGINE
OIL IS NOT AVAILABLE
219001761-085_a Use a 4-stroke SAE engine oil meeting or exceeding
LH REAR OF VEHICLE the following lubricant industry specifications:
1. Dipstick
– API service classification SJ, SL, SM or SN
4. Reinstall dipstick, screw it in completely. Always check the API service label certification on
the oil container, it must contain at least one of the
5. Remove dipstick and check oil level. It should indicated standards.
be near or equal to the upper mark.
All Other Countries
XPS™ RECOMMENDED ENGINE OIL
General 4T 5W40 SYNTHETIC BLEND
purpose OIL (P/N 779133)
Cold 4T 0W40 SYNTHETIC OIL
temperature (P/N 779139)
tmo2011-001-076_a
Warm 4T 10W50 SYNTHETIC OIL
TYPICAL
1. MIN temperature (P/N 779234)
2. MAX
3. Operating range IF THE RECOMMENDED XPS ENGINE
OIL IS NOT AVAILABLE
To add oil, remove the dipstick. Place a funnel into
Use a 4-stroke SAE engine oil meeting or exceeding
the dipstick tube. the following lubricant industry specifications:
Add a small amount of recommended oil and – API service classification SJ, SL, SM or SN
recheck oil level. Always check the API service label certification on
Repeat the above procedures until oil level the oil container, it must contain at least one of the
reaches the dipstick's upper mark. indicated standards.
NOTE: Do not overfill. Wipe off any spillage.

Changing the Engine Oil
Properly tighten dipstick.
Oil change and oil filter replacement should be
Recommended Engine Oil done with a warm engine.
Rotax® engines were developed and validated us-
CAUTION The engine oil can be very hot.
ing the XPS™ oil. BRP recommends the use of its
Wait until engine oil is warm.
XPS engine oil or an equivalent at all time. Dam-
ages caused by the use of an oil not suitable for NOTICE Engine oil and oil filter must be re-
the engine may not be covered by the BRP Lim- placed at the same time.
ited Warranty.
Ensure vehicle is on a level surface.
Remove dipstick.
Place a drain pan under the engine drain plug area.
4 219100971-007
Replace oil filter. Refer to REPLACING THE EN-

GINE OIL FILTER in this subsection.
Refill engine with recommended engine oil.
ENGINE OIL CAPACITY
Engine oil and engine oil
3.5 L (3.7 qt (U.S. liq.))
filter replacement
After filling, check the oil level, refer to VERIFYING

THE ENGINE OIL LEVEL in this subsection.
Dispose oil and filter as per your local environmen-
219001761-208_a tal regulations.
UNDERNEATH REAR OF VEHICLE
1. Magnetic drain plug Replacing the Engine Oil Filter
2. Secondary drain plug
Oil Filter Access
Clean the drain plug area.
Access the oil filter by the RH rear of the vehicle.
NOTE: A funnel can be used between the drain
holes and the skid plate to avoid spillage.
Unscrew drain plugs and discard the gasket rings.
219001761-205_a
1. Oil filter cover
Removing the Oil Filter

tmr2017-014-020_a Clean oil filter area.
1. Magnetic drain plug Remove oil filter cover.
2. Gasket ring
3. Secondary drain plug Remove oil filter.
4. Gasket ring
Allow oil to drain completely from the crankcase.

Clean the magnetic drain plug from metal shav-
ings and residue. Presence of debris gives an in-
dication of internal engine damage.
Install a NEW gasket rings on the drain plugs.
NOTICE Never use the gasket ring a second
time. Always replace by a NEW one.
Tighten drain plugs to specification.
TIGHTENING TORQUE
15 N•m ± 2 N•m
Secondary drain plug
(133 lbf•in ± 18 lbf•in) 219001761-206
30 N•m ± 3 N•m Installing the Oil Filter

Magnetic drain plug
Check and clean the oil filter inlet and outlet area
for dirt and other contaminations.
219100971-007 5
COOLING SYSTEM
Recommended Engine Coolant
BRP RECOMMENDED PRODUCT
EXTENDED LIFE
Scandinavia PRE-MIXED COOLANT
(EUR) (P/N 779223)
EXTENDED LIFE
All other countries PRE-MIXED COOLANT
(P/N 779150)
Distilled water and
219001761-091_a Alternative, or if not antifreeze solution (50%
1. Outlet to the engine oil providing system available distilled water, 50%
2. Inlet from the oil pump to the oil filter antifreeze)
Install a NEW O-ring on oil filter cover. NOTICE Always use ethylene-glycol an-
Install the filter into the cover. tifreeze containing corrosion inhibitors specif-
Apply engine oil on O-ring and oil filter seal. ically formulated for internal combustion
aluminum engines.
Verifying the Engine Coolant Level

WARNING
Check coolant level with engine cold.
1. Place vehicle on a level surface.

2. Remove service cover by unlatching the rear
lifting it upwards.
vmr2006-008-001_a
1. Slightly oil
2. Slightly oil
NOTICE Pay attention to avoid pinching the

O-ring during filter and cover installation.
Install the cover on the engine.
Tighten oil filter cover screws to specification.
TIGHTENING TORQUE
219001761-060_a
10 N•m ± 1 N•m LIFTING REAR OF SERVICE COVER

Oil filter cover screws
(89 lbf•in ± 9 lbf•in)
Wipe off any oil spillage on engine.
6 219100971-007
5. Add coolant in system as necessary. Use a fun-

nel to avoid spillage. Do not overfill.
6. Reinstall pressure cap on cooling tank.
Checking the Engine Coolant Specific

Gravity
Remove pressure cap.
Use an antifreeze tester to test coolant strength.
MINIMUM RECOMMENDED COOLANT
STRENGTH
219001761-059_a
-30°C (-22°F)
1. Service cover
Replacing the Engine Coolant
3. Remove pressure cap.
Draining Cooling System
WARNING
In order to avoid potential burns, do not re- WARNING
move the pressure cap if the engine is hot. In order to avoid potential burns, do not re-
move the pressure cap or loosen the coolant
drain plug if the engine is hot.
1. Lift the rear of the vehicle approximately 30 cm

(12 in).
219001761-095_a
1. Pressure cap
219001761-135_a
4. Ensure cooling system is full up to the MAX A. 30 cm (12 in)
line.
2. Place a drain pan under the lower hose of the
radiator.
219001761-094_a
219100971-007 7
219001761-095_a
1. Pressure cap
6. Wait until the coolant flow stops or decreases.

7. Remove the hose pincher to drain the rest of
219001834-013_a
the coolant.
1. Lower hose 8. Install radiator hose clamp.
3. Install a large hose pincher on the lower hose TIGHTENING TORQUE
of the radiator.
2.5 N•m to 3.5 N•m
Radiator hose clamp
(22 lbf•in to 31 lbf•in)
9. Fill cooling system with coolant, refer to

BLEEDING AND REFILLING THE COOLING
SYSTEM procedure.
Bleeding and Refilling the Cooling System
1. Remove the pressure cap.
219001761-134_a
1. Lower radiator hose

2. Hose pincher
4. Slowly detach hose from radiator.

5. Remove coolant bottle pressure cap.
219001761-095_a
1. Pressure cap
2. Fill the cooling system until level reaches the

MAX line on the coolant reservoir.
8 219100971-007
219001761-094_a tmr2017-015-002_a
LEAK INDICATOR HOLE

3. Install pressure cap.
3. Carry out a CHECKING THE ENGINE COOLANT
4. Run engine at idle with the pressure cap on un- SPECIFIC GRAVITY as detailed in this subsec-
til the cooling fan cycles 2 times. tion.
5. Depress throttle pedal two or three times. 4. Carry out a PRESSURE CAP TEST as detailed in
6. Stop engine and let it cool down. this subsection.
Add coolant if necessary. 5. Replace engine coolant if contaminated.
NOTE: Engine coolant should be replaced every 2
WARNING years or if contaminated.
In order to avoid potential burns, do not re-
move the pressure cap if the engine is hot. Performing a Cooling System Leak
Test
7. After the next ride following this procedure,
check coolant level. Add coolant as required. WARNING
Refer to VERIFYING THE ENGINE COOLANT To avoid potential burns, do not remove the
LEVEL in this subection. pressure cap or loosen the cooling system
drain plug if the engine is hot.
Inspecting the Cooling System
1. Check general condition of hoses and clamps 1. Open service cover.
for tightness. 2. Remove cooling system pressure cap.
2. Check the leak indicator hose for oil or coolant. 3. Install test cap on filler neck.
NOTE: Leaking coolant indicates a defective ro-
REQUIRED TOOL
tary seal. Leaking oil indicates a defective oil seal.
If either seal is leaking, both seals must be re-
placed at the same time. Refer to WATER PUMP TEST CAP (P/N 529 035 991)
in the COOLING SYSTEM - ENGINE subsection.
4. Pressurize cooling system.

REQUIRED TOOL
VACUUM/PRESSURE PUMP
(P/N 529 021 800)
COOLING SYSTEM LEAK TEST

103 kPa (15 PSI)
If there is no pressure drop after 10 minutes, there

is no leak in the cooling system.
219100971-007 9
If the pressure drops, check all hoses, radiator,

cylinders and engine base for coolant leaks or air
bubbles.
Check the leak indicator hole if there is oil or
coolant leaking.
NOTE: In general leaking coolant indicates a dam-
aged rotary seal. Leaking oil indicates a damaged
oil seal. If either seal is leaking, both seals must
be replaced at the same time. Refer to WATER
PUMP in COOLING SYSTEM - ENGINE subsec-
tion. vmr2006-021-005_a
1. Drive belt
2. Cord in drive belt
Drive Pulley, Driven Pulley and Hub

Needle Bearing Maintenance
Drive and Driven Pulley
Clean and inspect drive and driven pulley sheaves.
Refer to CONTINUOUSLY VARIABLE TRANSMIS-
SION (CVT) subsection.
Hub
Inspect drive pulley hub needle bearing. Refer
to CONTINUOUSLY VARIABLE TRANSMISSION
tmr2017-015-002_a (CVT) subsection.
LEAK INDICATOR HOLE
Cleaning the CVT Air Inlet/Outlet
Testing the Pressure Cap 1. Remove CVT cover, refer to CONTINUOUSLY
Test the pressure cap using a cooling system VARIABLE TRANSMISSION (CVT) subsection.
tester. 2. Inspect and clean the air inlet and outlet open-
Replace the cap if it does not hold the pressure, ings from inside the CVT cover.
or if it opens at a relief pressure that is too low or
too high.
PRESSURE CAP RELIEF PRESSURE
Approximately 110 kPa (16 PSI)
CONTINUOUSLY VARIABLE
TRANSMISSION (CVT)
Inspecting the Drive Belt
Inspect belt for 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).
SERVICE LIMIT tmr2017-007-001_a
CVT COVER - CVT INLET OPENING

Drive belt width 34.7 mm (1.366 in)
3. Inspect and clean the air inlet and outlet open-
ings from inside the inner CVT air guide.
10 219100971-007
Remove plug again and check oil level on the dip-

stick. It should be near or equal to the upper mark.
tmr2016-106-005_a
1. MIN.
2. MAX.
3. Operating range
tmr2017-007-002_a To add oil, place a funnel into the dipstick hole.

1. Air inlet opening Add a small amount of recommended oil and
2. Air inlet opening
3. Air outlet opening recheck oil level.
4. CVT air guide
Repeat the above procedures until oil level
4. Inspect and clean the aft end of air outlet duct reaches the dipstick's upper mark.
at rear of the vehicle.
NOTICE Operating the gearbox with an im-
NOTE: If a lot of debris or grime are found in the proper oil level may severely damage gearbox.
CVT system, it may be necessary to remove the
ducts and thoroughly clean them. NOTE: Do not overfill. Wipe off any spillage.
5. Reinstall CVT cover. Properly tighten the plug.
TIGHTENING TORQUE
GEARBOX
5 N•m ± 0.6 N•m
Gearbox oil level plug
Verifying the Gearbox Oil Level (44 lbf•in ± 5 lbf•in)
Place the vehicle on a level surface. Select PARK
position. Replacing the Gearbox Oil
Check the gearbox oil level by removing the gear- Draining Procedure
box oil level plug located at the rear of vehicle, on
Prior to change the oil, ensure vehicle is on a level
the RH side.
surface.
NOTICE Pay attention not to lose the oil level Oil change should be done with a warm engine.
plug O-ring.
CAUTION The gearbox oil can be very
hot.
Place a drain pan under the magnetic gearbox
drain plug area.
219001761-064_a
1. Gearbox oil level plug
Reinstall the plug, screw in it completely.
219100971-007 11
TIGHTENING TORQUE
30 N•m ± 3 N•m
Magnetic drain plug
Filling Procedure
Ensure vehicle on a level surface.
Make sure that magnetic drain plug is reinstalled
and tight.
Fill the gearbox through the oil dipstick hole.
RECOMMENDED GEARBOX OIL
219001761-065_a
75W140 SYNTHETIC GEAR OIL
1. Gearbox drain plug (EUR) (P/N 779215) or a gearbox
2. Engine oil drain plug Scandinavia
oil that meets the requirements of
Clean drain plug area. 75W 140 API GL-5 synthetic gear oil
Clean the oil level plug area. 75W140 SYNTHETIC

GEAR OIL (P/N 779160)
Remove the gearbox oil level plug (dipstick). All other
or a gearbox oil that meets
countries
NOTICE Pay attention not to lose O-ring on the requirements of 75W 140 API
GL-5 synthetic gear oil
plug.
Capacity 1.25 L (42.27 U.S. oz)
Remove magnetic drain plug and discard sealing
ring. After filling check the oil level, refer to VERIFYING
Wait a while to allow oil flow out of gearbox. THE GEARBOX OIL LEVEL in this subsection.
NOTE: Wait a while to allow oil to flow down to
the gearbox housing.
Install the gearbox oil level plug with its O-ring.
Tighten the gearbox oil level plug to specification.
TIGHTENING TORQUE
5 N•m ± 0.6 N•m
Gearbox oil level plug
Cleaning the Vehicle Speed Sensor

(VSS)
Remove the VSS. Refer to REMOVING THE VSS
in the GEARBOX AND 4X4 COUPLING UNIT sub-
tmr2016-106-006_a
section.
1. Magnetic drain plug
2. Sealing ring (discard) Remove all metal particles and oil from the VSS
3. Gearbox oil level plug (dipstick) magnet.
4. O-ring
NOTE: A dirty VSS will cause erratic speedometer
Dispose gearbox oil as per your local environmen- readings.
tal regulations.
Inspection FUEL SYSTEM
Clean the magnetic drain plug from metal shav- Inspecting the Throttle Body
ings and dirt. Presence of debris gives an indica-
tion of failure inside the gearbox. Check gearbox 1. Refer to ELECTRONIC FUEL INJECTION (EFI)
to correct the problem. subsection to access throttle body.
Reinstall magnetic drain plug. 2. Visually inspect throttle plate and throttle body
venturi for cleanliness.
Always install a NEW sealing ring.
12 219100971-007
3. Clean inside throttle body using a common

throttle body cleaner if necessary.
Evaporative Emission System

Pre-Filter (If Equipped)
Replacing the Evaporative Emission System
Pre-Filter
1. Remove the protective plate.
219001830-007_c
1. Filter
2. Retaining screw
5. Install a new pre-filter assembly. Secure the

hoses using clamps.
TIGHTENING TORQUE
Pre-filter retaining 2.5 N•m ± 0.5 N•m
screw (22 lbf•in ± 4 lbf•in)
6. Reinstall the protective plate.

219001830-006_b
TIGHTENING TORQUE
2. Remove the hose clamps.
Protective plate 6.5 N•m ± 0.5 N•m
retaining screw (58 lbf•in ± 4 lbf•in)
Replacing the Fuel Tank Vent Breather

Filter (Models without EVAP)
Remove the RH lateral panel.
219001830-007_b
1. Hose clamps
3. Remove the retaining screw.

4. Remove the pre-filter assembly.
tmr2017-007-400_a
Unlock the locking tie securing the breather filter.
219100971-007 13
Inspecting the Fuel System

1. Visually inspect fuel tank for cracks, wear
marks, signs of leakage or any other damages.
2. Visually inspect fuel system hoses for proper
rooting, cracking, wear marks, signs of leakage
or any other damages.
3. Carry out a fuel tank leak test. Refer to FUEL
TANK AND FUEL PUMP subsection.
WARNING
All fuel system leaks must be repaired. Dam-
aged, worn or leaking fuel system com-
tmr2017-007-401_a ponents should be replaced to ensure fuel
system tightness.
Remove the breather filter and install the new
one.
Fuel Pump Pressure Test
NOTICE Ensure breather filter is installed Refer to FUEL TANK AND FUEL PUMP subsec-
with the flow arrow pointing upwards. tion for procedure.
ELECTRICAL SYSTEM
Inspecting the Battery
Visually inspect battery casing for cracks or other
damage. If casing is damaged, replace battery
and thoroughly clean battery rack with water and
1 baking soda.
Inspect battery posts condition, battery rack
mounting, straps and strap attachment points.
For battery testing, refer to CHARGING SYSTEM
subsection.
tmr2017-007-402_a DRIVE SYSTEM

1. Flow arrow
Verifying the Front Differential Oil
When reinstalling the breather filter, secure it us- Level
ing the locking tie. Make sure the locking tie holds Clean filler plug prior to check oil level.
the body of the breather filter not the hose, as
shown.
219001799-018_a
TYPICAL
tmr2017-007-403_a 1. Filler plug
14 219100971-007
With vehicle on a level surface, check oil level Install drain plug.
by removing filler plug. Oil level must reach the
TIGHTENING TORQUE
lower edge.
Reinstall filler plug with a NEW sealing ring. 2.75 N•m ± .25 N•m
Drain plug
TIGHTENING TORQUE
Refill front differential with recommended oil.
22.5 N•m ± 2.5 N•m
Filler plug
(17 lbf•ft ± 2 lbf•ft) RECOMMENDED OIL CAPACITY
75W90 SYNTHETIC GEAR
Replacing the Front Differential Oil 400 ml
OIL (P/N 779158) or
(14 U.S. oz)
Place vehicle on a level surface. Set transmission a 75W 90 (API GL-5) gear oil
in park position.
Reinstall filler plug with a NEW sealing ring.
From underneath of vehicle, clean drain plug area.
TIGHTENING TORQUE
16.25 N•m ± 2.75 N•m
Filler plug
Inspecting Drive Shaft Boots

Visually inspect drive shaft boots conditions.
Check boots for cracks, tears, leaking grease, etc.
Repair or replace damaged parts as necessary.
219001799-019_b
UNDERNEATH THE VEHICLE

1. Drain plug
2. Access hole
Place a drain pan under the front differential.

Access the drain plug through the hole in the skid
plate.
Remove drain plug.
Unscrew filler plug. 219001761-103_a
FRONT OF VEHICLE
1. Inner drive shaft boot
219001799-018_a
MODELS WITH VISCO-LOK FRONT DIFFERENTIAL 219001761-104_a
1. Filler plug FRONT OF VEHICLE

1. Outer drive shaft boot
219100971-007 15
219001761-105_a
219001761-127_a
REAR OF VEHICLE (COMPONENTS REMOVED FOR CLARITY)
NOTICE Always use the recommended
wheel nuts for the type of wheel. Using a
different nut could cause damages to the rim
or studs.
Verifying the Wheel Beadlock Torque

NOTICE Do not use an impact wrench for
installing beadlock screws. The risk of screw
breaking or screw stripping is high when using
an impact wrench.
Tighten beadlock screws to the specified torque
using the illustrated sequence. The complete
219001761-106_a
beadlock installation procedure is available in
REAR OF VEHICLE
WHEELS AND TIRES.
TIGHTENING TORQUE
Inspecting Drive Shaft Joint Beadlock screws 25 N•m ± 1 N•m
(FINAL TORQUE) (18 lbf•ft ± 1 lbf•ft)
Turn and move drive shaft to detect excessive
play.
Inspecting the Propeller Shaft U-Joint

Condition
Check yoke U-joints for wear, backlash or axial
play, replace if necessary.
WHEELS AND TIRES

Verifying the Wheel Lug Nut Torque
If tires are unidirectional, their rotation must be
kept in a specific direction. Unidirectional tires
have inscriptions on the sidewall.
Tighten wheel lug nuts to the specified torque us-
ing the illustrated sequence. tmo2015-017-303_c
FINAL TIGHTENING SEQUENCE

TIGHTENING TORQUE
120 N•m ± 10 N•m
Wheel lug nuts
16 219100971-007
STEERING SYSTEM
Inspecting Wheel Bearing
1. Safely lift and support the front of vehicle. Re-
fer to INTRODUCTION subsection.
2. Hold wheel by the top and the bottom and
move it. Check 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 loose (ball joints, suspension pivots, etc). If vmr2010-004-702_a
necessary repair or replace all defective parts TYPICAL
before checking the wheel bearing condition. Be 1. Shock sleeve (2)
careful not to misjudge loose in the ball joint and 2. O-ring (2)
loose in the wheel bearing. 4. Clean spherical bearing using a shop rag to re-
move any dirt and debris.
Inspecting the Steering System
5. Inspect all components for wear and damage.
Steering Column Replace if needed.
Turn and move steering column to detect any play. 6. Lubricate spherical bearing with grease as illus-
Rack and Pinion trated.
Check rack and pinion boots for: SERVICE PRODUCT
– Damage SYNTHETIC GREASE SUSPENSION (P/N 779163)
– Cracks.
Tie-Rod End
Check tie-rod end for:
– Damage
– Pitting
– Play.
SUSPENSION
Inspecting Shock Absorber
vmr2010-004-701_b
Check shock absorber for any leaks, replace if nec- TYPICAL
essary. 1. Apply small amount of grease here
Inspecting and Cleaning Shock 7. Install O-rings then shock sleeves.

Absorber Spherical Bearing 8. Install shock absorber.
1. Remove shock absorber from vehicle.
Replacing Shock Absorber Spherical
2. Remove any dirt or debris prior to removing Bearing
shock sleeves. Cleanliness is critical.
Remove shock sleeves and O-rings refer to IN-
3. Remove shock sleeves then O-rings from SPECTING AND CLEANING SHOCK ABSORBER
shock absorber. SPHERICAL BEARING in this section. Discard
NOTE: There is no O-ring on the front shock lower O-rings.
spherical bearings. NOTE: There is no O-ring on the front shock lower
spherical bearings.
219100971-007 17
SERVICE PRODUCT
SYNTHETIC GREASE SUSPENSION (P/N 779163)
Lubricating Front Suspension Arm

Lubricate suspension arm at grease fittings.
SERVICE PRODUCT
SYNTHETIC GREASE SUSPENSION (P/N 779163)
tmr2013-057-702_a
TYPICAL
1. Sleeve - remove
2. O-ring - discard
Remove and discard both spring clips.
219001761-108_a
TYPICAL - FRONT SUSPENSION

1. Grease fittings
tmr2013-057-705_a
TYPICAL
1. Spring clip
Use a proper sized socket to press bearing out of

location on a press or a vise.
219001761-109_a

1. Grease fittings
Inspecting Front Suspension Arm

Check suspension arm for:
– Cracks
tmr2013-057-703_a – Pitting
TYPICAL
1. Proper sized socket – Bending
– Distortion.
Installation is the reverse of the removal proce-
Check suspension arm for abnormal play:
dure. However, pay attention to the following:
– Side to side
– Install NEW spring clips
– Up and down.
– Install NEW O-rings
– Apply small amount of grease on new bearing. If any play is detected, inspect:
– Bushings
18 219100971-007
– Inner sleeves Adding Brake Fluid

– Wear plates. Clean filler cap before removing.
Check ball joint for: Add fluid as required. Do not overfill.
– Damage NOTE: Ensure filler cap diaphragm is pushed in-
– Pitting side the cap before closing the brake fluid reser-
– Play. voir.
Check ball joint bellows for:
Inspecting and Cleaning the Brake
– Damage
System
– Cracks.
NOTICE Do not clean brake components in
BRAKES petroleum based solvent. Use brake system
cleaner only. Soiled brake pads must be re-
Verifying Brake Fluid Reservoir Level placed with new ones.
Remove the front service cover. Brake Pads
Measure brake pad lining thickness.
BRAKE PAD MINIMUM THICKNESS
0.5 mm (.02 in)
The brake pad grooves are wear indicators.
219001761-207_a
tmr2011-037-008_a
1. Front service cover
BRAKE PAD GROOVE
NOTICE Brake pads must always be replaced

in pairs.
Brake Caliper
1. Remove calipers then check the following com-
ponents:
– Check brake pad pins
– Check caliper boots for cracks
– Check caliper movement on its support
– Check pistons movement
– Check pistons for scratches, rust or other
damages.
219100971-007_001_a
1. Brake fluid cylinder reservoirs 2. Clean the following components using brake
2. MIN cleaner:
3. MAX
– Brake pads
With vehicle on a level surface, check brake fluid – Caliper support and slider
in reservoir for proper level. Brake fluid level – Caliper pistons, spring and pins.
should be between MIN. and MAX. marks.
NOTE: A low level may indicate leaks or worn
brake pads.
219100971-007 19
COUNTRY SERVICE PRODUCT Brake Hoses

XPS BRAKES AND PARTS Check hoses for leaks, crushed, deformations,
USA CLEANER (USA) (P/N 219 cracking or scrapes.
701 705) Any deformation can restrict the proper flow of
XPS BRAKES AND PARTS fluid and cause braking problems.
International
CLEANER (P/N 219 701 776) Wheel scraper
NOTE: Do not remove pistons from caliper for Check if the wear indicator still visible on the
cleaning them. wheel scraper.
3. Lubricate caliper sliders using an appropriate Replacing Brake Fluid
BRAKE CALIPER SYNTHETIC GREASE.
Do not apply grease to brake caliper pad pins. Draining Brake Fluid
1. Clean and remove reservoir cover with its di-
Brake Disc aphragm.
1. Check brake disc as follows: 2. Connect a clear hose into caliper bleeder.
– Check disc thickness
– Check disc surfaces
– Check disc warpage.
NOTE: Refer to INSPECTING THE BRAKE DISC in
BRAKES subsection for details.
2. Clean brake disc using brake cleaner.
COUNTRY SERVICE PRODUCT
XPS BRAKES AND PARTS
USA CLEANER (USA) (P/N 219
701 705)
XPS BRAKES AND PARTS
International
CLEANER (P/N 219 701 776)
tmr2011-037-101_a
Master Cylinder 1. Caliper bleeder

1. Check master cylinder as follows:
3. Loosen caliper bleeder.
– Check cleanliness of master cylinder rod and
boot. 4. Pump brake pedal until no more fluid flows out.
– Check master cylinder boot for cracks or 5. Repeat draining procedure for the other caliper
damage. bleeders.
2. If required, clean then lubricate master cylinder Filling the Brake Fluid
rod and boot using grease. Add recommended brake fluid to MAX. mark. Do
SERVICE PRODUCT not overfill.
COSMO RUBBER GREASE (P/N 715 900 399)
Brake Pedal
1. Check brake pedal as follows:
– Brake pedal pivot movement
– Brake pedal pivot cleanliness.
2. If required, clean then lubricate brake pedal
pivot using synthetic grease.
SERVICE PRODUCT
SYNTHETIC GREASE (P/N 779162)
20 219100971-007
9. Perform bleeding procedure for the other

caliper bleeders.
10. 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.
Bleeding Brake System (Manual Bleeding
Procedure)
NOTE: Brake fluid reservoir must be kept full to
prevent air from being pumped into the system.
219100971-007_001_a
1. Connect a clear hose onto caliper bleeder.
1. Brake fluid cylinder reservoirs
2. MIN 2. Pump up system pressure with brake pedal un-
3. MAX
til pedal resistance is felt.
RECOMMENDED BRAKE FLUID 3. Depress and hold brake pedal.
BRAKE FLUID DOT 4 (P/N 779151) 4. Open bleeder and then close it.
5. Release brake pedal slowly.
WARNING NOTE: Do not release brake pedal until bleeder
– Use only DOT 4 brake fluid from a sealed has been closed.
container. 6. Repeat procedure until fluid flows out without
– Do not use brake fluid from an old or al- any air bubbles.
ready opened container. 7. Tighten bleeder.
Bleeding Brake System (Procedure Using a TIGHTENING TORQUE
Vacuum Pump) 5.5 N•m ± 1.5 N•m
Bleeder
NOTE: Brake fluid reservoir must be kept full to (49 lbf•in ± 13 lbf•in)
prevent air from being pumped into the system.
8. Perform bleeding procedure for the other
1. On each caliper, unscrew bleeder until brake
caliper bleeders.
fluid comes out then close it.
9. Check brake pedal operation:
2. Install the vacuum pump onto caliper bleeder.
– If brake pedal feels spongy, bleed system
REQUIRED TOOL again then carry out the BRAKE SYSTEM
PRESSURE VALIDATION as detailed in
VACUUM/PRESSURE PUMP BRAKES subsection.
(P/N 529 021 800)
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 ap-
pear in clear hose.
7. Close then tighten bleeder.
TIGHTENING TORQUE
5.5 N•m ± 1.5 N•m
Bleeder
8. Add recommended brake fluid to MAX. mark.

Do not overfill.
219100971-007 21
Subsection XX (STORAGE PROCEDURE)
STORAGE PROCEDURE
SERVICE PRODUCTS
BRP HEAVY DUTY CLEANER ....................................................... 293 110 001 ........................................... 2
CLEANER AND DEGREASER PRO C1 ......................................... 779262 ........................................... 2
FUEL STABILIZER ......................................................................... 779171 ........................................... 1
LUB. & ANTI-CORROSIVE ............................................................ 779168 ........................................... 2
OIL STORAGE (EXCEPT USA) ...................................................... 779173 ........................................... 1
OIL STORAGE (USA)..................................................................... 779182 ........................................... 1
GENERAL 2. Spray storage oil into each cylinder.

If the SSV is not used or is to be stored for an NOTE: Use the storage oil as per country availabil-
extended period of time, more than 4 months, be ity.
sure to perform the storage procedures described STORAGE OIL
below.
OIL STORAGE (EXCEPT USA) (P/N 779173)
Where applicable, refer to the appropriate subsec-
tions in this manual for the required tasks outlined OIL STORAGE (USA) (P/N 779182)
in these procedures.
3. Press start button, 1 or 2 seconds maximum, to
lubricate cylinders.
PROCEDURES
4. Reinstall the spark plugs.
To facilitate the inspection and ensure adequate
lubrication of components, it is recommended NOTE: Do not run engine during storage period.
to clean the entire vehicle. Refer to VEHICLE
CLEANING in this subsection. Exhaust System
Block muffler outlet with a rag.
FUEL SYSTEM
Fuel System Protection
With the new fuel additives, it is critical to use the
FUEL STABILIZER (P/N 779171) or an equivalent to
prevent fuel deterioration and fuel system gum-
ming. Follow the manufacturer's instructions for
proper use.
NOTICE Fuel stabilizer should be added
prior to engine lubrication to ensure fuel sys-
tem components protection against varnish
deposits.
Pour fuel stabilizer in fuel tank. Fill up fuel tank. 1
ENGINE tmr2017-008-001_a
1. Muffler opening
Engine Internal Lubrication
CVT Protection
Engine internal parts must be lubricated to protect
them from rust formation during the storage pe- Remove drive belt. Refer to CVT subsection.
riod. Inspect and clean pulleys.
Proceed as follows: Protect pulleys by spraying XPS LUBE (P/N 293
1. Remove spark plugs, refer to IGNITION COILS 600 016) on pulley faces.
AND SPARK PLUGS subsection. NOTE: Do not reinstall drive belt.
219100971-008 1
Subsection XX (STORAGE PROCEDURE)
Close CVT cover. NOTICE The vehicle has to be stored in

Block all CVT outlets with rags . Refer to CVT sub- a cool and dry place and covered with an
section. opaque tarpaulin. This will prevent sun rays
and grime from affecting plastic components
and vehicle finish.
ELECTRICAL SYSTEM
Removing the Battery
Remove the battery.
Charge and store battery as per battery manufac-
turers instructions.
CHASSIS
Lubricating the Suspension
Lubricate the front suspension arms and stabilizer
bars. Refer to PERIODIC MAINTENANCE PRO-
CEDURES subsection.
Tire Pressure
Inflate tires to the recommended pressure.
Cleaning the Vehicle

Wash and dry the vehicle.
NOTICE Never use a high pressure washer
to clean the vehicle. USE LOW PRESSURE
ONLY (like a garden hose). The high pressure
can cause electrical or mechanical damages.
Remove any dirt or rust.
To clean the vinyl or plastic parts, use only flan-
nel clothes with CLEANER AND DEGREASER PRO
C1 (P/N 779262).
NOTICE It is necessary to use flannel cloths
on plastic parts to avoid damaging surfaces.
Never clean plastic parts with strong deter-
gent, degreasing agent, paint thinner, acetone,
products containing chlorine, etc.
To clean the entire vehicle, including metallic parts
use BRP HEAVY DUTY CLEANER (P/N 293 110 001).
Inspect the vehicle and repair any damage. Touch
up all metal spots where paint has been scratched
off. Spray all metal parts with LUB. & ANTI-CORRO-
SIVE (P/N 779168).
Vehicle Protection
Protect the vehicle with a cover to prevent dust
accumulation during storage.
2 219100971-008
Subsection XX (PRESEASON PREPARATION)
PRESEASON PREPARATION
Prior to using vehicle, proper vehicle preparation is required after a storage period.
If any worn, broken or damaged parts are found, replace them.
Remove rags that were installed for storage: CVT outlet hoses and mufflers.
Clean drive and driven pulleys to remove storage protective lubricant, then reinstall drive belt. Refer to
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) subsection.
Disconnect air inlet hose from the air filter housing and inspect for animal nests etc. Reinstall hose.
Drain fuel tank and fill with fresh fuel if a fuel stabilizer was not used for the storage.
Reinstall battery. Refer to CHARGING SYSTEM subsection.
Using the maintenance chart, perform the items titled:
IF OPERATED IN TRAIL RIDING CONDITIONS IF OPERATED IN SEVERE RIDING CONDITIONS
EVERY YEAR OR 3 000 km (2,000 mi) OR 100 EVERY YEAR OR 1 500 km (1,000 mi) OR 50
HOURS (whichever comes first) HOURS (whichever comes first)
NOTE: If the next maintenance service is due, also perform the related items as per the maintenance
chart.
Test drive vehicle to confirm proper operation.
tmr2017-009 1
Subsection XX (SPECIAL PROCEDURES)
SPECIAL PROCEDURES
SERVICE PRODUCTS
LUB. & ANTI-CORROSIVE ............................................................ 779168 ........................................... 2
GENERAL NOTICE A submerged vehicle may cause

several damages (short and long term) if not
NOTE: Component failures resulting from these serviced adequately or soon enough. If water
events are not warrantable. was drawn into the engine, the engine is most
Refer to the appropriate subsections in this man- likely in a hydraulic lock. Do not crank or start
ual for the required tasks outlined in these proce- engine or severe damage will occur. Inspect
dures. engine for water intrusion and hydraulic lock
damage (water in the oil and cylinders, bent
ROLLED OVER VEHICLE piston rod...). Carry out all items in this topic
before cranking or attempting to start engine.
1. In the event the vehicle was rolled over, check
the following. 1. Drain the entire air intake system. Inspect the
1.1 Inspect components of the following sys- throttle body. Remove parts as required.
tems: suspension, drivetrain and steering. 2. On turbo equipped vehicles, also check for wa-
1.2 Inspect body and chassis for damage ter intrusion through both sides of the turbo (im-
(welded joints, bent or cracked parts). peller and compressor sides). Clean and dry as
required.
1.3 Pay particular attention to the radiator,
cage, doors, seat belts and their mecha- 3. Inspect the boost control solenoid valve (turbo
nisms. engines). Clean valve, test engine and turbo
system for proper operation. Replace valve if
WARNING required.
Do not use vehicle if any of the safety 4. Replace the air filter.
devices are damaged or inoperative. 5. Drain, inspect and clean the CVT.
6. Empty mufflers (removal required).
1.4 Check all fluids level before restarting en-
gine (engine oil, coolant, differential oil, 7. Empty resonator (removal required).
gearbox oil, and brake fluid). 8. Unplug ECM, multifunction gauge, DPS, and
open fuse boxes. Check for presence of water.
NOTICE Check for oil accumulation in Dry as necessary.
the air intake system. Check air filter.
9. Inspect all lights for water intrusion. Dry as re-
1.5 Inspect engine and exhaust system for quired.
any signs of liquid spillage. If liquids are 10. Replace the engine oil (without starting the en-
present, use a cleaner and wipe the af- gine).
fected surfaces.
11. Remove spark plugs. Crank engine in
2. After restarting engine, check multifunction drowned mode to expel any water.
gauge if any malfunction is detected.
3. Troubleshoot and repair as required before us- CAUTION Keep away from spark plug
ing vehicle. holes to avoid being splashed when cranking
engine.
SUBMERGED VEHICLE 12. Add a small quantity of engine oil in cylinders
In the event the vehicle was submerged, proceed (approximately 2 teaspoonfuls).
with the following. 13. Install spark plugs (replace if required).
14. Look for water in fuel tank, if in doubt, flush
fuel tank and refill with new gas.
219100971-009 1
Subsection XX (SPECIAL PROCEDURES)
15. Look for water in brake system. Replace

brake fluid as required.
16. Before starting engine, use the BRP Diagnos-
tic Software (BUDS2) and check vehicle for
fault codes.
17. Start the engine and allow it to run at idle
speed until the engine reaches its operating
temperature.
18. Stop the engine.
19. Change engine oil and filter.
NOTE: Change oil as many times as necessary,
until there is no whitish appearance in engine oil.
20. Check gearbox oil. Replace oil if contaminated
with water.
21. Replace oil of front differential.
22. Lubricate front suspension arms and rear
stabilizer bar. Refer to PERIODIC MAINTE-
NANCE PROCEDURES subsection.
23. Spray all metal parts with LUB. & ANTI-CORRO-
SIVE (P/N 779168).
24. Test drive to confirm proper operation.
2 219100971-009
Subsection XX (ENGINE REMOVAL AND INSTALLATION)
ENGINE REMOVAL AND INSTALLATION
61 ± 9 N•m
(45 ± 7 lbf•in)
NEW
NEW
61 ± 9 N•m
(45 ± 7 lbf•in)
NEW = Component must be replaced when removed.
tmr2017-011-101_a
219100971-010 1
PROCEDURES
REMOVING THE ENGINE
Preparing the Vehicle and Engine
1. Place vehicle on a workstation that will have ac-
cess to an engine-lifting hoist.
2. Safely lift and support the vehicle. Refer to IN-
TRODUCTION subsection.
3. Drain the engine coolant. Refer to REPLAC-
ING THE ENGINE COOLANT in the PERIODIC
MAINTENANCE PROCEDURES subsection.
4. With BUDS2, Go to Function and execute a
fuel pressure relief.
5. Refer to the appropriate subsection and re-
move:
– Seats
– Rear body module
– Intercooler shroud
– Rear drive shafts
tmr2017-011-023
– Rear shock absorbers
– Muffler and its support 7. Drain engine oil. Refer to ENGINE OIL
– Exhaust heat shield CHANGE in the PERIODIC MAINTENANCE
– CVT air inlet and outlet hoses
PROCEDURES subsection.
– Air intake silencer NOTE: Drain engine oil only if engine overhaul is
necessary.
– shifter cable from gearbox
– Hose cover on the RH side of engine 8. Disconnect battery and ECM harness.
– Coolant hoses from water pump. Cut all lock- The ECM harness is located behind the driver's
ing ties. seat.
6. Remove the 2 coolant hoses shown from ex-
pansion tank.
219100971-010-002_a
2 219100971-010
219100971-010-003_a
NOTICE Always unplug battery cables ex- tmr2017-011-704

actly in the specified order, the BLACK (-) cable
first.
9. Disconnect:
– Starter cable
– Fuel hose from fuel rail
– Gearbox vent hose
– Engine ground wire
– Voltage regulator.
10. Remove seat belt tie bar. Drill rivets to re-
move.
tmr2017-011-703
tmr2017-011-010
Lifting the Engine

1. Install 2 straps as shown.
tmr2017-011-702
STRAPS UNDER MANIFOLD
2. Remove the front engine support bolts.
219100971-010 3
Final Assembly Procedure

1. Fill engine with the recommended oil and quan-
tity. Refer to CHANGING THE ENGINE OIL in
the PERIODIC MAINTENANCE PROCEDURES
subsection.
2. Fill and bleed cooling system. Refer to RE-
PLACING THE ENGINE COOLANT in the
PERIODIC MAINTENANCE PROCEDURES
subsection.
3. Check for any leaks.
tmr2017-011-020_a
4. Reinstall all remaining parts.
5. Test drive vehicle to confirm proper operation.
3. Lift engine with the rear support bolt still in
place, to tilt the engine and gearbox assembly.
ENGINE MOUNTS
NOTE: Use the same procedure for the front and
rear engine mounts.
Removing the Engine Mount

Insert a punch into engine mount bushing and
push the opposite engine mount out.
tmr2017-011-700
NOTE: Make sure engine does not tilt side-to-

side, readjust straps as necessary.
4. Remove rear support bolt and lift engine from tmr2011-007-011
TYPICAL
vehicle.
Installing the Engine Mount
INSTALLING THE ENGINE
The installation is the reverse of the removal pro-
The installation is the reverse of the removal procedure.
cedure. However, pay attention to the following.
Prior to install engine, inspect condition of engine
mounts.
TIGHTENING TORQUE
Engine mount screw 61 N•m ± 9 N•m
(M10) (45 lbf•ft ± 7 lbf•ft)
NOTE: Do not install plastic parts and seats prior

to FINAL ASSEMBLY.
4 219100971-010
Subsection XX (AIR INTAKE SYSTEM)
AIR INTAKE SYSTEM

AIR FILTER HOUSING
10 ± 2 N•m
(89 ± 18 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
tmr2017-012-100_a
tmr2017-012 1
GENERAL
NOTICE Never modify the air intake system.
Otherwise, engine performance degradation
or damage can occur. The engine is calibrated
to operate specifically with these components.
PROCEDURES
AIR FILTER
For air filter servicing, refer to PERIODIC MAIN-
TENANCE PROCEDURES subsection.
tmr2017-012-103_a
AIR FILTER HOUSING

Installing the Air Filter Housing
Removing the Air Filter Housing
Move the driver's seat forwards. cedure. However, pay attention to the following
Remove air filter housing screws and washers. details.
When installing the inlet tube, make sure to posi-
tion the tab of the inlet tube in the slot of the air
inlet housing.
1
3
tmr2017-012-102_a
4
From underneath of rear rack, disconnect inlet 2
hoses from air filter housing
tmr2017-012-104_a
1. Air inlet housing

2. Air inlet housing slot
3. Inlet tube
4. Inlet tube tab
During turbo inlet tube installation, position the

tab of the air filter housing inside both tab of the
turbo inlet tube.
tmr2017-012-101_a
MANY PARTS REMOVED FOR CLARITY PURPOSE

1. Loose these clamps
Remove the air filter housing from the vehicle.

2 tmr2017-012
tmr2017-012-105_a
When installing the turbo inlet tube on the turbo,

position the tab of the tube against the turbo.
tmr2017-012-106_a
tmr2017-012 3
Subsection XX (EXHAUST SYSTEM)
EXHAUST SYSTEM
See ELECTRONIC FUEL
INJECTION (EFI) 9.5 ± 0.5 N•m
42.5 ± 2.5 N•m (84 ± 4.5 lbf•in)
(31 ± 2 lbf•ft)
7 ± 1 N•m
(62 ± 9 lbf•in)
NEW
11 ± 1 N•m
(97 ± 9 lbf•in) NEW
9.5 ± 0.5 N•m
(84 ± 4.5 lbf•in)
Xmr models
NEW
NEW
32 ± 2 N•m
(23.5 ± 1.5 lbf•in)

219100971-011-100_b
219100971-011 1
PROCEDURES
WARNING
Never touch exhaust system components im-
mediately after the engine has run.
SPARK ARRESTER
For spark arrester servicing, refer to PERIODIC
MUFFLER tmr2017-013-002
3. Remove springs securing muffler to exhaust

pipe and remove muffler.
tmr2017-013-004
Removing the Muffler tmr2017-013-003

1. Remove rear fascia.
Inspecting the Muffler
Check muffler for cracks or other damages. Re-
place if necessary.
Installing the Muffler

For the installation, reverse the removal proce-
dure.
See exploded view for torque specifications.
EXHAUST PIPE GASKET

Replacing the Exhaust Pipe Gasket
tmr2017-013-001_a
1. Remove the muffler. See procedure in this sub-
2. Remove screws holding muffler to support on section.
each side. 2. Remove the old gasket from the exhaust pipe.
2 219100971-011
tmr2017-013-009_a tmr2017-013-010
DISCONNECT OXYGEN SENSOR

1. Exhaust pipe
2. Exhaust pipe gasket 3. Remove exhaust heat shield with brackets.
3. Install a new gasket on the exhaust pipe.
4. Install the muffler as per procedure in this sub-
section.
NOTE: Be sure to apply specified torques and ver-
ify for proper clearances as specified.
CATALYST
The catalyst is part of the exhaust pipe.
EXHAUST PIPE
tmr2017-011-025_a
4. Remove clamps securing heat shields to ex-

haust pipe and remove heat shields.
tmr2017-013-005
Removing the Exhaust Pipe

1. Remove the muffler, refer to REMOVING THE
MUFFLER in this subsection.
2. Disconnect oxygen sensor.
tmr2017-013-007
5. Remove V-Band clamp and remove exhaust

pipe.
NOTE: The V-band clamp nut is stainless steel, do
not use power tools as nut may seize on stud.
219100971-011 3
tmr2017-013-008
Inspecting the Exhaust Pipe

Check head pipe for cracks, bending or other dam-
ages. Replace if need.
Installing the Exhaust Pipe

Install new exhaust gasket.
See exploded view for torque specifications.
Make sure V-band clamp is properly seated by
rotating it back and forth before final clamping.
Make sure V-band clamp heat shield is located as
shown.
NOTE: The V-band clamp nut is stainless steel, do
not use power tools as nut may seize on stud.
4 219100971-011
Subsection XX (LUBRICATION SYSTEM)
LUBRICATION SYSTEM
SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 5
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................................. 5
OIL PRESSURE HOSE .................................................................. 529 036 394 ............................................. 5
PRESSURE GAUGE....................................................................... 529 036 395 ............................................. 6
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 6, 9
219100971-012 1
7 2
4
tmr2017-014-001_a
ENGINE LUBRICATION CIRCUIT

1. Oil channel to camshaft bearings
2. Oil pressure switch
3. Crankshaft main bearings
4. Oil strainers
5. Oil pressure regulator
6. Oil filter
7. Oil cooler
8. Timing chain tensioner
9. Oil Nozzles
2 219100971-012
9 ± 1 N•m
Oil filter (80 ± 9 lbf•in)
See PERIODIC MAINTENANCE See tightening procedure
PROCEDURES Engine oil
NEW
See NEW
tightening 10 ± 1 N•m
procedure (89 ± 9 lbf•in)
Loctite 243
Engine oil
7 ± 0,8 N•m
17 ± 2 N•m NEW (62 ± 7 lbf•in)
(150 ± 18 lbf•in)
Engine
12 ± 1 N•m oil
NEW
(106 ± 9 lbf•in)
Loctite 243
NEW
15 ± 2 N•m 9 ± 1 N•m NEW

(133 ± 18 lbf•in) (80 ± 9 lbf•in)
See
TURBO CHARGER
AND INTERCOOLER
10 ± 1 N•m
15 ± 2 N•m (89 ± 9 lbf•in)
(133 ± 18 lbf•in)
12 ± 1 N•m
Loctite 243 NEW
15 ± 2 N•m NEW
(133 ± 18 lbf•in)
See See tightening procedure

TURBO CHARGER NEW
AND INTERCOOLER
30 ± 3 N•m
(22 ± 2 lbf•ft)
NEW = Component must be replaced when removed. NEW
tmr2017-014-002_a
219100971-012 3
9 ± 1 N•m
(80 ± 9 lbf•in)
Engine oil
9 ± 1 N•m
(80 ± 9 lbf•in)
Engine oil
Engine oil
9 ± 1 N•m
(80 ± 9 lbf•in) Engine oil
NEW
9 ± 1 N•m NEW
(80 ± 9 lbf•in)
19 ± 2 N•m
Engine oil (168 ± 18 lbf•in)
Engine oil

tmr2017-014-003_a
4 219100971-012
GENERAL The oil pressure is provided by a pump and regu-

lated by a spring loaded pressure regulator.
The following tools are required to test most of
the electrical parts.
INSPECTION
REQUIRED TOOL
ENGINE OIL PRESSURE
FLUKE 115 MULTIMETER The engine oil pressure plug is located on the LH
(P/N 529 035 868)
side of the cylinder block, behind the CVT housing
and below the timing chain tensioner.
ECM ADAPTER TOOL

(P/N 529 036 166)

ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
1
WARNING
tmr2017-014-201_a
must be strictly adhered to. Locking devices
1. Oil pressure test plug screw
when removed (e.g.: locking tabs, elastic
stop nuts, cotter pins, etc.) must be replaced 1. Remove oil pressure test plug screw from cylin-
with new ones. der block.
NOTICE Hoses, cables or locking ties re-

moved during a procedure must be reinstalled
as per factory standards.
SYSTEM DESCRIPTION
This engine uses dry sump lubrication. The oil
from the cylinder block, timing chain chamber and
magneto cover is pumped by two suction pumps.
Both suction pumps are integrated into one mod-
ule.
The 20 mm (.79 in) large oil suction pump returns
tmr2017-014-004_a
the crankshaft and magneto chamber oil to the
reservoir. 2. Timing chain tensioner
The 11 mm (.43 in) small oil suction pump returns
the timing chain chamber oil to the oil reservoir. 2. Install the adapter hose on cylinder block.
An oil filter and three oil strainers are used to filter REQUIRED TOOLS
dirt and debris from the oil circuit.
The oil strainers are located between oil sump OIL PRESSURE HOSE
cover and crankcase lower underneath the oil (P/N 529 036 394)
pressure pump.
219100971-012 5
tmr2017-014-005_a tmr2017-014-004_a

3. Connect the pressure gauge to adapter hose. 2. Timing chain tensioner
REQUIRED TOOL 8. Reinstall all removed parts.
TROUBLESHOOTING
PRESSURE GAUGE (P/N 529 Always check for fault codes. If a fault code is de-
036 395) tected, service the fault code first.
LOW OR NO ENGINE OIL PRESSURE

1. Oil level is too low.
4. Start engine and check the oil pressure. - Refill engine oil.
ENGINE OIL PRESSURE @ 100°C (212°F) - Check for high oil consumption. See below.
- Check for oil leaks (oil leaking out of leak indica-
ENGINE SPEED MINIMUM PRESSURE tor hole, gaskets, oil seal or O-rings). Repair or
Idle 80 kPa (11.6 PSI) replace.
4000 RPM 270 kPa (39.16 PSI) 2. Defective or clogged oil filter
- Replace engine oil and filter.
6000 to 7250 RPM 350 kPa (50.76 PSI)
3. Use of a bad grade oil
If the engine oil pressure is out of specification, - Replace engine oil with BRP recommended oil.
refer to TROUBLESHOOTING in this subsection.
4. Oil pressure regulator valve sticks open, or
5. Remove engine oil pressure test tools. spring load is insufficient.
6. Clean threads of oil pressure test plug screw - Clean oil regulator piston and its bore. Replace if
before installing the plug screw. necessary.
7. Tighten oil pressure test plug screw to specifi- - Measure spring free length. Replace if out of
cation. specification.
TIGHTENING TORQUE 5. Oil pump(s) worn or damaged.

- Check if oil pump drive gears are damaged. Re-
12 N•m ± 1 N•m place if necessary.
Oil pressure test plug - Check oil pump rotors and its bore for wear limits.
+ Replace if out of specification.
screw
LOCTITE 243 (BLUE)
(P/N 293 800 060) 6. Engine oil strainer is clogged.
- Remove and clean engine oil strainer.
7. Heavy wear on plain bearings.
- Check radial clearance of plain bearings. Replace
if out of specification.
6 219100971-012
HIGH OIL CONSUMPTION

1. Oil in breathing system.
- Check if breather V-ring is brittle, hard or dam-
aged. Replace V-ring.
- Check if oil separator cover is damaged or miss-
ing.
2. Valve stem seals worn or damaged.
- Replace valve stem seals.
3. Piston rings worn out (blue colored exhaust
smoke).
- Replace piston rings.
OIL CONTAMINATION
tmr2017-014-202_a
(WHITE APPEARANCE)
1. Oil seal and rotary seal on water pump shaft Inspecting the OPS
leaking. First, ensure oil pressure is adequate. Refer to
- Replace oil seal, rotary seal and water pump ENGINE OIL PRESSURE.
shaft. Change engine oil.
If the oil pressure is good, check the resistance of
2. Cylinder head gasket leaking. the oil pressure switch.
- Replace cylinder head gasket. Change engine oil.
Testing the OPS Resistance
3. Cylinder head screws not properly tightened.
- Retighten screws with recommended torque.
The engine must be warm to check the oil pres-
Change engine oil. sure switch properly.
4. Oil cooler gasket leaking. WARNING
- Replace gasket. Change engine oil. Be careful when working near hot part. To
avoid potential burns, never touch exhaust
PROCEDURES system components immediately after the
engine has been running as these compo-
OPS (OIL PRESSURE SWITCH) nents are very hot. Always use long sleeves
and gloves.
OPS Activation
The oil pressure switch activates when the engine 1. Cut locking tie and disconnect the OPS connec-
oil pressure is lower than following specified pres- tor.
sure range.
NOTE: ECM does not trigger the OPS signal be-
low 4500 rpm.
OIL PRESSURE SWITCH ACTIVATION RANGE
20 kPa to 40 kPa (2.9 PSI to 5.8 PSI)
OPS Location
The OPS is located on the front of the cylinder
head, near the starter.
tmr2017-014-006_a
UNDER EXHAUST MANIFOLD

1. Locking tie
2. OPS connector
2. Check the oil pressure switch resistance.
219100971-012 7
3. Read result and compare to table. If the continuity is good and all other tests are per-
formed, try a NEW ECM.
RESISTANCE ( )
If the continuity is bad, repair or replace defective
ENGINE NOT RUNNING wire or connectors.
Close to 0
OPS pin Engine ground (normally Removing the OPS
closed switch) 1. Cut locking tie and unplug the OPS switch con-
nector.
If resistance is out of specification, replace the oil
pressure switch.
If the resistance is correct, continue procedure. It
will be necessary to use jumper wires.
4. Start engine.
5. Read result and compare to table.
RESISTANCE ( )
ENGINE RUNNING
Infinitely high
OPS pin Engine ground
(OL)
If resistance is out of specification, replace the oil

pressure switch. tmr2017-014-006_a
1. Locking tie
If the resistance is correct, check the oil pressure 2. OPS connector
switch circuit continuity.
2. Unscrew and remove the OPS.
Testing the OPS Circuit Continuity NOTICE During OPS removal hold threaded
1. Disconnect ECM connector A. Refer to ECM nipple.
CONNECTOR ACCESS in ELECTRONIC FUEL
INJECTION) subsection.
2. Install connector A to the ECM adapter.
3. Cut locking tie and disconnect the OPS connec-
tor.
tmr2017-014-007_a
1. Oil pressure switch

2. Threaded nipple
Installing the OPS

tmr2017-014-006_a
Install oil pressure switch as per the following in-
1. Locking tie
formations.
2. OPS connector
4. Check continuity as follows.

CIRCUIT CONTINUITY
OPS connector ECM A pin E3 Close to 0
8 219100971-012
TIGHTENING TORQUE Installing the Oil Filler Tube

12 N•m ± 1 N•m 1. Install NEW O-rings on the oil filler tube.
Oil pressure switch +
LOCTITE 243 (BLUE)
(P/N 293 800 060)
Install all other removed parts.

NOTICE When installing the locking tie on
the OPS connector, take care that the wires do
not make a sharp bend.
OIL FILLER TUBE

Oil Filler Tube Location
The oil filler tube is located behind the throttle tmr2017-014-009_a
body.
2. Lubricate the oil tank cover bore with engine oil.
tmr2017-014-010_a
tmr2017-014-203_a 1. Lubricate the oil tank cover bore
Removing the Oil Filler Tube 3. Install the oil filler tube.
1. Remove the oil filler tube retaining screw. 4. Tighten retaining screw to the specified torque.
TIGHTENING TORQUE
7 N•m ± 0.8 N•m
Oil filler tube screw
5. Install all other removed parts.
OIL TANK
Removing the Oil Tank Cover
1. Drain engine oil. Refer to PERIODIC MAINTE-
2. Remove the engine from vehicle. Refer to EN-
GINE REMOVAL AND INSTALLATION subsec-
tmr2017-014-008_a
tion.
1. Oil filler tube
2. Retaining screw 3. Remove intake manifold. Refer to AIR INTAKE
SYSTEM subsection.
2. Pull filler tube out of the oil tank cover
219100971-012 9
4. Place a drain pan underneath oil tank.

5. Unscrew oil tank cover retaining screws.
tmr2017-014-011_b
TIGHTENING SEQUENCE STEP A
2.2 Tighten the following screws to the speci-

tmr2017-014-011_a fied torque and sequence.
RETAINING SCREWS
TIGHTENING TORQUE
6. Remove oil tank from the engine. Oil tank 9 N•m ± 1 N•m
STEP B
Installing the Oil Tank Cover
1. Install NEW gasket.
2. Install the oil tank on the engine, then tighten
screws in two steps as follows:
fied torque and sequence.
TIGHTENING TORQUE
Oil tank 5 N•m ± 0.6 N•m
STEP A
tmr2017-014-011_c
TIGHTENING SEQUENCE STEP B
3. Wipe off any oil spillage.

4. Install intake manifold. Refer to AIR INTAKE
SYSTEM subsection.
5. Install the engine in the vehicle. Refer to EN-
GINE REMOVAL AND INSTALLATION subsec-
tion.
10 219100971-012
6. Fill up oil tank and check oil level. Refer to PERI-

ODIC MAINTENANCE PROCEDURES subsec-
tion.
OIL COOLER
Oil Cooler Location
The oil cooler is located on the RH side of the en-
gine, over the magneto cover.
tmr2017-014-012_a
1. Retaining screws
2. Oil cooler
3. Gasket
Inspecting the Oil Cooler

Check oil cooler for cracks and other damage.
tmr2017-014-204_a
Removing the Oil Cooler

1. Refer to PERIODIC MAINTENANCE PROCE-
DURES subsection to :
– Drain engine oil
– Drain cooling system.
2. Place rags or towels under oil cooler to catch tmr2017-014-013_a
remaining oil and coolant.

3. Remove: Replace parts as necessary.
– Retaining screws Installing the Oil Cooler
– Oil cooler
For installation, reverse the removal procedure.
– Gasket. However, pay attention to the following.
Tighten oil cooler screws in two steps to the spec-
ified torque following the illustrated sequence.
TIGHTENING TORQUE
5 N•m ± 0.6 N•m
STEP A
OIL COOLER (44 lbf•in ± 5 lbf•in)
SCREWS 9 N•m ± 1 N•m
STEP B
219100971-012 11
mmr2011-070-023_a
tmr2017-014-014_a 1. Plug
2. Sealing washer
TIGHTENING SEQUENCE OIL-COOLER 3. Regulator spring
4. Regulator piston
Wipe off any oil and coolant spillage.
Refer to PERIODIC MAINTENANCE PROCE- Inspecting the Oil Pressure Regulator
DURES subsection to: Clean bore and thread in the magneto cover from
– Fill up oil tank and check oil level any contamination.
– Refill and bleed cooling system. Inspect oil pressure regulator piston and its bore
in cylinder block for scoring or other damages.
OIL PRESSURE REGULATOR Check if piston moves easily in its bore.
Oil Pressure Regulator Location Check compression spring for free length.
The engine oil pressure regulator is located inside SPRING FREE LENGTH
the magneto cover.
NEW NOMINAL 46 mm (1.811 in)
SERVICE LIMIT 45 mm (1.772 in)
Visually check compression spring for square-

ness.
Replace worn or damaged components.
Installing the Oil Pressure Regulator

However, pay attention to the following.
Install a NEW sealing washer on plug.
Tighten regulator plug to the specified torque.
mmr2011-070-022_a
1. Engine oil pressure regulator TIGHTENING TORQUE
Removing the Oil Pressure Regulator Oil pressure regulator 17 N•m ± 2 N•m
plug (150 lbf•in ± 18 lbf•in)
1. Drain engine oil. Refer to PERIODIC MAINTE-
NANCE PROCEDURES subsection. Wipe off any oil spillage.
2. Remove regulator plug and sealing washer. Fill up oil tank and check oil level. Refer to PE-
Discard sealing washer. RIODIC MAINTENANCE PROCEDURES subsec-
3. Pull oil pressure regulator parts out of the mag- tion.
neto cover. Install all other removed parts.
12 219100971-012
OIL PUMP DRIVE GEARS

Oil Pump Drive Gear Location
The oil pump gears are located on the MAG side,
behind the magneto cover.
mmr2011-070-026_a
1. Intermediate gears
2. Bearing Sleeves
3. Remove oil pump gears and needle pins.
mmr2011-070-024_a
1. Oil pump drive gear

3. Oil pressure pump gear
4. Oil suction pump gear
Removing the Oil Pump Drive Gear

Refer to MAGNETO AND STARTER subsection to
remove:
– Magneto cover
– Rotor mmr2011-070-027_a
1. Oil pump gears

– Sprag clutch gear. 2. Needle pins
1. Unscrew oil pump intermediate gear screws.
Inspecting the Oil Pump Drive Gear
Inspect gears for wear, cracks or other damage.
Replace if damaged.
Installing the Oil Pump Drive Gear

For installation, reverse the removal procedure,
however, pay attention to the following.
1. Ensure not to mix up the oil pump gears, see
next illustration.
1.1 Install the BROWN oil pump gear
(29 teeth) on oil pressure pump.
1.2 Install the BLACK oil pump gear (28 teeth)
mmr2011-070-024_b on oil suction pump.
1. Retaining screws
2. Remove bearing sleeves and oil pump interme-

diate gears.
219100971-012 13
mmr2011-070-028_a
1. BROWN oil pump gear - 29 teeth mmr2011-070-030_b

2. BLACK oil pump gear - 28 teeth
1. Retaining screws
2. Oil pump cover
2. Lubricate intermediate gears bearing sleeves
with engine oil, then install gears. 3. Remove the following parts.
tion.
OIL PRESSURE PUMP

Oil Pressure Pump Location
The oil pressure pump is located in the cylinder
block, behind the magneto cover.
mmr2011-070-032_a
1. Inner rotor
2. Oil pump shaft
3. Needle pin
4. Outer rotor
Inspecting the Oil Pressure Pump

Inspect oil pump and oil pump cover bore for
marks, scratches or other damage. Replace any
damaged parts.
Check oil pump cover for damages and for surface
straightness with a straight edge.
mmr2011-070-030_a
Check inner rotor for corrosion, worn pin slots or
1. Oil pressure pump
other damages. If so, replace inner and outer rotor
at the same time.
Removing the Oil Pressure Pump
1. Remove OIL PUMP DRIVE GEARS, see proce-
dure in this subsection.
2. Remove oil pump cover.
14 219100971-012
rmr2008-011-020
OUTER ROTOR THICKNESS
Using a depth gauge, measure the depth of oil

vmr2008-012-016_a pump bore in the lower crankcase.
1. Pitting on the teeth
Radial Clearance
Using a feeler gauge, measure the clearance of
outer rotor and inner rotor where shown with the
arrows.
mmr2011-070-056
OIL PUMP BORE DEPTH (OIL PUMP COVER)
Substract bore depth from rotor thickness to ob-

tain axial clearance.
OIL PUMP AXIAL CLEARANCE
SERVICE LIMIT 0.15 mm (.0059 in)
NOTE: When the axial clearance of the oil pump

assembly increases, the oil pressure decreases.
Installing the Oil Pressure Pump

vmr2008-012-014_c
OIL PUMP RADIAL CLEARANCE
1. Lubricate outer rotor with engine oil.
NOTICE Install rotors with the marks out-
NOTE: If clearance of inner and outer rotors ex- wards.
ceeds the tolerance, replace oil pump.
2. Install outer rotor into crankcase oil pump bore.
Axial Clearance
Measure outer rotor thickness with a micrometer.
219100971-012 15
OIL SUCTION PUMP MODULE

Oil Suction Pump Module Location
The oil suction pump module is located in the
cylinder block, behind the magneto cover.
vmr2008-012-014_b
TYPICAL mmr2011-070-039_a
1. Marks on inner and outer rotor
1. Oil suction pump module
3. Install needle pin in oil pump shaft.

Disassembling the Oil Suction Pump
NOTICE The oil pump shaft is not symmetri- Module
cal, the longer side must be installed inward. 1. Remove OIL PUMP DRIVE GEARS, see proce-
2. Remove oil pump module cover.
mmr2011-070-057_a
1. Towards engine
A. 16.96 mm (.67 in)
B. 11.43 mm (.45 in)
C. 60.5 mm (2.38 in)
4. Place inner rotor onto the oil pump shaft. Lubri-

cate oil pump shaft and inner rotor with engine
oil. mmr2011-070-040_a
1. Oil pump module cover

5. Install oil pump assembly into the crankcase. 2. Retaining screws
After installation of the remaining parts, check for
smooth operation of the oil pump assembly and 3. Disassemble the large oil suction pump as
axial play of the oil pump shaft. shown.
tion.
Start engine and make sure oil pressure is within
specifications (refer to ENGINE OIL PRESSURE in
this subsection).
16 219100971-012
Inspecting the Oil Suction Pumps

The inspection of both oil suction pumps is the
same as for the oil pressure pump. Refer to OIL
PRESSURE PUMP in this subsection.
Assembling the Oil Suction Pump
Module
1. Lubricate small oil suction pump outer rotor
with engine oil.
mmr2011-070-041_a
1. Inner rotor NOTICE When installing the oil pump rotors,

2. Needle pin
3. Outer rotor make sure both marks are pointing toward the
inside of the crankcase.
4. Disassemble the small oil suction pump as
shown.
mmr2011-070-046_a
1. Mark on inner rotor

mmr2011-070-042_a
2. Mark on outer rotor
1. Oil pump cover
2. Oil pump shaft
3. Needle pin 2. Install small oil suction pump outer rotor into
4. Inner rotor crankcase oil pump bore.
5. Outer rotor
5. Remove and discard the oil pump cover O-ring.
mmr2012-133-004_a
1. Small oil suction pump outer rotor

mmr2011-070-043_a
3. Install needle pin in bore of the oil pump shaft
1. Oil pump cover O-ring
and place the small inner rotor on the shaft.
219100971-012 17
8. Align tab of the oil pump cover with the upper

recess in the crankcase. Push cover in until a
click is heard, indicating the cover is properly
installed.
mmr2012-133-005_a
1. Needle pin
2. Oil pump shaft
3. Small suction pump inner rotor
4. Lubricate oil pump shaft and inner rotor with

engine oil.
5. Install oil pump shaft assembly into the
crankcase.
mmr2011-070-048_a
1. Oil pump cover tab properly positioned
9. Install large oil suction pump needle pin.

10. Install large oil suction pump inner rotor and
outer rotor with the marks outwards.
mmr2011-070-045_a
1. Oil pump shaft with small oil suction pump
6. Install a NEW oil pump cover O-ring.
mmr2011-070-050_a
1. Marks on inner and outer rotor
11. Lubricate large oil suction pump parts with en-

gine oil.
12. Install other removed parts.
After installation is complete, check for smooth
operation of the oil pump assembly and axial play
of the oil pump shaft.
13. Fill up oil tank and check oil level. Refer to PE-
RIODIC MAINTENANCE PROCEDURES sub-
mmr2011-070-047_a
section.
1. Oil pump cover O-ring
Start engine and make sure oil pressure is within
7. Lubricate both sides of the oil pump cover with specifications (refer to ENGINE OIL PRESSURE in
engine oil. this subsection).
18 219100971-012
OIL SUMP COVER

Oil Sump Cover Location
The oil sump cover is located on the engine bot-
tom.
tmr2017-014-018_a
4. Unscrew oil sump cover retaining screws.

5. Remove oil sump cover. Discard gasket.
6. Remove and clean engine oil strainers.
tmr2017-014-024_a
BOTTOM OF ENGINE
Removing the Oil Sump Cover

1. Remove the drive shaft from the engine. Refer
to FRONT DRIVE subsection.
2. Drain engine oil, refer to PERIODIC MAINTE-
tmr2017-014-017_a
1. Retaining screws
2. Oil sump cover
3. Gasket
4. Engine oil strainers
Inspecting the Oil Sump Cover

Clean oil sump cover and engine oil strainers with
a part cleaner, then use an air gun to dry it.
tmr2017-014-016_a
Blow out the oil orifices and check if they are not
clogged.
3. Remove clamp and turbo oil return hose.
219100971-012 19
tmr2017-014-019_a tmr2017-014-015_a
TIGHTENING SEQUENCE STEP A

Check oil sump cover for cracks or other damage.
Check oil sump cover for flatness with straight 3.2 Tighten the following screws to the speci-
edge. fied torque and sequence.
Replace oil sump cover if necessary. TIGHTENING TORQUE
Check engine oil strainer for damage and change Oil sump
9 N•m ± 1 N•m
if necessary. cover STEP B
screws
Installing the Oil Sump Cover
1. Install a NEW oil sump cover gasket.
2. Install the strainers as shown.
tmr2017-014-015_b
TIGHTENING SEQUENCE STEP B
4. Reinstall oil drain plugs using NEW sealing

tmr2017-014-017_b washers.
1. Oil strainers
2. Gasket TIGHTENING TORQUE
3. Oil sump cover
4. Retaining screws 15 N•m ± 2 N•m
Secondary drain plug
3. Install the oil sump cover on the engine, then
tighten screws in two steps as follows: 30 N•m ± 3 N•m
Magnetic drain plug
fied torque and sequence.
TIGHTENING TORQUE
Oil sump
5 N•m ± 0.6 N•m
cover STEP A
screws
20 219100971-012
Remove:
– Banjo bolt (discard it)
– Oil nozzle.
tmr2017-014-020_a

2. Sealing washer
4. Sealing washer
5. Reinstall oil return hose and clamp.

tmr2017-014-022_a
6. Install engine in vehicle. Refer to ENGINE RE-
1. Banjo bolt (discard it)
MOVAL AND INSTALLATION subsection. 2. Oil nozzle
ODIC MAINTENANCE PROCEDURES subsec- Cleaning and Inspecting the Oil Nozzle
tion. Clean oil nozzle with a parts cleaner, then use an
air gun and dry the parts.
OIL NOZZLES If the oil nozzles are damaged or bent during work
in the cylinder block, they must be replaced imme-
Oil Nozzle Location diately.
The oil nozzles are located inside the cylinder
Check if ball inside Banjo bolt moves freely.
block upper half.
mmr2009-111-049_a
1. Ball
tmr2017-014-021_a 2. Spring
3. Banjo bolt
4. Oil nozzle
NOTICE If the engine has to be dismantled
within the scope of repair work, take this op- Installing the Oil Nozzle
portunity to clean the oil nozzles.
NOTICE At assembly make sure the contact
Removing the Oil Nozzle surface of the oil nozzles are well fitted onto
Separate cylinder block halves. Refer to CYLIN- the cylinder block. If this is not ensured, the oil
DER BLOCK subsection. spray direction will change, causing potential
engine damage.
219100971-012 21
tmr2017-014-023_a
1. Oil nozzle
2. Stop collar
Tighten banjo bolts to specification.

TIGHTENING TORQUE
19 N•m ± 2 N•m
Banjo bolt
22 219100971-012
Subsection XX (COOLING SYSTEM - ENGINE)
COOLING SYSTEM - ENGINE

SERVICE TOOLS
HANDLE ........................................................................................ 420 877 650 ............................................. 6
OIL SEAL PUSHER........................................................................ 529 036 210 ............................................. 6
ROTARY SEAL INSTALLER ........................................................... 529 036 211 ......................................... 6–7
SERVICE PRODUCTS
ISOFLEX GREASE TOPAS NB 52 ................................................. 293 550 021 ............................................. 6
tmr2017-015 1
ENGINE COMPONENTS
NEW
NEW
NEW
See tightening
sequence
9 ± 1 N•m NEW
(80 ± 9 lbf•in)
NEW CTS
See ELECTRONIC FUEL
INJECTION (EFI)
16 ± 2 N•m
(142 ± 18 lbf•in)
9 ± 1 N•m
ISOFLEX Grease
TOPAS Nb52
Engine oil
Engine
oil
9 ± 1 N•m
(80 ± 9 lbf•in)

tmr2017-015-001_a
2 tmr2017-015
GENERAL 3. Air in cooling system.

- Refill and bleed cooling system.
For a better understanding, some illustrations
were taken with engine out of vehicle. 4. Defective thermostat (does not open when en-
gine is warm up).
NOTE: It is a good practice to check for fault
codes using B.U.D.S. software as a first trou- - Replace thermostat.
bleshooting step. Refer to the DIAGNOSTIC 5. Defective water pump.
AND FAULT CODES subsection. - Inspect and replace defective components.
During assembly/installation, use the torque
6. Coolant temperature sensor defective.
values and service products as shown in the ex-
ploded views. - Check and replace.
Clean threads before applying a threadlocker. Re- 7. Wrong coolant concentration.
fer to SELF-LOCKING FASTENERS and LOCTITE - Check and adjust coolant concentration according
APPLICATION at the beginning of this manual for to BRP's recommendations or replace coolant.
complete procedure. 8. Defective coolant reservoir cap.
WARNING - Replace cap.
To avoid potential burns, do not remove the 9. Defective cooling fan.

coolant tank cap or loosen the cooling drain - Check cooling fan motor operation.
plug if the engine is hot. - Check fuse and relay of cooling fan motor.
- Check wiring harness of cooling fan motor.
WARNING 10. Snow guard is too high.
Torque wrench tightening specifications - Check and adjust rear suspension.
must strictly be adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pin, etc.) must PROCEDURES
be replaced with new ones.
WATER PUMP
NOTICE Hoses, cables and locking ties re- Water Pump Location
moved during a procedure must be reinstalled The water pump is located on engine MAG side.
INSPECTION
TROUBLESHOOTING
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and
should not be assumed to show all causes for all
problems.
Always check for fault codes. If a fault code is de-
tected, service the fault code first.
ENGINE OVERHEATING tmr2017-015-003_a
1. Low coolant level.

- Refill and check for leaks (coolant leaking out of Water Pump Access
leak indicator hole, hoses or clamps missing or 1. Remove RH rear wheel and shock absorber.
defective, or cylinder head gaskets leaks). Repair
or replace. 2. Remove the coolant hose cover.
2. Dirty heat exchanger.
- Clean heat exchanger fins. Replace heat ex-
changer as required.
tmr2017-015 3
tmr2017-015-007
tmr2017-015-004_a
1. Supercharger inlet hose

Removing the Water Pump Housing 2. Locking ties
1. Drain engine coolant. Refer to PERIODIC
MAINTENANCE PROCEDURES subsection. 7. Remove retaining screws of water pump hous-
ing.
2. Remove locking ties that secure hoses on the
support and move hoses aside. 8. Discard sealing washer.
9. Remove water pump housing with thermostat
cover from magneto cover.
tmr2017-015-008
3. Disconnect outlet hose from thermostat hous-

ing. tmr2017-015-005_a
1. Retaining screws
4. Disconnect inlet hose from water pump hous- 2. Sealing washer
ing. 3. Housing
4. Gasket
5. Thermostat cover
6. O-ring
NOTE: Use shop rags to catch any spilled engine

coolant.
Disassembling the Water Pump

1. Unscrew impeller counterclockwise using ap-
propriate pliers.
tmr2017-015-009
5. Disconnect supercharger inlet hose from water

pump housing. Discard clamp.
6. Remove both locking ties securing CPS wire.
4 tmr2017-015
mmr2011-071-013_a
1. Impeller mmr2011-071-015_a
2. Pliers 1. Water pump shaft
2. Remove magneto cover. Refer to MAGNETO 5. Remove the following components from mag-
AND STARTER subsection. neto cover:
3. Remove the following components from mag- – Oil seal
neto cover: – Remaining parts of rotary seal.
– Water pump gear
– Needle pin
– Thrust washer.
mmr2011-071-016
NOTICE Be careful not to damage the surface

mmr2011-071-014_a
of the rotary seal bore in the magneto cover.
1. Water pump gear
2. Needle pin 6. Separate rotary seal from water pump shaft.
3. Thrust washer
4. Remove water pump shaft using a plastic mal-

let.
tmr2017-015 5
REQUIRED TOOL
OIL SEAL PUSHER
(P/N 529 036 210)
HANDLE (P/N 420 877 650)
mmr2011-071-017_a
1. Water pump shaft.

2. Rotary seal
Inspecting the Water Pump

Check area of water pump housing for cracks or
other visible damage.
Check water pump gear for wear or broken teeth. mmr2011-071-020_a
Check if housing gasket is brittle, hard or dam- 1. Oil seal

aged.
Check water pump shaft for visible damage.
Replace parts if necessary.
Assembling the Water Pump

NOTE: Always replace oil seal and rotary seal at
the same time.
1. Clean rotary seal surface from old sealant.
mmr2011-071-039_a
1. Oil seal correctly installed
4. Lubricate sealing lip of the oil seal.

OIL SEAL
ISOFLEX GREASE TOPAS
Service product
NB 52 (P/N 293 550 021)
5. Install new rotary seal on magneto cover using

mmr2011-071-018_b a press.
1. Clean surface NOTE: Prior to installing, ensure that sealing lip of
2. Apply engine oil on the press fit area of oil seal. rotary seal is not damaged.
REQUIRED TOOL
NOTICE Never use engine oil on the press fit
area of the rotary seal. Press
3. Install new oil seal in magneto cover. ROTARY SEAL INSTALLER

(P/N 529 036 211)
6 tmr2017-015
NOTICE Never use a hammer for rotary seal

installation. Only use a press to avoid damag-
ing the ceramic component.
mmr2011-071-041_a
1. Press
2. Water pump shaft
3. Needle pin
4. Thrust washer
mmr2011-071-025_a
5. Rotary seal installer
1. Rotary seal
2. Rotary seal installer 8. Carefully press water pump shaft until needle
pin touches thrust washer.
6. Assemble the following components onto wa-
ter pump shaft.
– Needle pin
– Thrust washer.
mmr2011-071-040_a
mmr2012-134-201_a
1. Water pump shaft
2. Thrust washer 1. Press
3. Needle pin 2. Rotary seal installer
3. Needle pin touches thrust washer
7. Slide water pump shaft into rotary seal using a
press. NOTICE Never use a hammer to install water
pump shaft into rotary seal.
NOTE: To avoid damaging the rotary seal and to
achieve the proper preload support the rotary seal NOTE: After installation, water pump shaft must
with the ROTARY SEAL INSTALLER (P/N 529 036 rotate freely.
211). 9. Screw impeller clockwise using appropriate pli-
ers.
NOTICE Be careful not to damage impeller
wings during its installation.
10. Install magneto cover. Refer to MAGNETO
AND STARTER subsection.
tmr2017-015 7
Installing the Water Pump Housing

NOTICE To prevent leaking, take care that the
new gasket is exactly in groove when you rein-
stall the water pump housing.
Install the thermostat cover into magneto cover.
Install a new sealing washer on drain screw.
Tighten water pump housing retaining screws to
specification as per the following procedure.
TIGHTENING TORQUE
mmr2011-071-035_a
Water pump housing 9 N•m ± 1 N•m 1. Water pump drive gear 31 T
retaining screws (80 lbf•in ± 9 lbf•in) 2. Intermediate gear, refer to LUBRICATION SYSTEM
Water Pump Drive Gear Access

Refer to MAGNETO AND STARTER subsection
and remove:
– Magneto cover
– Magneto flywheel.
Removing the Water Pump Drive Gear

1. Remove screw securing water pump drive
gear.
2. Remove bearing sleeve.
3. Slide off water pump drive gear.
tmr2017-015-006_a
TIGHTENING SEQUENCE
Tighten hose clamps to specification.

TIGHTENING TORQUE
5.5 N•m ± 0.5 N•m
Coolant hose clamps
WATER PUMP DRIVE GEAR mmr2011-071-036_a
Water Pump Drive Gear Location 1. Water pump drive gear 31 T

2. Bearing sleeve
The water pump drive gearis located behind the 3. M6 x 20 screw
magneto cover.
Inspecting the Water Pump Drive Gear
Inspect gear for wear or other damage.
Replace gear if necessary.
Installing the Water Pump Drive Gear

8 tmr2017-015
Apply engine oil on bearing sleeve.

Tighten water pump drive gear to specification.
TIGHTENING TORQUE
Water pump drive gear 9 N•m ± 1 N•m
retaining screw (80 lbf•in ± 9 lbf•in)
tmr2017-015 9
Subsection XX (COOLING SYSTEM - VEHICLE)
COOLING SYSTEM - VEHICLE

SERVICE TOOLS
LARGE HOSE PINCHER................................................................ 529 032 500 ........................................... 4
RADIATOR
NEW
NEW
NEW

tmr2017-054-100_a
1
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW

tmr2017-054-101_a
2
GENERAL
NOTICE Never start engine without coolant.
Some engine parts such as the rotary seal on
the water pump shaft can be damaged.
PROCEDURES
THERMOSTAT
The thermostat is a single action type.
Thermostat Location
The thermostat is mounted in-line in the cooling
system circuit.
tmr2017-054-003
4. Remove thermostat.
Testing the Thermostat

To check thermostat, put it in water and heat the
tmr2017-054-001
water.
THERMOSTAT LOCATION - RH SIDE UNDER VEHICLE - PARTS
REMOVED FOR CLARITY THERMOSTAT OPENING TEMPERATURE
1. In-line thermostat
2. Voltage rectifier STARTS TO OPEN FULLY OPEN
65°C (149°F) 88°C (190°F)
Removing the Thermostat
1. Drain cooling system, refer to PERIODIC MAIN- Replace thermostat if it does not begin to open at
TENANCE PROCEDURES subsection. specified temperature.
2. Remove the rear skid plate. Check if gasket is brittle, hard or damaged. If so,
replace gasket.
Installing the Thermostat

Reverse removal procedures.
Refill cooling system.
Bleed cooling system, refer to PERIODIC MAIN-
NOTICE The cooling system must be bled as
specified.
Check for coolant leaks.
tmr2017-054-004
SKID PLATE
RADIATOR
3. Remove Oetiker clamps that secure hoses to Inspecting the Radiator
thermostat. Check radiator fins for clogging or damage.
3
Remove insects, mud or other obstructions with

compressed air or low pressure water.
Removing the Radiator

1. Remove front body module, refer to BODY sub-
section.
tmr2017-054-006_a
5. Remove the radiator.
Installing the Radiator

1. For installation, reverse the removal procedure.
Ensure new clamps are installed for the 2 radi-
ator hoses and for the vent line as well.
tmr2017-054-005
2. Fill radiator with the recommended coolant.

2. Install hose pinchers on both radiator hoses. Refer to PERIODIC MAINTENANCE PROCE-
REQUIRED TOOL DURES subsection.
3. Bleed the cooling system, refer to PERIODIC
LARGE HOSE PINCHER MAINTENANCE PROCEDURES subsection.
(P/N 529 032 500)
NOTICE The cooling system must be bled as
specified.
4. Check for coolant leaks from radiator and
hoses.
RADIATOR COOLING FAN RELAY

(R1)
Relay Operation Test
(Radiator Cooling Fan)
The easiest way to check the relay is to remove
it and temporarily substitute with the accessory
tmr2017-054-007_a
relay. If the radiator cooling fan operates, replace
the relay.
INSTALL HOSE PINCHERS
3. Remove radiator vent line.

RADIATOR COOLING FAN
4. Remove screws from the cooling fan. Radiator Cooling Fan Operation
The ECM controls the radiator cooling fan via the
inputs of the coolant temperature sensor (CTS).
Refer to the following table.
4
MESSAGE IN
ENGINE CHECK ENGINE LIMP HOME
COOLING FAN MULTIFUNCTION
TEMPERATURE LIGHT MODE
GAUGE
96°C (205°F) Turns ON –– –– ––
92°C (198°F) Turn OFF –– –– ––
Gradual power
reduction
- Limp Home
114°C (237°F) ON OFF according
- Hi Temp
to engine
temperature.
Testing the Radiator Cooling Fan

1. Connect the vehicle to the appropriate BRP di-
agnostic software, refer to COMMUNICATION
TOOLS for procedure and connector location.
2. In BUDS2, select the following:
– Functions tab
– Activate Cooling Fan button.
If fan turns on, check CTS, wiring harness and
connectors. If all parts are good, replace the ECM.
If fan does not turn on when the Activate Cool-
ing Fan button is pressed, refer to the following
troubleshooting chart.
5
COOLING FAN TROUBLESHOOTING CHART

Is fan working? YES  Everything is OK
NO 
Check "Relay driver"
fuse (5A) and fan Replace fuse
fuse (F9 25A).
YES  Is fan working?
Is fuse burnt?
NO 
Bypass fan relay R1

tmr2017-054-009_a
Replace relay
3. Remove screws holding the fan.
Fan turns? YES  Is fan working?
NO 
Apply 12 Vdc to fan
connector

Replace fan
Fan turns? NO  Is fan working?
YES 
Check CTS
 tmr2017-054-008_a
CTS works? NO  Replace CTS

Is fan working?
Installing the Radiator Cooling Fan
For the installation, reverse the removal proce-
YES  dure.
Check wiring harness
and connectors

Harness and Repair or replace
connectors good?
NO  defective part(s)
YES 
Try a new ECM  Is fan working?
Removing the cooling fan

1. Remove radiator, refer to REMOVING THE RA-
DIATOR.
2. Disconnect electrical connector, unhook differ-
ential vent and cut tie-raps.
6
Subsection XX (MAGNETO AND STARTER)
MAGNETO AND STARTER

SERVICE TOOLS
CRANKSHAFT PROTECTOR ......................................................... 529 036 213 ............................................. 7
FLYWHEEL PULLER...................................................................... 420 976 235 ............................................. 7
SERVICE PRODUCTS
CLUTCH AND PULLEY FLANGE CLEANER PRO S1.................... 779244 ......................................... 8–9
KLÜEBER PASTE 46 MR 401........................................................ 420 297 616 ........................................... 12
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 6, 8
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ............................................. 9
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ............................................. 4
219100971-013 1
9 ± 1 N•m NEW = Component must be replaced when removed.

(80 ± 9 lbf•in)
KLUEBER PASTE 46 MR 401
Engine oil
Loctite 648
Engine oil
30 ± 2 N•m
(22 ± 1.5 lbf•ft)
150 ± 10 N•m
(111 ± 7 lbf•ft)
Loctite 243
9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243
NEW
CPS
See ELECTRONIC
FUEL INJECTION 9 ± 1 N•m
(EFI) (80 ± 9 lbf•in)
9 ± 1 N•m Engine oil

(80 ± 9 lbf•in)
mmr2014-016-001_a
2 219100971-013
GENERAL
WARNING
Always disconnect BLACK (-) cable first and
reconnect last.

ues and service products as in the exploded view.
fer to self-locking fasteners and loctite application
in INTRODUCTION subsection.
WARNING
tmr2017-016-200_a
must strictly be adhered to. 3. Cut all locking ties securing hoses on the hoses
Locking devices when removed (ex: locking support.
tabs, cotter pin, etc.) must be replaced.

TROUBLESHOOTING
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to DIAG-
NOSTIC AND FAULT CODES subsection.
ENGINE DOES NOT CRANK
1. Battery voltage too low.
tmr2017-016-201_a
- Check battery condition.
4. Remove the hoses support.
2. Starter is turning but engine does not crank.
- Check sprag clutch for wear or other damages.
3. Starter is defective.
- Check starter condition. Perform STARTER OP-
ERATION TEST and STARTER VOLTAGE DROP
TEST.
4. Engine is only cranking 1 - 2 seconds before it
stops.
- Check battery condition. 1
PROCEDURES
MAGNETO COVER
Removing the Magneto Cover tmr2017-016-202_a
1. Drain engine oil and coolant. Refer to PERI- 5. Refer to COOLING SYSTEM subsection and re-
ODIC MAINTENANCE PROCEDURES subsec- move:
tion. – Water pump housing
2. Remove the protective cover. – Thermostat housing.
219100971-013 3
6. Refer to LUBRICATION SYSTEM subsection 3. Ensure starter drive gear pin is in place.
and remove: 4. Apply engine oil on starter drive gear pin.
– Oil pressure regulator
– Oil cooler.
7. Remove the CPS.
mmr2011-072-004_a mmr2011-072-005_a
1. CPS APPLY ENGINE OIL

1. Starter drive gear pin
8. Remove magneto cover retaining screws.
5. Apply engine oil on water pump shaft.
mmr2011-072-006_a
1. Water pump shaft - apply engine oil

mmr2012-135-004_a
MAGNETO COVER SCREWS

NOTICE Make sure that the stator cable har-
ness is embedded into the channel. The part of
9. Place an oil pan under magneto area to catch the harness that is out of the channel must be
remaining oil. tight, otherwise it might chafe or jam.
10. Pull magneto cover off.
Inspecting the Magneto Cover

Check magneto cover for cracks or other damage.
Installing the Magneto Cover

1. Clean magneto cover.
SERVICE PRODUCT
LOCTITE CHISEL (GASKET REMOVER)
(P/N 413 708 500)
2. Install a NEW magneto cover gasket.
4 219100971-013
REQUIRED TOOL
FLUKE 115 MULTIMETER

(P/N 529 035 868)
3. Probe each pair of YELLOW wires by touching

(NOT inserting) terminals lock tabs as shown.
NOTICE Never insert a multimeter probe into
a terminal as it would ruin the terminal.
mmr2011-072-007_a
1. Embedded in that area

2. Tight in this area
6. Carefully install magneto cover.
CAUTION Magnetic force between mag-

neto flywheel and stator is very high. Avoid
finger contusions.
7. Tighten magneto cover screws according to the
following sequence.
TIGHTENING TORQUE
9 N•m ± 1 N•m
Magneto cover screws
vbs2012-014-001
mmr2009-113-036_a
1. Pin #1
2. Pin #2
3. Pin #3
mmr2011-072-002_b
4. Read resistance as per following table.
TIGHTENING SEQUENCE
STATOR
Testing the Stator Continuity
1. Disconnect the stator connector from voltage
regulator.
2. Set the multimeter to .
219100971-013 5
STATOR CONTINUITY TEST

YELLOW WIRES RESISTANCE @
(EACH PAIR) 20°C (68°F)
Pins 1 and 2
Pins 1 and 3 0.1 - 1
Pins 2 and 3
If any resistance reading is not as specified, the

stator or the wiring (including connector) is open
and needs to be repaired or replaced.
If resistance is good, perform the stator insulation
test. mmr2011-072-008_a
1. Stator
2. Stator retaining screws
Testing the Stator Insulation
1. Connect multimeter between any YELLOW 3. Remove stator.
wire and chassis ground.
Inspecting the Stator
Check stator windings and insulation for cracks
and other damages. If damaged replace it.
Check if stator wires are brittle, hard or otherwise
damaged.
Installing the Stator

1. Ensure that the stator cable is underneath the
cable holder during installation of the stator.
mmr2009-113-036_b
2. Read resistance.
STATOR INSULATION TEST
RESISTANCE @
PROBE POSITIONS
20°C (68°F)
Any YELLOW wire and
Infinity (OL)
chassis ground
If any resistance reading is not as specified, the

stator or the wiring is shorted to ground and needs
to be repaired or replaced.
mmr2011-072-009_a
If the insulation test is good, perform the output 1. Cable holder
voltage test. 2. Stator cable
Removing the Stator 2. Apply theadlocker on stator retaining screws,

install and tighten to specification.
1. Remove the MAGNETO COVER, see proce-
dure in this subsection. TIGHTENING TORQUE
2. Remove stator retaining screws. 9 N•m ± 1 N•m
Stator retaining screws +
LOCTITE 243 (BLUE)
(P/N 293 800 060)
6 219100971-013
3. Reinstall MAGNETO COVER, see procedure in

this subsection.
ROTOR
Removing the Rotor
1. Remove the magneto cover. Refer to MAG-
NETO COVER in this subsection.
2. Lock crankshaft. Refer to CYLINDER BLOCK
subsection.
3. Remove rotor retaining screw and lock washer.
mmr2011-072-023_a
1. Rotor
2. Flywheel puller screw
Inspecting the Rotor

Check the inner side of the rotor for scratches or
other damage.
Check keyway for wear or damages.
Check if trigger wheel teeth are bent or otherwise
damaged.
mmr2011-072-010_a
1. Retaining screw
2. Lock washer
3. Rotor
4. Remove rotor.
REQUIRED TOOL
CRANKSHAFT PROTECTOR
(P/N 529 036 213)
FLYWHEEL PULLER (P/N 420
976 235)
NOTE: Apply some grease on the crankshaft pro-

tector surface to ease puller operation. mmr2011-072-012_b
1. Rotor with trigger wheel

2. Oil passage in magneto hub
3. Rotor taper
Check woodruff key and keyway on the crank-

shaft for wear or damages.
Replace parts as necessary.
Installing the Rotor

dure. However, pay attention to the following.
1. Blow the oil passage in the magneto hub using
compressed air. Check if it is clogged.
2. Using parts cleaner, clean:
– The oil passage
219100971-013 7
– The crankshaft thread

– The crankshaft taper
– The rotor taper.
NOTICE Taper on crankshaft and rotor must
be free of grease.
mmr2011-072-015_a
Step 1: Rotate to align teeth

1. Sprag clutch gear
2. Starter double gear
7. Install washer and retaining screw.

8. Tighten to specification.
mmr2011-072-013_b TIGHTENING TORQUE
1. Crankshaft taper
2. Oil passage 150 N•m ± 10 N•m
3. Thread (111 lbf•ft ± 7 lbf•ft)
Rotor retaining screw +
SERVICE PRODUCT LOCTITE 243 (BLUE)
CLUTCH AND PULLEY FLANGE CLEANER (P/N 293 800 060)
PRO S1 (P/N 779244)
3. Apply oil on sprag clutch and needle bearing.

SPRAG CLUTCH
4. Install sprag clutch gear onto the rotor. Removing the Sprag Clutch
1. Remove the magneto cover. Refer to proce-
2. Lock crankshaft. Refer to CYLINDER BLOCK
subsection.
3. Loosen and remove sprag clutch housing
screws.
mmr2011-072-014_a
1. Apply engine oil here

2. Sprag clutch
3. Sprag clutch housing
5. Slide rotor along with the sprag clutch gear onto

the crankshaft. The woodruff key and keyway mmr2011-072-016_a
1. Sprag clutch housing screws

must be aligned. 2. Rotor
6. Rotate sprag clutch gear counterclockwise to
align with starter double gear. 4. Remove rotor. Refer to MAGNETO COVER in
this subsection.
8 219100971-013
5. Remove sprag clutch housing.

6. Remove sprag clutch from sprag clutch hous-
ing.
mmr2011-072-018_b
Step 1: Lock
mmr2011-072-017_a
Installing the Sprag Clutch
1. Sprag clutch housing screws 1. Clean sprag clutch housing with a parts cleaner.
2. Rotor
3. Sprag clutch NOTICE Threads of sprag clutch housing
must be free of any lubricants.
Inspecting the Sprag Clutch SERVICE PRODUCT
Inspect sprag clutch and sprag clutch housing for CLUTCH AND PULLEY FLANGE CLEANER
wear and damage. PRO S1 (P/N 779244)
Check the collar of the sprag clutch gear. Refer to
SPRAG CLUTCH GEAR in this subsection. 2. Apply thread locker on threads of sprag clutch
Rotate sprag clutch gear clockwise. Gear must ro- housing screws.
tate freely. SERVICE PRODUCT
LOCTITE 648 (GREEN) (P/N 413 711 400)
3. Loosely install screws.

4. Apply engine oil on sprag clutch and sprag
clutch gear needle bearing.
mmr2011-072-018_a
Step 1: Free
Rotate sprag clutch gear counterclockwise. Gear

must lock.
mmr2011-072-014_a

2. Sprag clutch
219100971-013 9
5. Install rotor. Refer to MAGNETO COVER in this

subsection.
6. Tighten sprag clutch housing screws to specifi-
cation.
TIGHTENING TORQUE
Sprag clutch housing 30 N•m ± 2 N•m
screws (22 lbf•ft ± 1 lbf•ft)
SPRAG CLUTCH GEAR

mmr2011-072-019_a
Removing the Sprag Clutch Gear 1. Teeth

2. Collar
1. Remove rotor and sprag clutch gear together. 3. Needle bearing
Refer to ROTOR in this subsection.
Replace sprag clutch gear if necessary.
2. Pull sprag clutch gear out of the rotor.
Installing the Sprag Clutch Gear
NOTE: Apply engine oil on needle bearing and col-
lar of sprag clutch gear.
STARTER DRIVE GEARS

The starter drive gears are located on the engine
MAG side behind the magneto cover.
Removing the Starter Drive Gear

1. Remove magneto cover. Refer to MAGNETO
COVER in this subsection.
mmr2011-072-014_b
1. Sprag clutch gear 2. Remove location pin and starter double gear.
2. Rotor
Inspecting the Sprag Clutch Gear

Inspect gear, especially teeth and sprag clutch col-
lar for wear and other damage.
Check needle bearing for wear and pittings.
mmr2011-072-005_c
1. Location pin
2. Starter double gear
Inspecting the Starter Drive Gear

Inspect starter drive gears and location pin for
wear and damage.
10 219100971-013
Installing the Starter Drive Gear

Apply engine oil on the location pin.
STARTER
Starter Location
The starter is located at the front of the engine,
behind the rear service cover.
tmr2017-016-205_a
If the starter turns, test other starting system

components. Refer to STARTING SYSTEM sub-
section.
Removing the Starter

1. Disconnect the BLACK (–) cable from the bat-
tery.
2. Remove the starter cable from starter.
3. Remove starter retaining screws.
tmr2017-016-203_a
1 tmr2017-016-206_a
4. Pull starter off the cylinder block.

tmr2017-016-204_a
1. Starter
Installing the Starter
1. Ensure starter and engine mating surfaces are
Testing the Starter Operation free of debris.
Use booster cables and a booster battery to sup- NOTICE Serious problems may arise if the
ply current directly to the starter. starter is not properly aligned.
1. Connect the RED jumper cable from the
booster battery to the starter screw.
2. Momentarily connect the BLACK jumper cable
to a mounting screw of the starter.
219100971-013 11
mmr2011-072-021_a
1. Clean mating surfaces
2. Lubricate on starter end and starter O-ring be-

fore installation.
SERVICE PRODUCT
KLÜEBER PASTE 46 MR 401 (P/N 420 297 616)
mmr2009-113-030_c
1. Apply grease here
3. Insert starter gear into engine.

4. Install starter screws and tighten to specifica-
tion.
TIGHTENING TORQUE
9 N•m ± 1 N•m
Starter screws
5. Connect the starter cable to the starter and

tighten nut to specification.
TIGHTENING TORQUE
6 N•m ± 0.5 N•m
Starter cable nut

7. Reconnect BLACK (–) cable on battery post.
8. Test for proper starter operation.
12 219100971-013
Subsection XX (INTAKE MANIFOLD)
INTAKE MANIFOLD
9 ± 1 N•m
See ELECTRONIC FUEL (80 ± 9 lbf•in)
INJECTION (EFI)
Engine oil
7 ± 0,8 N•m 7 ± 0,8 N•m

(62 ± 7 lbf•in) (62 ± 7 lbf•in)
See tightening
sequence
9 ± 1 N•m Engine oil
(80 ± 9 lbf•in)
See
ELECTRONIC FUEL
INJECTION (EFI)
NEW
See ELECTRONIC FUEL
INJECTION (EFI)
7 ± 0,8 N•m
(62 ± 7 lbf•in) See tightening
sequence
9 ± 1 N•m
(80 ± 9 lbf•in)
1,1 ± 0,1 N•m

(10 ± 1 lbf•in)
1,1 ± 0,1 N•m

(10 ± 1 lbf•in) See ELECTRONIC FUEL
INJECTION (EFI)
RTX903CARBSSV_001-001_a
RTX903CARBSSV-001 1
PROCEDURES
INTAKE MANIFOLD
Removing the Intake Manifold
1. Remove the rear rack assembly. Refer to
FRAME subsection.
2. Remove the intercooler and its support to make
room.
3. Remove the rear CVT outlet hose.
tmr2017-012-003_a
1. Locking ties
2. MAPTS connector
6. Cut locking tie securing hoses to intake mani-

fold.
tmr2017-017-200_a
4. Loosen clamp securing air intake manifold to

throttle body.
tmr2017-017-201_a
7. Disconnect fuel hose from fuel rail. Refer to

ELECTRONIC FUEL INJECTION (EFI) subsec-
tion.
tmr2017-017-202_a
5. Cut locking ties securing MAPTS harness and

disconnect MAPTS..
tmr2017-017-203_a
8. Disconnect fuel injector connectors.
2 RTX903CARBSSV-001
If removed, refer to ELECTRONIC FUEL INJEC-

TION (EFI) subsection to install:
– MAPTS
– Fuel rail with injectors.
Install NEW gasket.
tmr2017-012-004_a
9. Remove screws securing intake manifold to

cylinder head.
tmr2017-012-007_a
NOTICE Engage intake manifold gasket onto

silent block sleeves.
tmr2017-012-005_a
INTAKE MANIFOLD SCREWS
10. Remove intake manifold from engine.

11. Remove and discard intake manifold gaskets.
12. If required, remove following parts from intake
manifold, refer to ELECTRONIC FUEL INJEC-
TION (EFI) subsection:
– MAPTS
rmr2016-006-004_a
– Fuel rail with injectors. 1. Intake manifold gasket engaged on silent block sleeve
2. Silent block sleeve
Inspecting the Intake Manifold 3. Silent block rubber
Check intake manifold for cracks, warping at Ensure rubber grommets are properly inserted.
flanges or any other visible damage. Replace if
required.
Drain intake manifold of any accumulated liquids.
Flush intake manifold with solvent and let dry.
Installing the Intake Manifold

Reverse the removal procedure. However, pay at-
tention to the following.
RTX903CARBSSV-001 3
TIGHTENING TORQUE
0.9 N•m ± 0.1 N•m
Intake manifold clamp
tmr2017-012-008_a
RUBBER GROMMETS
Tighten intake manifold screws to specification as

per the following sequence.
TIGHTENING TORQUE
9 N•m ± 1 N•m
Intake manifold screws
tmr2017-012-005_b
TIGHTENING SEQUENCE
Make sure to index connecting socket notch with

the intake manifold tab.
tmr2017-012-011_a
INTAKE MANIFOLD TAB
4 RTX903CARBSSV-001
Subsection XX (TIMING CHAIN)
TIMING CHAIN
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......................................... 4, 8
50 ± 3 N•m
(37 ± 2 lbf•ft)
Loctite 243
Engine oil
Engine oil
17 ± 2 N•m
(150 ± 18 lbf•in)
NEW
9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243
Engine oil

smr2014-019-001_a
tmr2017-018 1
GENERAL 2. Chain guide(s) worn out.

- Replace chain guide(s).
Engine removal is necessary to work on the fol-
lowing components: 3. Stretched timing chain or worn sprockets.
– Timing chain - Replace timing chain and sprockets.
– Timing chain guide (tensioner side). 4. Camshaft timing gear screws loose.
Always disconnect BLACK (-) cable from the bat- - Retighten screws to recommended torque.
tery, then RED (+) cable before working on the en-
gine. 5. Incorrect camshaft timing adjustment.
- Replace damaged components and readjust
WARNING camshaft timing.
Always disconnect BLACK (-) cable first and ENGINE LACKS ACCELERATION OR
reconnect last. POWER
During assembly/installation, use torque values 1. Incorrect camshaft timing adjustment.
and service products as specified in the exploded - Replace damaged components and readjust
view. camshaft timing.
fer to SELF-LOCKING FASTENERS and LOCTITE PROCEDURES
APPLICATION at the beginning of this manual for
complete procedure. TIMING CHAIN TENSIONER
WARNING Timing Chain Tensioner Location
Torque wrench tightening specifications The timing chain tensioner is located in the cylin-
must be strictly adhered to. der head beside the intake port of the PTO cylin-
Locking devices when removed (e.g.: locking der.
tabs, elastic stop nuts, cotter pin, etc.) must
be replaced.
Hoses, cables or locking ties removed during a

procedure must be reinstalled as per factory stan-
dards.
When disassembling parts that are duplicated
in the engine, (e.g.: valves, springs, etc.), it is
strongly recommended to note their position
and to keep the parts of the same assembly as
a “group”. If you find a defective component,
it will be much easier to find the cause of the
failure. Since parts were broken-in together dur-
tmr2017-018-001_a
ing engine operation, they will maintain their SCREW PLUG, TIMING CHAIN TENSIONER
matched fit when reassembled together within
their “group”. Timing Chain Tensioner Access
Remove throttle body with connecting socket.
TROUBLESHOOTING Refer to ELECTRONIC FUEL INJECTION (EIF)
The following is provided to help in diagnosing the subsection.
probable source of troubles. It is a guideline and
should not be assumed to provide solutions to ev- Removing the Timing Chain Tensioner
ery cause of all problems. 1. Lock crankshaft, refer to CYLINDER BLOCK
subsection.
UNUSUAL ENGINE NOISE OR
VIBRATIONS 2. Remove screw plug and discard the sealing
washer.
1. Faulty chain tensioner.
3. Pull out spring and chain tensioner.
- Replace chain tensioner.
2 tmr2017-018
tmr2017-018-002_a
1. Screw plug
2. Sealing washer
3. Spring
4. Chain tensioner
Inspecting the Timing Chain Tensioner mmr2014-017-004_a
TIMING CHAIN TENSIONER INSTALLATION

1. Check chain tensioner for scoring and freedom 1. Plunger
of movement in bore. 2. Chain tensioner
3. Tensioner bore in cylinder head
2. Compress chain tensioner and check for proper
operation. 3. Install spring on chain tensioner.
NOTE: The chain tensioner is difficult to com- 4. Tighten screw plug to specified torque.
press when properly charged with oil, and easily
TIGHTENING TORQUE
compressed when it is not.
Sealing washer NEW
3. Check spring for straightness, corrosion and
other visible damage. Screw plug timing chain 17 N•m ± 2 N•m
tensioner (150 lbf•in ± 18 lbf•in)
Installing the Timing Chain Tensioner
1. Apply engine oil on chain tensioner. 5. Install all other removed parts.
2. Insert chain tensioner in its bore with the
plunger pointing outwards. CAMSHAFT TIMING GEARS
Removing the Camshaft Timing Gear
Remove camshaft assembly. Refer to CYLINDER
HEAD subsection.
Clamp camshaft in a vice using aluminium protec-
tors.
NOTICE Take care not damaging the cams.
Unscrew and remove camshaft timing gear
screw.
Remove camshaft timing gear.
tmr2017-018 3
Install breather cover on exhaust camshaft.
smr2014-020-048_a
1. Breather cover
smr2014-019-007_a
1. Camshaft timing gear screw Install remaining parts.

2. Camshaft timing chain gear
3. Camshaft
4.
5.
Aluminium protectors
Vice TIMING CHAIN
Removing the Timing Chain
Inspecting the Camshaft Timing Gear
1. Remove engine from vehicle. Refer to ENGINE
Check camshaft timing gears for wear or dete- REMOVAL AND INSTALLATION subsection.
rioration. If a gear is worn or damaged, replace
camshaft timing gears and timing chain as a set. 2. Remove air intake manifold, refer to AIR IN-
TAKE SYSTEM subsection.
NOTE: For crankshaft timing gear inspection, re-
fer to CYLINDER BLOCK subsection. 3. Remove valve cover, refer to CYLINDER HEAD
subsection.
Installing the Camshaft Timing Gear 4. Refer to LUBRICATION SYSTEM subsection
Installation is the reverse of the removal proce- and remove the following parts:
dure. However, pay attention to the following de- – Oil tank
tails. – Oil pressure regulator valve
Tighten camshaft timing gear screw to specifica- – Oil cooler
tion. – Oil sump cover.
NOTICE Do not torque timing gear screws 5. Refer to COOLING SYSTEM (ENGINE) subsec-
when camshafts are installed in cylinder head tion and remove following parts:
to avoid overstressing timing chain. – Water pump housing
– Thermostat.
TIGHTENING TORQUE
6. Check timing chain for excessive radial play
LOCTITE 243 (BLUE) while still installed on timing gears.
Service product
(P/N 293 800 060)
50 N•m ± 3 N•m
Timing gear screws
NOTICE Improper camshaft timing will dam-

age engine components. Make sure camshafts
and crankshaft are still locked. If not, lock
them before beginning this procedure. Refer
to CAMSHAFTS in the CYLINDER HEAD sub-
section.
4 tmr2017-018
tmr2017-018-004_a
mmr2011-073-025_a
13. Remove lower timing chain guide from lower
1. Radial play
half of cylinder block.
7. Remove the CAMSHAFTS, refer to CYLINDER
HEAD subsection.
8. Refer to MAGNETO AND STARTER subsection
and remove the following parts:
– Magneto cover
– Rotor
– Starter drive gears.
9. Remove oil pump intermediate gears, refer to
LUBRICATION SYSTEM subsection.
smr2014-019-011_a
1. Lower timing chain guide

2. Lower half of cylinder block
Inspecting the Timing Chain

Check timing chain for wear and teeth condition.
mmr2011-073-020_a
1. Oil pump intermediate gears mmr2009-114-015_a
1. Check teeth condition

10. Remove crankshaft locking bolt.
NOTICE If timing chain is excessively
11. Separate cylinder block, refer to CYLINDER
worn or damaged, replace timing chain and
BLOCK subsection.
camshaft timing gears as a set.
12. Remove timing chain.
Check lower chain guide for wear, cracks or defor-
NOTE: Make a mark on the timing chain to indi-
mation. Replace as required.
cate the operating direction of the chain before re-
moval.
tmr2017-018 5
mmr2011-073-027_a
smr2014-019-014_a
1. Lower chain guide
1. Lower chain guide
2. Lower half of cylinder block
Replace lower chain guide if timing chain wear
grooves are visible. 3. Reassemble cylinder block, refer to CYLINDER
CHAIN GUIDE GROOVE DEPTH BLOCK subsection.
No timing chain wear 4. Lock crankshaft, refer to CRANKSHAFT LOCK-
SERVICE LIMIT ING PROCEDURE in the CYLINDER BLOCK
groove allowed
subsection.
NOTE: Also check the chain guide, tensioner 5. Reinstall timing chain properly on camshaft
side. Refer to INSPECTING THE CHAIN GUIDE timing gears. Refer to INSTALLING THE
(TENSIONER SIDE) in this subsection. CAMSHAFT in the CYLINDER HEAD sub-
section.
Installing the Timing Chain
age engine components.
dure. However, pay attention to the following de-
tails. 6. Install all other removed parts.
1. Install timing chain on crankshaft timing gear. NOTE: Be sure to remove camshaft and crank-
NOTE: If the same timing chain is reinstalled, be shaft locking tools when timing chain is com-
sure to reinstall it in the same operating direction pletely installed.
as marked during removal procedure.
CHAIN GUIDE (TENSIONER SIDE)
Removing the Chain Guide (Tensioner
Side)
NOTE: Removal of chain guide is not recom-
mended if there is no need for replacement.
1. Remove the CAMSHAFTS. Refer to CYLINDER
HEAD subsection.
2. Remove screw plug that covers the chain guide
bearing pin.
tmr2017-018-003_a
2. Reinstall lower chain guide in lower half of cylin-

der block.
6 tmr2017-018
mmr2014-017-008_a
1. Screw plug location

2. PTO cover
3. Use an M6 bolt to pull chain guide bearing pin

out of cylinder block.
mmr2014-017-010_a
1. Chain guide (tensioner side)
Inspecting the Chain Guide

(Tensioner Side)
Check chain guide for wear, cracks or deforming.
Replace as required.
Replace chain guide if groove depth caused by
timing chain exceeds service limit.
CHAIN GUIDE GROOVE DEPTH
SERVICE LIMIT 1 mm (.039 in)
mmr2014-017-009_a
1. Chain guide bearing pin

2. M6 bolt
4. Remove chain guide (tensioner side).

mmr2009-114-022_a
TYPICAL
1. Chain guide
Installing the Chain Guide

(Tensioner Side)
dure however, pay attention to the following de-
tails.
1. Insert chain guide.
2. Apply engine oil on bearing pin and install it with
M6 threads facing outwards.
NOTICE Ensure chain guide bearing pin is
properly inserted in the chain guide.
tmr2017-018 7
mmr2014-017-011_a
1. Bearing pin
3. M6 threads facing outwards
3. Tighten screw plug as specified.

NOTE: Install screw plug only in final assembled
cylinder block to avoid warpage of sealing surface.
TIGHTENING TORQUE
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
9 N•m ± 1 N•m
Screw plug
4. Properly reinstall camshafts. Refer to

CAMSHAFTS in the CYLINDER HEAD sub-
section.
age engine components.
8 tmr2017-018
Subsection XX (CYLINDER HEAD)
CYLINDER HEAD
SERVICE TOOLS
CAMSHAFT LOCKING TOOL........................................................ 529 036 206 ........................................... 11
ENGINE LEAK DOWN TEST KIT ................................................... 529 035 661 ........................................... 5
VALVE SPRING COMPRESSOR CUP............................................ 529 036 209 ........................................... 17
VALVE SPRING COMPRESSOR .................................................... 529 035 724 ........................................... 17
SERVICE TOOLS – OTHER SUPPLIER

SNAP-ON VALVE HOLDER............................................................ VL2 ........................................... 20
SNAP-ON VALVE STEM SEAL PLIERS ......................................... YA 8230 ........................................... 18
tmr2017-019 1
VALVE COVER
9 ± 1 N•m
(80 ± 9 lbf•in)
9 ± 1 N•m
(80 ± 9 lbf•in) Engine oil
See tightening sequence 9 ± 1 N•m
(80 ± 9 lbf•in)
NEW
Engine oil
NEW
NEW
NEW
See
PERIODIC
MAINTENANCE
PROCEDURES
11 ± 1 N•m
(97 ± 9 lbf•in)
Heat-Sink paste P12

mmr2014-018-001_b
2 tmr2017-019
CAMSHAFTS
See tightening
procedure
NEW
Engine oil
Engine oil
NEW
NEW

smr2014-020-002_a
tmr2017-019 3
CYLINDER HEAD
Engine oil
Engine oil
NEW See tightening

sequence
See tightening
sequence
NEW
15 ± 2 N•m
(133 ± 18 lbf•in)
Loctite 243
NEW
Engine oil
Engine oil

smr2014-020-003_a
4 tmr2017-019
GENERAL CAUTION Engine parts could be hot.

NOTE: For a better understanding, some illustra- NOTE: The following steps are the same for each
tions are taken with engine out of the vehicle. cylinder.
Disconnect the battery before working on the en-
gine. Preparation
1. Remove an ignition coil and a spark plug. Refer
WARNING to IGNITION COILS AND SPARK PLUGS sub-
Always disconnect BLACK (-) cable first and section.
reconnect last. 2. Remove the VALVE COVER, see procedure in
this subsection.
During assembly/installation, use the torque val- 3. Using the drive pulley, turn the engine counter-
ues and service products as in the exploded clockwise to bring piston to TDC of compres-
views. sion stoke. Use a dial gauge or a suitable tool
Clean threads before applying a threadlocker. Re- to position the piston to TDC.
fer to SELF-LOCKING FASTENERS and LOCTITE NOTE: The piston must be set precisely to TDC
APPLICATION at the beginning of this manual for of compression stroke. If not, the engine will con-
complete procedure. tinue to rotate when pressure builds up.
WARNING Leak Test
Torque wrench tightening specifications 1. Install a gauge adaptor into spark plug hole.
must be strictly adhered to.
Locking devices when removed (e.g.: locking REQUIRED TOOL
tabs, cotter pin, etc.) must be replaced.
ENGINE LEAK DOWN TEST
KIT (P/N 529 035 661)
2. Connect the leak down tester to an adequate
air supply.
When disassembling parts that are duplicated 3. Set gauge needle to zero.
in the engine, (e.g.: valves, springs, etc.), it is
NOTE: All testers have specific instructions on
strongly recommended to note their position
gauge operation and required pressure. Refer to
and to keep the parts of the same assembly as a
manufacturer's instructions.
“group”. If you find a defective component, it will
be much easier to find the cause of the failure. 4. Supply combustion chamber with air pressure.
Since parts were break-in together during the 5. Note the amount or percentage of leakage (de-
engine operation, they will keep their matched fit pending on tester).
when parts are reassemble together within their
“group”. LEAKAGE ENGINE
PERCENTAGE CONDITION
INSPECTION 0% to 15% Excellent condition
16% to 25% Good condition
CYLINDER LEAK TEST Fair condition; reduced
26% to 40%
General engine performance
Before performing the cylinder leak test, verify the Poor condition, diagnose
41% and higher
following: and repair engine
– Clamp tightness
– Hoses condition. Diagnosis
NOTE: For best accuracy, the leak test should be Listen for air leaks.
done with the engine at normal operating temper- – Air escaping on intake port or throttle body
ature. means leaking intake valve(s).
tmr2017-019 5
– Air escaping on exhaust port means leaking ex- 6. Loose timing chain gear screws.
haust valve(s). - Retighten screws with recommended torque.
– Air bubbles out of coolant tank means leaking
7. Incorrect camshaft timing.
cylinder head gasket.
- Replace damaged components and readjust
– Air or coolant escaping from cylinder head camshaft timing.
means damaged gasket or loosened screws.
– Air escaping into crankcase area means exces- OIL LEAKAGE FROM CYLINDER HEAD
sively worn cylinder or broken piston rings.
1. Leaking valve cover gasket.
– Air or oil escaping from crankcase means dam-
- Replace valve cover gaskets and retighten valve
aged gasket or loosened screws. cover with recommended torque.
Repair Tips - Check valve cover for cracks or other damage.
Blue exhaust gas means damaged or worn piston 2. Leaking spark plug tube O-rings.
rings or valve stem seals. - Replace spark plug tube O-rings.
White exhaust gas means damaged cylinder head - Clean spark plug area from oil spillage.
gasket. 3. Blow-by connector is leaking.
Coolant tank cap opening without overheat means - Replace blow by connector O-ring.
damaged cylinder head gasket.
4. Leaking cylinder head gasket.
Leaking valves can be caused by carbon deposits - Check cylinder head for damage.
or burnt valve face.
- Replace cylinder head gasket and retighten
screws with recommended torquing procedure.
Assembly
Reverse the preparation procedure. ENGINE SUDDENLY TURNS OFF OR
LACKS ACCELERATION OR POWER
TROUBLESHOOTING 1. Incorrect camshaft timing.
Always check for fault codes. If a fault code is de- - Replace damaged components and readjust
tected, service the fault code first. Refer to DIAG- camshaft timing.
NOSTIC AND FAULT CODES subsection. 2. Leaking intake or exhaust valves.
NOTE: When diagnosing an engine problem, al- - Perform a CYLINDER LEAK TEST. Repair or re-
ways perform the cylinder leak test. This will help place damaged components.
pinpoint a problem. Refer to CYLINDER LEAK 3. Broken valve spring(s).
TEST in this subsection.
- Replace defective parts.
VIBRATIONS PROCEDURES
1. Discharged or defective valve lifters.
- Check engine oil pressure, refer to LUBRICATION
VALVE COVER
SYSTEM subsection. Removing the Valve Cover
- Replace valve lifters.
1. Remove ignition coils. Refer to IGNITION
2. Camshaft(s) or camshaft holder(s) worn out. COILS AND SPARK PLUGS subsection.
- Check and replace damaged parts. 2. Remove screws securing the electrical harness
3. Faulty chain tensioner. to the valve cover.
- Replace chain tensioner. Refer to TIMING CHAIN
subsection.
4. Chain guide(s) worn out.
- Replace chain guide(s). Refer to TIMING CHAIN
subsection.
5. Stretched timing chain or worn out sprockets.
- Replace timing chain and sprockets. Refer to
TIMING CHAIN subsection.
6 tmr2017-019
Installing the Valve Cover

For installation reverse the removal procedure.
However, pay attention to the following details.
1. Properly fit the NEW small gaskets into the
camshaft holder grooves.
2. Properly lay the NEW large gasket onto the
cylinder head flat surface.
3. Apply engine oil to the sealing surface of the
V-ring.
tmr2017-019-004_a
3. Remove valve cover retaining screws.
smr2014-020-013_a
INSIDE VALVE COVER

4. Install valve cover.
mmr2014-018-005_a
NOTICE Adhere to the following proce-
1. Valve cover screws dure, otherwise damage to the V-ring will
occur causing crankcase venting malfunc-
4. Remove the valve cover. tion.
5. Remove and discard the valve cover gasket and 4.1 Move the valve cover towards the MAG
small gaskets around spark plug holes . side.
mmr2014-018-008_a
Step 1: Move valve cover towards MAG side
smr2014-020-012_a 4.2 Put valve cover onto cylinder head.

1. Spark plug hole gaskets
NOTICE Make sure the valve cover gas-
Inspecting the Valve Cover ket is well positioned in the cover groove.
Check the valve cover for cracks or other damage.
Replace defective parts.
tmr2017-019 7
4.3 Push valve cover towards the PTO side to

ensure that the V-ring properly seals on
sealing surface inside the cover.
mmr2014-018-009_a
Step 1: Push valve cover towards PTO side smr2014-020-048_a
1. Breather cover
5. Install valve cover screws and tighten as per fol-
lowing sequence: 3.2 Upper timing chain guide
TIGHTENING TORQUE 3.3 Timing chain guide.
9 N•m ± 1 N•m
Step A
Valve cover (80 lbf•in ± 9 lbf•in)
screw 9 N•m ± 1 N•m
Step B
smr2014-020-047_b
1. Upper timing chain guide

2. Timing chain guide
4. Remove timing chain from camshaft timing

gears.
mmr2014-018-005_b 5. Remove camshaft holder retaining
TIGHTENING SEQUENCE screws (x16).
CAMSHAFTS
Removing the Camshaft
1. Remove VALVE COVER, see procedure in this
subsection.
2. Lock crankshaft, refer to CRANKSHAFT LOCK-
ING PROCEDURE in the CYLINDER BLOCK
subsection.
Remove timing chain tensioner. Refer to TIMING
CHAIN subsection.
3. Remove: mmr2014-018-013_a
3.1 Breather cover 1. Camshaft holder retaining screws
8 tmr2017-019
6. Remove the camshaft holder upper half.
smr2014-020-022_a
A. Camshaft journal (PTO)

B. Camshaft journal (center and MAG)
C. Camshaft lobes
mmr2014-018-014_a
CAMSHAFT JOURNAL DIAMETER
1. Upper half of camshaft holder
PTO JOURNAL (A)
7. Put timing chain aside.
25.967 mm to 25.980 mm
8. Remove camshafts with timing gears. NEW
(1.0223 in to 1.0228 in)
SERVICE LIMIT 25.940 mm (1.0213 in)
CENTER AND MAG JOURNAL (B)
22.957 mm to 22.970 mm
NEW
(.9038 in to .9043 in)
CAMSHAFT LOBE HEIGHT
EXHAUST and INTAKE CAMSHAFT (C)

38.35 mm to 38.55 mm
NEW
(1.51 in to 1.518 in)
mmr2014-018-015_a
1. Intake camshaft Replace parts if necessary.

2. Exhaust camshaft
For camshaft journal radial clearance and
9. Remove camshaft timing gears only if neces- camshaft holder bearing diameter refer to
sary. Refer to TIMING CHAIN subsection. CAMSHAFT HOLDER in this subsection.
Inspecting the Camshaft 4. Check timing chain guide for wear, cracks or
deformation. Replace as required.
1. Check each lobe and bearing journal for scoring,
scuffing, cracks, or other signs of wear. 5. Replace timing chain guide if any groove
caused by timing chain exceeds service limit.
2. Check V-ring if it is brittle, hard or otherwise
damaged. CHAIN GUIDE GROOVE DEPTH
3. Measure camshaft bearing journal diameter SERVICE LIMIT 1 mm (.039 in)
and lobe height, using a micrometer.
tmr2017-019 9
5. Install exhaust camshaft assembly with mark

"EX" parallel to cylinder head gasket.
mmr2011-073-012_a
Installing the Camshaft

The assembly is the reverse of the removal proce-
dure. However pay attention to the following de-
tails.
1. Ensure crankshaft is still locked.
2. Apply engine oil on camshaft bearings.
smr2014-020-040_a
1. Exhaust camshaft
2. Camshaft timing gear
3. Mark "EX"
6. Install intake camshaft assembly with mark "IN"

parallel to cylinder head gasket.
mmr2014-018-016_a
1. Areas where to apply engine oil
NOTE: The camshafts are not identical. Any

mix-up of the components would lead to engine
damage. The exhaust camshaft has a machined
area on MAG side for the V-ring.
smr2014-020-041_a
1. Intake camshaft
2. Camshaft timing gear
3. Mark "IN"
7. Install the camshaft holder upper half, then

tighten screws as per following sequence:
TIGHTENING TORQUE
Camshaft 5 N•m ± 0.5 N•m
Step A
holder (44 lbf•in ± 4 lbf•in)
smr2014-020-024_a
1. Machined area
2. Exhaust camshaft
3. Intake camshaft
3. If removed, reinstall camshaft timing gears

on camshafts. Refer to CAMSHAFT TIMING
GEARS in the TIMING CHAIN subsection.
4. Apply engine oil on camshaft journal diameter.
10 tmr2017-019
mmr2014-018-013_b
CAMSHAFT HOLDER TIGHTENING SEQUENCE - STEP A mmr2014-018-017_a
1. Camshaft locking tool

TIGHTENING TORQUE
Camshaft 9 N•m ± 1 N•m 9. Lift timing chain out of timing chain compart-
Step B ment.
holder (80 lbf•in ± 9 lbf•in)
10. Pull timing chain up on exhaust side and install
it on the exhaust camshaft timing gear.
mmr2014-018-013_c
CAMSHAFT HOLDER TIGHTENING SEQUENCE - STEP B
NOTE: After the reassembly of the camshafts is smr2014-020-043_a

completed, check if camshafts can be turned eas- 1. Timing chain
ily. 2. Exhaust camshaft timing gear
8. Lock camshafts. 11. Pull timing chain towards intake side and in-
REQUIRED TOOL stall it on the intake camshaft timing gear.
CAMSHAFT LOCKING TOOL
(P/N 529 036 206)
smr2014-020-044_a
1. Intake camshaft timing gear
12. Install timing chain guide.
tmr2017-019 11
16. Install breather cover.
mmr2014-018-020_a
13. Install upper timing chain guide on camshaft

holder.
smr2014-020-048_a
1. Breather cover
17. Remove camshaft locking tool.
smr2014-020-046_a
1. Upper timing chain guide
14. Install TIMING CHAIN TENSIONER, refer to

TIMING CHAIN subsection.
15. Ensure marks on camshaft timing gears are mmr2014-018-024_a
still aligned. If not, repeat procedure. 1. Camshaft locking tool removal
NOTICE After installation of timing chain ten- 18. Remove crankshaft locking tool.
sioner, the marks "IN" on intake and "EX" on ex-
haust camshafts must be aligned.
CAMSHAFT HOLDER
Removing the Camshaft Holder
Remove camshafts, see procedure in this subsec-
tion.
Remove the camshaft holder lower half with gas-
kets from cylinder head.
Remove and discard gaskets from camshaft
holder halves.
smr2014-020-047_a
CAMSHAFT TIMING GEARS

1. Marks must be aligned
12 tmr2017-019
tmr2017-019-005_a
Inspecting the Camshaft Holder smr2014-020-027_a
1. Check camshaft holder for scoring, scuffing, 1. Camshaft holder lower half - view from beneath
2. Camshaft holder lower half - view from above
cracks, or other signs of wear. 3. Gaskets
4. Oil orifices
2. Make sure oil orifices are not clogged. Blow
them out with pressurized air. Install camshaft holder on cylinder head.
Tighten camshaft holder screws to specification,
refer to INSTALLING THE CAMSHAFT in this sub-
section.
Measure camshaft holder bearing diameter.
smr2014-020-026_a
smr2014-020-028_a
1. Camshaft holder upper half - view from beneath
2. Camshaft holder upper half - view from above CAMSHAFT HOLDER BEARINGS
3. Gaskets 1. PTO bearings
4. Oil orifices 2. Center and MAG bearings
A. Diameter PTO bearing
B. Diameter center and MAG bearing
tmr2017-019 13
CAMSHAFT HOLDER BEARING DIAMETER

PTO BEARING
26.000 mm to 26.021 mm
NEW
(1.024 in to 1.024 in)
CENTER AND MAG BEARING
23.000 mm to 23.021 mm
NEW
(.906 in to .906 in)
Measure clearance between camshaft journals

and camshaft holder, using the plastic feeler
gauge.
vmr2008-016-066_b
NOTE: The plastic feeler gauge is available at au-
TYPICAL
tomotive parts retailer. 1. Pressed plastic gauge
2. Graduated scale
Install camshaft holder lower half on cylinder
head. CAMSHAFT JOURNAL RADIAL CLEARANCE
Place the camshafts in the camshaft holder lower PTO, CENTER AND MAG BEARING
half and apply a plastic-gauge on the camshaft
bearing journal. 0.020 mm to 0.054 mm
NEW
(.001 in to .002 in)
Installing the Camshaft Holder

Install camshaft holder lower half.
Continue procedure as explained in INSTALLING
THE CAMSHAFT in this subsection.
HYDRAULIC VALVE LIFTERS

Removing the Hydraulic Valve Lifter
NOTE: Hydraulic valve lifter are maintenance
free.
See procedures in this subsection to remove:
vmr2008-016-066_a
TYPICAL
– Valve cover
1. Plastic gauge – Camshafts
2. Camshaft bearing journal
– Camshaft holder.
Install camshaft holder upper half in the proper po- Pull hydraulic valve lifter off the cylinder head.
sition and tighten screws to specification, refer to
INSTALLING THE CAMSHAFT in this subsection. NOTE: When disassembling the hydraulic valve
lifter, it is strongly recommended to note their
Unfasten camshaft holder. original position.
Measure the maximum width of the pressed plas-
tic gauge with the corresponding graduated scale.
14 tmr2017-019
CYLINDER HEAD
Removing the Cylinder Head
1. Remove the engine from the vehicle. Refer to
ENGINE REMOVAL AND INSTALLATION sub-
section.
2. Remove the following components, see proce-
dures in this subsection.
– Valve cover
– Camshafts
– Camshaft holder
mmr2014-018-027_a
– Hydraulic valve lifters.
1. Hydraulic valve lifter 3. Remove M6 cylinder head screws.
Inspecting the Hydraulic Valve Lifter

1. Check surface of hydraulic valve lifter for scor-
ing or other damage.
2. Measure valve lifter diameter. Replace if out of
specification.
HYDRAULIC VALVE LIFTER
28.354 mm to 28.370 mm
NEW
(1.1163 in to 1.1169 in)
HYDRAULIC VALVE LIFTER RADIAL CLEARANCE
Installing the Hydraulic Valve Lifter

However pay attention to the following details. mmr2014-018-028_a
1. Apply engine oil on the outside diameter of the 1. Remove M6 cylinder head screws
hydraulic valve lifter.
4. Remove and discard M9 cylinder head screws.
mmr2014-018-027_b
1. Apply engine oil on outer diameter smr2014-020-032_a
1. Remove M9 cylinder head screws
5. Pull cylinder head off the cylinder block.

6. Remove and discard cylinder head gasket.
tmr2017-019 15
Cleaning the Cylinder Head If warpage exceeds specification, resurface the

1. Remove carbon deposits from combustion cylinder head as follows.
chambers, exhaust ports and piston tops. Use a 400 - 600 grit wet sandpaper on a surface
2. Clean cylinder head, especially cylinder head plate and gently grind off the mating surface.
screw surface from oil spillage. NOTE: To ensure an even surface, rotate cylinder
3. Blow out the oil orifices with pressurized air and head several times during resurfacing.
make sure they are not clogged. Replace cylinder head, if resurfacing fails.
Installing the Cylinder Head

However, pay attention to the following details.
1. Install a NEW cylinder head gasket.
NOTICE Each installation of the cylinder
head requires a NEW cylinder head gasket.
Using a gasket twice would cause engine
damage.
2. Install cylinder head on the cylinder block.
3. Install NEW M9 cylinder head screws.
smr2014-020-033_a
NOTICE This assembly uses stretch screws.
1. Oil orifices Always use NEW screws and strictly adhere to
the tightening procedure.
Inspecting the Cylinder Head 4. Tighten cylinder head screws as follows:
Check for cracks between valve seats or other
NOTE: Always perform step A on all M9 cylinder
damage, if so, replace cylinder head.
head screws before going to the step B.
Check cylinder head mating surface for flatness
using a straight edge. TIGHTENING TORQUE
Check hydraulic valve lifter bores for scoring or Cylinder 20 N•m ± 2 N•m
Step A
other damage, if so, replace cylinder head. head screws (15 lbf•ft ± 1 lbf•ft)
- M9 Step B Additional 150° ± 5°
smr2014-020-034_a
1. Cylinder head
2. Straight edge smr2014-020-032_b
3. Feeler gauge M9 SCREWS TIGHTENING SEQUENCE
Check cylinder head warpage. NOTE: Use a torque angle gauge to carry out the
CYLINDER HEAD WARPAGE
step B.
16 tmr2017-019
smr2014-020-035_a smr2014-020-036_a
1. Torque angle gauge 1. Valve spring compressor clamp

2. Valve spring compressor cup
5. Install M6 screws. Tighten as follows.
3. Remove valve cotters.
TIGHTENING TORQUE
4. Withdraw valve spring compressor tools.
Cylinder head screws 9 N•m ± 1 N•m 5. Remove valve spring retainer and valve spring.
- M6 (80 lbf•in ± 9 lbf•in)
mmr2011-074-039_a
1. Valve cotters
2. Valve spring retainer
3. Valve spring
mmr2014-018-028_b
NOTE: Identify the position of each part very care-
M6 SCREWS TIGHTENING SEQUENCE
fully, so it can be reinstalled in its original place.
Inspecting the Valve Spring

VALVE SPRINGS 1. Check valve spring for rust, corrosion or other
Removing the Valve Spring visible damage.
1. Remove CYLINDER HEAD, see procedure in 2. Check valve spring free length and straight-
this subsection. ness.
2. Compress valve spring.
REQUIRED TOOLS
VALVE SPRING COMPRESSOR

(P/N 529 035 724)
VALVE SPRING COMPRESSOR

CUP (P/N 529 036 209)
tmr2017-019 17
VALVES
Removing the Valve
1. Remove VALVE SPRING, see procedure in this
subsection.
2. Push on the valve stem, then pull valves out of
cylinder head.
R400motr80A A
A. Spring free length
VALVE SPRING FREE LENGTH

NEW 31.35 mm (1.2343 in)
Replace valve spring, if out of specification.
Installing the Valve Spring

For installation, reverse the removal procedure. mmr2009-115-070_a
Pay attention to the following details. 1. Intake valves 29 mm

2. Exhaust valves 25 mm
NOTE: Ensure to reinstall all parts in their original
position as marked during removal. 3. Remove and discard valve stem seal.
1. Apply some grease on valve cotters, so that REQUIRED TOOL
they remain in place while releasing the valve
spring. SNAP-ON VALVE STEM SEAL
PLIERS (P/N YA 8230)
2. Make sure valve cotters are properly engaged
into valve stem groove.
mmr2011-074-040_a tmr2017-019-006_a
1. Valve cotters
NOTE: Identify the position of each part very care-
3. After spring is installed, ensure it is properly fully, so it can be reinstalled in its original place.
locked by lightly tapping on valve stem end with
a soft punch and a hammer so that valve opens Inspecting the Valve
and closes a few times. Inspect valve surface, check for abnormal stem
NOTICE Improperly locked valve spring will wear and bending.
cause severe engine damage and hitting the
valve stem end with excessive force could
damage the valve.
18 tmr2017-019
3. Measure valve guide inner diameter, using a

small bore gauge.
mmr2009-115-072_a
VALVE OUT OF ROUND

INTAKE AND EXHAUST VALVE mmr2009-115-073_a
NEW 0.005 mm (.0002 in) 1. Valve guides

A. Valve guide inner diameter
VALVE GUIDE INNER DIAMETER
Replace valve if out of specification.
5.000 mm to 5.012 mm
Valve Stem and Valve Guide Clearance NEW
(.1969 in to .1973 in)
1. Measure valve stem at three places, using a mi- SERVICE LIMIT 5.050 mm (.1988 in)
crometer.
Replace cylinder head, if valve guide is out of
specification.
Valve Face and Seat
2 3
R400motr83A
A. Valves stem diameter
VALVE STEM DIAMETER

INTAKE VALVE
4.958 mm to 4.972 mm
NEW
(.1952 in to .1957 in) R1503motr107A 1
SERVICE LIMIT 4.940 mm (.1945 in) TYPICAL
1. Valve seat
EXHAUST VALVE 2. Exhaust valve contaminated area
3. Valve face (contact surface to valve seat)
4.956 mm to 4.970 mm
NEW 1. Check valve face and seat for burning, pitting
(.1951 in to .1957 in)
and other signs of damage.
2. Check if valve seats properly in cylinder head.
Replace valve if stem is out of specification or if Proceed as follows.
its surface is damaged or worn. 2.1 Apply some lapping compound on valve
2. Clean valve guide from carbon deposits. face and work valve on its seat with a lap-
ping tool.
tmr2017-019 19
REQUIRED TOOL NOTICE Be careful when passing the valve

stem through the sealing lip of the seal.
SNAP-ON VALVE HOLDER (P/N VL2)
NOTE: The location of contact area should 1

be in center of valve face.
2.2 Repeat procedure until valve seat and
valve face fit together.
3. Measure valve seat contact width, using a
caliper.
A B
R1503motr254B
TYPICAL
1. Sealing lips of valve stem seal
3. Install VALVE SPRING. See procedure in this

subsection.
V01C1HA
A. Valve face contact width

B. Valve seat contact width
VALVE SEAT CONTACT WIDTH (B)

INTAKE VALVE
1.05 mm to 1.35 mm
NEW
(.041 in to .053 in)
EXHAUST VALVE
1.25 mm to 1.45 mm
NEW
(.049 in to .057 in)
Replace parts if out of specification.
Installing the Valve

Pay attention to the following details.
NOTICE Ensure to reinstall all parts in their
original position as marked during removal.
1. Install a NEW valve stem seal whenever valve
is removed.
2. Apply engine oil on valve stem and carefully
slide through cylinder head and valve stem seal.
20 tmr2017-019
Subsection XX (CYLINDER BLOCK)
CYLINDER BLOCK
SERVICE TOOLS
CRANKSHAFT LOCKING TOOL .................................................... 529 036 272 ........................................... 14
OIL SEAL/BEARING PUSHER ....................................................... 529 036 284 ......................................... 5–6
PISTON CIRCLIP INSTALLER........................................................ 529 036 426 ........................................... 20
PISTON RING COMPRESSOR ...................................................... 529 036 208 ........................................... 22
SERVICE PRODUCTS
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 7
LOCTITE 5910 ............................................................................... 293 800 081 ........................................... 12
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ........................................... 10
SUPER LUBE GREASE.................................................................. 293 550 030 ............................................. 5
tmr2017-020 1
12 ± 1 N•m
(106 ± 9 lbf•in)
Loctite 243
23 ± 3 N•m 9 ± 1 N•m
(17 ± 2 lbf•ft) (80 ± 9 lbf•in)
Loctite 243
Loctite 243
40 ± 4 N•m
NEW (30 ± 3 lbf•ft)
See ELECTRONIC FUEL 10 ± 1 N•m
INJECTION (EFI) (89 ± 9 lbf•in) See tightening
sequence
9 ± 1 N•m
(80 ± 9 lbf•in)
See LUBRICATION SYSTEM

Engine oil Engine oil
Engine oil
Loctite 5910
NEW
See tightening procedure Multi Purpose

Grease BP LS3
See tightening
sequence
NEW See tightening See tightening
sequence sequence
9 ± 1 N•m Loctite 243
23 ± 3 N•m 23 ± 3 N•m
(80 ± 9 lbf•in) (17 ± 2 lbf•ft)
NEW = Component must be replaced when removed. (17 ± 2 lbf•ft)
tmr2017-020-001_a
2 tmr2017-020
NEW
Engine oil
Engine oil NEW
Engine oil
See tightening
procedure
Engine oil
NEW
Engine oil
Engine oil

tmr2017-020-002_a
tmr2017-020 3
GENERAL 5. Crankshaft PTO ball bearing is worn.

- Remove PTO cover and check ball bearing for ex-
When disassembling parts that are duplicated in cessive play. Replace ball bearing if necessary.
the engine, (e.g.: pistons, connecting rods etc.),
it is strongly recommended to note their position BLUE SMOKE IN THE EXHAUST
and to keep the parts of the same assembly as
a “group”. If you find a defective component, it 1. Oil scraper rings worn out.
would be much easier to find the cause of the fail- - Replace piston rings.
ure. Since parts were broken-in during engine op-
eration, they will maintain their matched fit when ENGINE SUDDENLY TURNS OFF (POOR
reassembled together within their “group”. IDLING)
During assembly/installation, use torque values 1. Piston rings worn out.
and service products as in the exploded views. - Replace piston rings.
Clean threads before applying a threadlocker. Re- 2. Piston/cylinder clearance out of specification.
fer to SELF-LOCKING FASTENERS and LOCTITE - Check piston/cylinder clearance. Replace if out of
APPLICATION at the beginning of this manual for specification.
complete procedure.
3. Melted or broken piston.
WARNING - Replace piston and cylinder block if necessary.
must be strictly adhered to. PROCEDURES
tabs, elastic stop nuts, self-locking fasteners, PTO COVER AND PTO OIL SEALS
cotter pins, etc.) must be replaced.
PTO Cover Access
To replace the PTO oil seal, it is not necessary to
NOTICE Hoses, cables or locking ties re- remove engine from the vehicle.
as per factory standards. Remove drive pulley. Refer to CONTINUOUSLY
VARIABLE TRANSMISSION (CVT subsection.
TROUBLESHOOTING Removing the PTO Cover
Always check for fault codes. If a fault code is de- Remove screws retaining the PTO cover.
tected, service the fault code first. Refer to DIAG- Remove PTO cover and discard gasket.
VIBRATIONS
1. Heavy wear on plain bearings.
- Check radial play of plain bearings. Replace if out
of specification.
2. Crankshaft axial play out of specification.
- Measure crankshaft axial play. If crankshaft axial
play is out of specification, replace thrust wash-
ers.
3. Connecting rod axial play out of specification.
- Measure connecting rod axial play on crankshaft.
Replace connecting rod or crankshaft if out of tmr2017-020-003_a
specification.
1. PTO cover screws
4. Connecting rod screws got loose. 2. PTO cover
3. Gasket
- Replace damaged components and retighten
screws with the recommended torque. PTO Oil Seal and Bearing Replacement
NOTE: Always replace PTO oil seal and roller
bearing at the same time.
4 tmr2017-020
Removing the PTO Oil Seal and Bearing

1. Use pliers to remove inner retaining ring.
tmr2017-020-005_a
1. Roller bearing
2. Oil seal
3. PTO cover
tmr2017-020-004_a Installing the PTO Oil Seal and Bearing

2. Heat PTO cover up to 130°C (266°F) before re- NOTE: Check the oil seal running surface of
moving the roller bearing and oil seal. crankshaft for grooves and deposits, before in-
stallation of NEW oil seal.
NOTICE Clean PTO cover from oil before
1. Clean crankshaft PTO side from deposits.
heating.
2. Clean oil seal and roller bearing areas in PTO
3. Carefully push out oil seal and roller bearing. cover.
REQUIRED TOOL 3. Lubricate oil seal outer diameter and sealing lip.
Punch 4 mm (.157 in) OIL SEAL SEALING LIP AND OUTER DIAMETER
SUPER LUBE GREASE
Service product
(P/N 293 550 030)
4. Press NEW oil seal in PTO cover.

NOTICE Oil seal must be installed with seal-
ing lip facing to the engine.
REQUIRED TOOL
OIL SEAL/BEARING PUSHER

(P/N 529 036 284)
mmr2014-019-005_a
PUSH OUT CIRCULAR

1. Punch
2. PTO cover
4. Remove and discard roller bearing and oil seal.
tmr2017-020 5
tmr2017-020-004_a
Installing the PTO Cover

Pay attention to following details.
Install a NEW PTO cover gasket in proper position.
mmr2014-019-007_a
1. OIL SEAL/BEARING PUSHER (P/N 529 036 284)

2. Oil seal
3. PTO cover
5. Place NEW roller bearing in PTO cover.

6. Carefully press in the roller bearing.
NOTICE During installation never push on
the inner race of the bearing.
REQUIRED TOOL
OIL SEAL/BEARING PUSHER

tmr2017-020-008_a
(P/N 529 036 284)
1. Gasket
2. Tab
Tighten PTO cover screws as per following se-

quence.
tmr2017-020-006_a
1. OIL SEAL/BEARING PUSHER (P/N 529 036 284)

2. Roller bearing
3. PTO cover
7. Install retaining ring.
6 tmr2017-020
– Thermostat
– Water pump drive gear.
9. Refer to LUBRICATION SYSTEM subsection
and remove:
– Oil tank
– Oil cooler
– Oil pressure regulator
– Oil pump drive gears and oil pumps
– Oil sump cover
– Oil strainers.
10. Refer to MAGNETO AND STARTER subsec-
tion and remove:
– Rotor
– Starter drive gears
– Electric starter.
mmr2014-019-011_a 11. Refer to TIMING CHAIN subsection and re-
PTO COVER TIGHTENING SEQUENCE move:
TIGHTENING TORQUE – Timing chain tensioner
– Timing chain guides.
LOCTITE 243 (BLUE)
Service product 12. Refer to CYLINDER HEAD subsection and re-
(P/N 293 800 060)
move:
23 N•m ± 3 N•m
PTO cover screws
(17 lbf•ft ± 2 lbf•ft) – Camshaft holders
– Cylinder head.
13. Remove PTO cover. Refer to PTO COVER
CYLINDER BLOCK AND PTO OIL SEAL in this subsection.
Disassembling the Cylinder Block NOTE: Before splitting the cylinder block, mea-
1. Remove engine from the vehicle. Refer to EN- sure crankshaft axial play. Refer to CRANKSHAFT
GINE REMOVAL AND INSTALLATION subsec- in this subsection.
tion. 14. Remove crankshaft locking tool.
2. Drain engine oil. 15. Remove cylinder block screws.
3. Refer to CONTINUOUSLY VARIABLE TRANS- 15.1 Start removing the M6 screws.
MISSION (CVT) subsection to remove following 15.2 Then remove the M8 screws.
parts:
– Drive pulley 15.3 Finally remove and discard the M9
screws.
– Driven pulley
– CVT air guide.
4. Detach gearbox from engine. Refer to GEAR-
BOX AND 4X4 COUPLING UNIT subsection.
5. Remove the valve cover. Refer to CYLINDER
HEAD subsection.
6. Lock crankshaft, refer to CRANKSHAFT LOCK-
ING PROCEDURE in this subsection.
7. Remove air intake manifold. Refer to AIR IN-
TAKE SYSTEM subsection.
8. Refer to COOLING SYSTEM subsection and re-
move:
– Water pump housing
tmr2017-020 7
smr2014-021-012_a tmr2017-020-009
INTAKE SIDE
1. Cylinder block screws (M6) screwed from top to bottom 17. Remove connecting rod caps. Refer to PIS-
TONS AND CONNECTING RODS in this sub-
section.
18. Refer to CRANKSHAFT in this subsection and
remove:
– Crankshaft thrust washers
– Crankshaft.
19. Remove pistons and connecting rods. See
procedure in this subsection.
Removing the Plain Bearing
When the plain bearings need to be removed from
the cylinder block, mark them to identify the cor-
rect position at installation. See the illustration as
tmr2017-020-013_a
an example.
CYLINDER BLOCK SCREW (M6) SCREWED FROM TOP TO
BOTTOM - EXHAUST SIDE
tmr2017-020-010_a
MARKS ON CRANKSHAFT PLAIN BEARINGS

tmr2017-020-012_d
BOTTOM SIDE Cleaning the Cylinder Block

1. M6 screws
2. M8 screws Clean cylinder block using a part cleaner, then use
3. M9 screws (discard)
compressed air to dry it.
16. Carefully remove cylinder block lower half by Blow out the oil orifices using compressed air and
using a soft hammer. make sure they are not clogged.
NOTE: Take care not to damage the sealing sur- Inspect oil nozzles, refer to LUBRICATION SYS-
faces of the cylinder block halves. TEM subsection.
8 tmr2017-020
smr2014-021-020_a
tmr2017-020-011_a
CYLINDER BLOCK - TOP
CYLINDER BLOCK UPPER HALF 1. Oil orifices
1. Oil orifices
2. Oil nozzles
smr2014-021-021_a
smr2014-021-018_a
CYLINDER BLOCK - REAR CYLINDER BLOCK LOWER HALF

1. Oil orifices 1. Oil orifices
smr2014-021-019_a
CYLINDER BLOCK - MAG SIDE

smr2014-021-022_a
1. Oil orifices
CYLINDER BLOCK LOWER HALF
1. Oil orifices
Clean all metal components in a solvent.
tmr2017-020 9
Clean cylinder block mating surfaces with LOCTITE Cylinder Out of Round
CHISEL (GASKET REMOVER) (P/N 413 708 500) and Measure cylinder bore diameter as shown and at
a brass brush. Brush a first pass in one direction the same measuring points as for CYLINDER TA-
then make the final brushing perpendicularly (90°) PER.
to the first pass (cross hatch).
NOTE: Do not wipe with rags. Use a new clean
hand towel only.
Inspecting the Cylinder Block

Check cylinder block for cracks or other damage.
Check cylinder block mating surfaces for flatness
using a straight edge.
Replace cylinder block if necessary.
Check cylinder bores for cracks, scoring and wear
ridges on top and bottom of the cylinders.
Cylinder Taper
Measure cylinder bore diameter at 4 recom-
mended positions. See illustration. smr2014-021-025_a
1. Perpendicular to piston pin axis

2. Parallel to piston pin axis
To obtain the cylinder out of round, calculate the

difference between the perpendicular measures.
CYLINDER OUT OF ROUND
NEW MAXIMUM 0.008 mm (.0003 in)
Inspecting Plain Bearings Diameter

Check the plain bearings for scoring or other dam-
ages.
Measure plain bearing inside diameter and com-
pare with crankshaft bearing journal diameter (re-
fer to CRANKSHAFT in this subsection). Proceed
mmr2011-075-022_a
as follows.
TYPICAL
1. First measure – Use the OLD plain bearings and put both cylin-
2. Second measure der block halves together.
3. Third measure
4. Fourth measure – Tighten screws as described in ASSEMBLING
A. 5 mm to 10 mm (.197 in to .394 in) THE CYLINDER BLOCK.
B. 30 mm to 35 mm (1.181 in to 1.378 in)
C. 57 mm to 62 mm (2.244 in to 2.441 in) – Measure the inside diameter of the crankshaft
D. 111 mm to 113 mm (4.37 in to 4.449 in) plain bearings using a bore gauge.
The difference between measurements should
not exceed the service limit mentioned in next
table.
CYLINDER TAPER
NEW MAXIMUM 0.030 mm (.0012 in)
10 tmr2017-020
mmr2011-075-024_a
1. Bore gauge smr2014-021-022_b

2. Crankshaft plain bearing
1. Flat bearings
CRANKSHAFT PLAIN BEARING INSIDE
DIAMETER 1.4 Bearings must be flush with the cylinder
block split surface and their protrusions
SERVICE LIMIT 36.080 mm (1.4205 in) have to fit in the notched areas in the
cylinder block seat.
Replace bearings if they are out of specifications.
1
Assembling the Cylinder Block
For assembly, reverse the disassembly proce-
dure. Pay attention to the following details.
1. Correctly reinstall plain bearings as follows.
1.1 Use NEW bearings if diameters are out
of specification. Refer to INSPECTING
PLAIN BEARING DIAMETER in this sub-
section.
1.2 Install bearings with lubrication grooves in
the cylinder block upper half.
R1503motr36A
TYPICAL
1. Bearing protrusion in cylinder block notch
2. Install pistons, refer to PISTONS AND CON-

NECTING RODS in this subsection.
3. Apply engine oil on all plain bearings.
4. Install the following components:
– Crankshaft and thrust washers (refer to
CRANKSHAFT)
tmr2017-020-010_b
– Connecting rod caps (refer to PISTONS AND
1. Plain bearings CONNECTING RODS).
2. Lubrication grooves
5. Apply sealant on mating surface of cylinder
1.3 Install flat bearings in the cylinder block block lower half as shown on next illustration.
lower half.
tmr2017-020 11
CYLINDER BLOCK SEALANT

LOCTITE 5910 (P/N 293
Service product
800 081)
IMPORTANT: When beginning the application of

the cylinder block sealant, the assembly and first
tightening have to be done within 12 minutes. It
is suggested to have all you need on hand to save
time.
smr2014-021-027_a
1. Bypass passage of engine oil pressure regulator

2. Loctite 5910 applied
6. Install NEW cylinder block M9 screws and

tighten as follows.
NOTICE This assembly uses stretch
screws. Always use NEW screws and
smr2014-021-026_a strictly adhere to the tightening proce-
1. Apply Loctite 5910 following this pattern dure.
NOTICE Ensure not to apply too much 6.1 Torque the M9 screws according the se-
sealant, as it will spread out inside the cylinder quence.
block. TIGHTENING PROCEDURE
NOTICE Take care that the bypass passage of Cylinder block 20 N•m ± 2 N•m
the engine oil pressure regulator is not clogged STEP A
M9 screws (15 lbf•ft ± 1 lbf•ft)
with sealant.
tmr2017-020-012_a
M9 SCREWS TIGHTENING SEQUENCE - FIRST AND SECOND

STEPS
6.2 Use a torque angle gauge to carry out

the second step, following the same se-
quence.
12 tmr2017-020
TIGHTENING PROCEDURE
Cylinder block
STEP B Additional 150° ± 5°
M9 screws
7. Install the M8 screws and tighten as follows.

TIGHTENING TORQUE
Cylinder block M8 23 N•m ± 2 N•m
smr2014-021-012_b
M6 SCREWS TIGHTENING SEQUENCE (INTAKE SIDE OF

CRANKCASE)
tmr2017-020-012_b
M8 SCREWS TIGHTENING SEQUENCE
8. Install the M6 screws and tighten as follows.

TIGHTENING TORQUE
Cylinder block M6 9 N•m ± 1 N•m tmr2017-020-013_b
screws (80 lbf•in ± 9 lbf•in) M6 SCREW TIGHTENING SEQUENCE (EXHAUST SIDE OF
CRANKCASE)
NOTE: Check the crankshaft axial play before

continuing the assembly. Refer to CRANKSHAFT
in this subsection for the procedure.
9. Lubricate PTO oil seals properly before rein-
stalling the PTO cover. Refer to PTO COVER
AND PTO OIL SEALS in this subsection.
10. Reassemble engine in accordance with the
proper assembly procedures.
CRANKSHAFT
Crankshaft Locking Procedure
tmr2017-020-012_c
NOTICE When crankshaft is locked, the sec-
M6 SCREWS TIGHTENING SEQUENCE (BOTTOM OF
CRANKCASE) ond cylinder is set to TDC.
Crankshaft must be locked whenever the mag-
neto rotor retaining nut has to be removed or
whenever working on the valve train.
tmr2017-020 13
NOTICE When working on the valve train or REQUIRED TOOL

timing chain, crankshaft must be locked with
the marks "IN" and "EX" on the camshaft timing CRANKSHAFT LOCKING TOOL
gears facing each other. (P/N 529 036 272)
1. If working on the valve train or timing chain,

remove the valve cover. Refer to CYLINDER
HEAD subsection.
2. Remove spark plugs.
3. Remove crankshaft access plug and discard
gasket ring.
tmr2017-020-015_a
Removing the Crankshaft

1. Disassemble CYLINDER BLOCK, see proce-
2. Remove connecting rod caps. Refer to PIS-
TONS AND CONNECTING RODS in this sub-
tmr2017-020-014_a
section.
4. Turn engine on PTO side counterclockwise to 3. Remove crankshaft thrust washers.
bring crankshaft to locking position.
For turning the crankshaft install drive pulley or
use a suitable screw locked by a counter nut.
R1503motr09A
TYPICAL
1. Thrust washer
4. Remove crankshaft from cylinder block.

mmr2014-019-014_a
1. Crankshaft PTO side
NOTICE Crankshaft locking position is

reached when marks "IN" and "EX" on the
camshaft timing gears face each other.
5. Use a flashlight to check if the groove in the
crankshaft is aligned with the hole.
6. Lock crankshaft.
14 tmr2017-020
Crankshaft Radial Play

Measure crankshaft bearing journal diameter, us-
ing a micrometer.
tmr2017-020-016_a
Inspecting the Crankshaft

Check each bearing journal of crankshaft for scor- mmr2009-116-030_a
ing, scuffing, cracks or other signs of wear. TYPICAL
1. Micrometer
Check if crankshaft gears are worn or otherwise 2. Crankshaft area for plain bearing
damaged.
To obtain the radial play, calculate the difference
between the bearing journal diameter and the
crankshaft plain bearings inner diameter (see
CYLINDER BLOCK).
CRANKSHAFT BEARING JOURNAL DIAMETER
35.990 mm to 36.006 mm
NEW
(1.4169 in to 1.4176 in)
CRANKSHAFT RADIAL PLAY

tmr2017-020-017_a
Crankshaft Pin Diameter
1. Oil pump drive gear
2. Crankshaft timing gear Measure crankshaft pin diameter, using a microm-
eter.
Replace crankshaft if damaged.
Blow the oil orifices using compressed air and between the crankshaft pin diameter and the con-
make sure they are not clogged. necting rod plain bearings inner diameter (see IN-
SPECTING THE CONNECTING ROD).
tmr2017-020-017_b
tmr2017-020 15
mmr2009-116-031_a
mmr2009-116-033_a
TYPICAL
TYPICAL
1. Micrometer
1. Crankshaft thrust washers
2. Crankshaft pin area for plain bearing
CRANKSHAFT PIN DIAMETER Installing the Crankshaft

35.979 mm to 35.995 mm For installation, reverse the removal procedure.
NEW Pay attention to following details.
(1.4165 in to 1.4171 in)
SERVICE LIMIT 35.969 mm (1.4161 in) Turn cylinder block upside down.
NOTICE Be careful that connecting rods do
CONNECTING ROD BIG END RADIAL PLAY
not hit the cylinder block.
Apply engine oil on all plain bearings before in-
Crankshaft Axial Play stalling them.
With the crankshaft in the cylinder block, measure Install crankshaft along with the timing chain.
the crankshaft axial play, using a dial indicator. Lubricate (both sides) and reinstall crankshaft
thrust washers with the slots facing against
crankshaft counterweights.
NOTE: Thrust washers have to be flush with the
cylinder block sealing surface.
mmr2009-116-032_a
TYPICAL
1. Dial indicator
2. Crankshaft
CRANKSHAFT AXIAL PLAY

0.120 mm to 0.352 mm
NEW
(.005 in to .014 in) R1503motr16A
SERVICE LIMIT 0.450 mm (.018 in) TYPICAL

1. Thrust washer
2. Sealing surface
If play is out of specification, replace the crank-
shaft thrust washers and repeat measurement. Install connecting rod caps. Refer to PISTONS
AND CONNECTING RODS in this subsection.
16 tmr2017-020
NOTICE It is absolutely necessary to follow

this procedure. Otherwise severe engine dam-
age can occur.
Install cylinder block lower half. Refer to CYLIN-
DER BLOCK in this subsection.
Lock crankshaft before further assembly of the
engine. See CRANKSHAFT LOCKING PROCE-
DURE in this subsection.
PISTONS AND CONNECTING mmr2009-116-075_a

RODS TYPICAL
1. Piston pin circlip
Removing the Piston and Connecting
Rod NOTE: The removal of both piston pin circlips is
not necessary to remove the piston pin.
NOTE: It is recommended to measure connecting
rod big end axial play prior to remove connecting 2. Push piston pin out of the piston.
rod. Refer to CONNECTING ROD INSPECTION.
1. Disassemble CYLINDER BLOCK as per proce- 1 2 3
2. Remove connecting rod cap.
NOTICE Mark cylinder position of connecting
rod before disassembly.
R1503motr27A
TYPICAL
1. Piston
2. Piston pin
3. Circlip
3. Detach piston from connecting rod.

tmr2017-020-018_a
Inspecting the Connecting Rod
1. Connecting rod screws
2. Connecting rod cap Connecting Rod Big End Axial Play
3. Remove CRANKSHAFT as per procedure in this Using a feeler gauge, measure distance between
subsection. butting face of connecting rod and crankshaft
4. Turn cylinder block and push piston with con- counterweight. If the distance exceeds specified
necting rod out of the cylinder. tolerance, replace the worn part.
Disassembling the Piston and

Connecting Rod
1. Remove one piston pin circlip and discard it.
tmr2017-020 17

between the piston pin diameter (INSPECTING
THE PISTON PIN) and the connecting rod small
end inner diameter.
CONNECTING ROD SMALL END RADIAL PLAY
Connecting Rod Big End Radial Play

1. Measure inside diameter of connecting rod big
end.
1.1 Install the OLD plain bearings as they were
mounted initially.
smr2014-021-035_a 1.2 Perform the tightening procedure as de-
1. Crankshaft scribed in INSTALLING PISTON AND
2. Connecting rod
3. Feeler gauge CONNECTING ROD in this subsection.
NOTE: To measure the connecting rod big
CONNECTING ROD BIG END AXIAL PLAY end diameter, ALWAYS use the OLD con-
0.100 mm to 0.352 mm necting rod screws.
NEW
(.004 in to .014 in) 1.3 Measure inside diameter in longitudinal di-
SERVICE LIMIT 0.450 mm (.018 in) rection of the connecting rod.
Connecting Rod Small End Radial Play

Measure connecting rod small end, using a bore
gauge.
vmr2006-044-039_a
TYPICAL
A. Connecting rod big end bearing
2 1 CONNECTING ROD BIG END DIAMETER

To obtain the connecting rod big end radial play,

R1004motr11A calculate the difference between the big end di-
TYPICAL ameter and the crankshaft pin diameter (see IN-
1. Bore gauge SPECTING THE CRANKSHAFT).
2. Connecting rod
CONNECTING ROD BIG END RADIAL PLAY
CONNECTING ROD SMALL END DIAMETER
17.010 mm to 17.020 mm
NEW
(.6697 in to .6701 in) If connecting rod big end diameter is out of spec-
SERVICE LIMIT 17.060 mm (.6717 in) ification, install NEW plain bearings.
If the connecting rod small end diameter is out of Inspecting the Piston Pin
specification, replace the connecting rod. Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracks or other
damage.
18 tmr2017-020
Measure piston pin diameter, using a micrometer. Piston/Cylinder Clearance

See the following illustration for the proper mea- 1. Adjust and lock a micrometer to the piston di-
surement position. mension.
R400motr30A A
TYPICAL
A. Measure piston pin diameter here
F00B08A
PISTON PIN DIAMETER
TYPICAL
16.996 mm to 17.00 mm 1. Micrometer set to the piston dimension
NEW
(.6691 in to .6693 in)
NOTE: Make sure used piston is not worn.
2. With the micrometer locked at step 1, adjust a
Replace the piston pin if it is out of specification. cylinder bore gauge to the micrometer dimen-
sion and set the indicator to 0 (zero).
Inspecting the Piston
Inspect piston for scoring, scuffing, cracks or
other damage. Replace piston and piston rings if
necessary.
Using a micrometer, measure piston perpendicu-
larly (90°) to piston pin axis at 8.5 mm (11/32 in) 2 1
from the skirt edge.
F00B09A
TYPICAL
1. Use the micrometer to set the cylinder bore gauge
2. Cylinder bore gauge
A
R400motr96A
TYPICAL
1. Measuring perpendicularly (90°) to piston pin axis
A. 8.5 mm (11/32 in)
PISTON MEASUREMENT
73.950 mm to 73.966 mm
NEW
(2.9114 in to 2.912 in)
Replace piston if it is out of specification.
tmr2017-020 19
NOTICE Always replace removed piston

pin circlips by NEW ones.
3.1 Place the circlip in the sleeve and push
piston circlip installer handle until circlip
reaches the mid position in the sleeve.
F00B0AA
TYPICAL
1. Indicator set to 0 (zero)
NOTE: Make sure the cylinder bore gauge indica- mmr2011-075-041_a

tor is set exactly at the same position as with the TYPICAL
micrometer, otherwise the reading will be false. 1. Circlip
2. Sleeve
3. Position the cylinder bore gauge 35 mm 3. Installer handle
(1-3/8 in) below the cylinder head mating sur-
face, measuring perpendicularly (90°) to piston 3.2 Put the distance sleeve on the installer
pin axis. handle.
4. Read the measurement on the cylinder bore 3.3 Push piston circlip installer handle until
gauge. The result is the exact piston/cylinder distance sleeve makes contact with the
clearance. sleeve.
PISTON/CYLINDER CLEARANCE
0.037 mm to 0.067 mm
NEW
(.0015 in to .0026 in)
If clearance exceeds the specified tolerance, re-

place the piston and repeat the measurement pro-
cedure.
Assembling Piston and Connecting mmr2011-075-029_a
Rod 1.
2.
Circlip
Sleeve
For assembly, reverse the disassembly proce- 3. Installer handle
4. Distance sleeve
dure. Pay attention to the following details.
1. Apply engine oil on the piston pin. 3.4 Remove distance sleeve and insert in-
staller handle into the sleeve.
2. Insert piston pin into piston and connecting rod.
3.5 Insert the end of the handle into the piston
NOTE: Ensure to reinstall all parts in their original pin, then push to engage the circlip into
position as marked during removal. the piston groove.
3. Install NEW piston pin circlip(s).
REQUIRED TOOL
PISTON CIRCLIP
INSTALLER (P/N 529
036 426)
20 tmr2017-020
1
2
3
2
R1503motr28A
TYPICAL
1. Sleeve with piston circlip inside
2. Piston clip installer handle
R1004motr20A
NOTE: Take care that the hook of the piston
pin circlip is positioned properly. TYPICAL
1. Half bearing of connecting rod big end
2. Split surface of the connecting rod
3. Protrusion of bearing in line with connecting rod groove
NOTICE The arrow on top of the piston and

the punched marks on the connecting rods
must always point towards exhaust.
R400motr102A
CORRECT POSITION OF THE PISTON PIN CIRCLIP
NOTICE If piston pin circlip installation fails,

repeat step 3 by using a NEW circlip.
4. Correctly install plain bearings and carefully
clean split surface on both sides (cracked area) mmr2011-075-042_a
with compressed air. 1. Piston
2. Arrow on top
3. Connecting rod
4. Punched marks
Installing the Piston and Connecting

Rod
1. Use engine oil and lubricate:
– Piston
– Piston rings
– Cylinder bore
– Connecting rod bearings.
2. Slide piston into cylinder bore. Pay attention to
the following.
tmr2017-020 21
REQUIRED TOOL
PISTON RING
COMPRESSOR
(P/N 529 036 208)
smr2014-021-037_a
1. Arrows
2. Exhaust
3. Turn cylinder block upside down.

mmr2009-116-017
4. Install CRANKSHAFT as per procedure in this
TYPICAL
subsection.
2.1 If reused, install piston in its original bore. 5. Oil the crankshaft pin.
2.2 Make sure piston rings are properly 6. Install connecting rod caps.
spaced. NOTE: Printed marks on connecting rod and cap
NOTICE The ring gaps of both compres- must point together.
sion rings should always be 180° from
each other and 90° from the arrow on top
of the piston.
mmr2009-116-019_a
TYPICAL
1. Printed marks
NOTICE This assembly uses stretch screws.

Always use NEW screws and strictly adhere to
mmr2011-075-044_a
the tightening procedure.
RING GAPS AT 180° FROM EACH OTHER AND 90° FORM
ARROW
1. Rectangular ring - ring gap 7. Tighten connecting rod screws as follows:
2. Taper-face ring - ring gap
3. Arrow 7.1 Torque both connecting rod screws of a
connecting rod.
2.3 The arrow on top of the piston must point
towards exhaust.
NOTICE Piston installed with the arrow in the
wrong direction would cause serious engine
damage.
22 tmr2017-020
Connecting STEP 12 N•m ± 2 N•m
rod screws A (106 lbf•in ± 18 lbf•in)
7.2 Use a torque angle gauge to carry out the

second step. 2
Connecting STEP
Additional 70° ± 5°
rod screws B
R1503motr32A 1
TYPICAL
1. Piston
2. Feeler gauge
RING/PISTON GROOVE CLEARANCE

UPPER COMPRESSION RING
0.030 mm to 0.066 mm
NEW
(.0012 in to .0026 in)
tmr2017-020-019
LOWER COMPRESSION RING
NOTICE Failure to strictly follow this proce- 0.020 mm to 0.056 mm
dure may cause screws to loosen and lead to NEW
(.0008 in to .0022 in)
severe engine damage.
8. Install all other removed parts. OIL SCRAPER RING
PISTON RINGS 0.010 mm to 0.040 mm

NEW
(.0004 in to .0016 in)
Removing the Piston Ring SERVICE LIMIT 0.150 mm (.0059 in)
1. Remove piston, see procedure in this subsec-
tion. If clearance is out of specification, the piston and
2. Remove rings from piston. rings should be replaced.
Ring End Gap
Inspecting the Piston Ring
1. Place piston ring in the cylinder bore between
Ring/Piston Groove Clearance 8 mm to 16 mm (5/16 in to 5/8 in) from the top
Using a feeler gauge measure each ring/piston of cylinder.
groove clearance. NOTE: In order to correctly position the ring in the
cylinder bore, use a piston as a pusher.
2. Using a feeler gauge, check ring end gap.
tmr2017-020 23
RING END GAP

UPPER COMPRESSION RING
0.20 mm to 0.35 mm
NEW
(.008 in to .014 in)
LOWER COMPRESSION RING
0.30 mm to 0.50 mm
NEW
(.012 in to .02 in)
OIL SCRAPER RING
0.20 mm to 0.70 mm
NEW
(.008 in to .028 in)
If ring end gap is out of specification, replace pis-

ton rings.
Installing the Piston Ring

1. Install piston rings in the following order.
NOTE: Use a ring expander to prevent break-
age during installation. The oil ring must be
installed by hand.
1.1 Install oil scraper ring.
1.2 Install the lower compression ring with the
letter “N” facing up.
1.3 Install upper compression ring with the let-
ter “N” facing up.
mmr2011-075-046_a
1. Rectangular ring
2. Taper-face ring
3. Oil scraper ring
4. Letter “N” facing up
NOTICE Ensure that upper and lower

compression rings are not interchanged.
2. Check that rings rotate smoothly after installa-
tion.
24 tmr2017-020
Subsection XX (CONTINUOUSLY VARIABLE TRANSMISSION (CVT))
CONTINUOUSLY VARIABLE
TRANSMISSION (CVT)
SERVICE TOOLS
CLUTCH HOLDER ......................................................................... 529 036 432 ................................. 7, 18, 24
DRIVE PULLEY PULLER ............................................................... 529 000 064 ............................................. 8
DRIVEN PULLEY ADAPTER .......................................................... 708 200 720 ....................................... 6, 18
DRIVEN PULLEY SPACER............................................................. 529 036 351 ........................................... 18
GOVERNOR CUP PULLER............................................................ 529 036 350 ............................................. 8
PULLER/LOCKING TOOL .............................................................. 529 000 088 ....................................... 6, 18
PULLEY SPRING COMPRESSOR TOOL....................................... 529 036 012 ..................................... 10, 18
SERVICE PRODUCTS
CLUTCH AND PULLEY FLANGE CLEANER PRO S1.................... 779244 ............................... 11, 16, 22
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 25
XPS BRAKES AND PARTS CLEANER (USA)................................. 219 701 705 ........................................... 24
219100971-014 1
Turb o w ith ou t In terco oler an d Na turally-A sp irated
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
NEW
61 ± 6 N•m
(45 ± 4 lbf•ft)
NEW
3,5 ± 0,4 N•m

(31 ± 4 lbf•in)
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)
70 ± 5 N•m
(52 ± 4 lbf•ft)
NEW
10 ± 1 N•m
(89 ± 9 lbf•in)
NEW
8 ± 0,8 N•m
(70 ± 7 lbf•in)
120 ± 8 N•m
(89 ± 6 lbf•ft)
2 ± 0,2 N•m
(18 ± 2 lbf•in)
6 ± 0,7 N•m
(53 ± 6 lbf•in)
See tightening sequence

tmr2017-021-001_b
2 219100971-014
Turb o w ith Interc oo le r
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
NEW
NEW
61 ± 9 N•m
(45 ± 7 lbf•ft)
Loctite 243
3,5 ± 0,4 N•m

(31 ± 4 lbf•in)
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)
70 ± 5 N•m
(52 ± 4 lbf•ft)
NEW
10 ± 2 N•m
(89 ± 18 lbf•in)
NEW
5 ± 0,6 N•m NEW

(44 ± 5 lbf•in)
1,5 ± 0,1 N•m
(13 ± 1 lbf•in)
120 ± 8 N•m
(89 ± 6 lbf•ft)
2 ± 0,2 N•m
(18 ± 2 lbf•in)
6 ± 0,7 N•m
(53 ± 6 lbf•in)

RTX903CARBSSV-008-001_a
219100971-014 3
2.5 ± 0.5 N•m

(22 ± 4 lbf•in) 2.5 ± 0.5 N•m
(22 ± 4 lbf•in)
NEW
10 ± 2 N•m
(89 ± 18 lbf•in)
10 ± 2 N•m
(89 ± 18 lbf•in)
2.0 ± 0.3 N•m
(18 ± 3 lbf•in)
2.0 ± 0.3 N•m

(18 ± 3 lbf•in)
2.0 ± 0.3 N•m

(18 ± 3 lbf•in)

tmr2017-021-200_a
4 219100971-014
GENERAL 3. Let water drain from CVT cover.

NOTE: For a better understanding, the following 4. Reinstall bayonet cap and O-ring.
illustrations are taken with engine out of vehicle. TIGHTENING TORQUE
To perform the following instructions, it is not nec-
essary to remove engine. 2 N•m ± 0.2 N•m
Bayonet cap
This CVT is lubrication free. Never lubricate any
components except drive pulley hub. NOTICE If any debris entered the CVT cover,
CVT must be cleaned and inspected.
WARNING
Never touch CVT while engine is running. Removing the CVT Cover
Never drive vehicle when CVT cover is re- Detach CVT hoses from CVT cover.
moved.
Remove the CVT cover.
WARNING NOTE: Remove the center top screw last to sup-
port the cover during removal.
Any drive pulley repairs must be performed
by an authorized Can-Am dealer. Subcompo- NOTICE Do not use and impact tool to re-
nent installation and assembly tolerances remove CVT cover screws.
quire strict adherence to procedures detailed.
WARNING
The clutch assembly is a precisely balanced
unit. Never replace parts with used parts
from another clutch assembly.
PROCEDURES
CVT COVER
Draining the CVT Cover
If water is present in CVT cover, it can be drained
as follows:
tmr2017-021-003_a
1. Turn bayonet cap 90° counterclockwise to open 1. Retaining screws
it. 2. CVT cover
3. Gasket
2. Remove bayonet cap and O-ring.
Installing the CVT Cover
Install the center top screw of first.
Tighten the CVT cover retaining screws as per fol-
lowing sequence.
tmr2017-021-002_a
1. Bayonet cap
2. O-ring
219100971-014 5
tmr2017-021-005_a
tmr2017-021-004_a
1. Driven pulley adapter
2. Puller/locking tool
TIGHTENING TORQUE
Slip the belt over the top edge of fixed sheave, as
CVT cover retaining 6 N•m ± 0.7 N•m
shown.
DRIVE BELT
Removing the Drive Belt
NOTICE In case of a drive belt failure, the
CVT, cover and air outlet must be cleaned.
Remove CVT COVER.
REQUIRED TOOLS
PULLER/LOCKING TOOL
(P/N 529 000 088)
DRIVEN PULLEY ADAPTER

(P/N 708 200 720) tmr2017-021-006_a
Inspecting the Drive Belt

Screw in the driven pulley adapter into the driven
pulley shaft. For drive belt inspection refer to INSPECTING
THE DRIVE BELT in the PERIODIC MAINTE-
Screw in the puller/locking tool into the threaded NANCE PROCEDURES subsection.
offset hole of the adapter.
Tighten the puller/locking tool to open the pulley. Installing the Drive Belt
The installation, is the reverse of the removal pro-
cedure. However pay attention to following.
The maximum drive belt life span is obtained
when the drive belt has the proper rotation direc-
tion. Install it so that the arrow printed on belt
is pointing towards front of the vehicle, viewed
from top.
6 219100971-014
tmr2017-021-007_a tmr2017-021-009_a
1. Arrow printed on belt 1. Clutch holder

2. Rotation direction 2. Drive pulley screw
3. Drive pulley (front)
4. Driven pulley (rear) NOTICE Never use any type of impact
wrench for drive pulley removal.
DRIVE PULLEY
NOTE: Do not unscrew the drive pulley screw
Removing the Drive Pulley completely.
1. Remove DRIVE BELT, see procedure in this 5. Remove service tool.
subsection. 6. Apply axial pressure with your hand on the gov-
2. Prior to removing the drive pulley, mark sliding ernor cup until clutch puller for removal is in-
sheave and governor cup to ensure correct installed.
dexation at reinstallation. 7. Remove:
– Drive pulley screw
– Spring washer.
CAUTION Sliding sheave of drive pulley is

spring loaded.
tmr2017-021-008_a
1. Mark on drive pulley sliding sheave

2. Mark on governor cup
3. Lock the drive pulley.

REQUIRED TOOL tmr2017-021-010_a
Step 1: Push
CLUTCH HOLDER (P/N 529 1. Drive pulley screw
036 432) 2. Spring washer
8. Screw clutch puller in fixed sheave to remove

4. Loosen the drive pulley screw. drive pulley.
NOTICE Use only recommended tool.
219100971-014 7
REQUIRED TOOL
DRIVE PULLEY PULLER
(P/N 529 000 064)
tmr2017-021-028_a
1. M16 x 80 puller screw

2. Governor cup puller
3. M8 x 35 puller retaining screws
4. Clutch puller
5. Governor cup
tmr2017-021-011_a NOTICE Ensure that the hexagonal head of

the clutch puller engages in the slot of the gov-
Disassembling the Drive Pulley ernor cup puller.
Drive Pulley
Screw clutch puller into fixed sheave shaft (maxi-
mum protrusion of 63 mm (2-1/2 in)).
tmr2015-022-073_a
1. Slot
2. Inner side of puller
tmr2017-021-026_a Tighten M8 x 35 puller retaining screws.

A. Maximum protrusion of 63 mm (2-1/2 in)
TIGHTENING TORQUE
1. Clutch puller
2. Fixed sheave
3. Sliding sheave
M8 x 35 puller retaining 20 N•m ± 2 N•m
Place the governor cup puller on governor cup.
Put the governor cup puller into a vice and screw
REQUIRED TOOL in the M16 x 80 puller screw.
GOVERNOR CUP PULLER
(P/N 529 036 350)
8 219100971-014
Tmr2013-071-011_a
1. Slider shoe
tmr2017-021-029_a
SCREW IN M16 X 80 PULLER SCREW

Put governor cup on a vice to push out bearing
sleeve of roller in the foreseen direction (against
CAUTION The fixed sheave will bounce arrow). Use an appropriate punch (diameter of
up. punch must be smaller than the bearing sleeve
diameter).
Remove the governor cup puller from the drive
pulley. NOTICE Do not clamp the governor cup in
the vice to push out bearing sleeve. Governor
Governor Cup cup will be damaged.
Carefully lift governor cup until slider shoes come
at their highest position into guides. NOTE: Use protection plates to avoid marks
and/or damages to the governor cup.
NOTICE Always replace all rollers at the
same time. Partly worn rollers may cause
damage to the CVT system.
tmr2017-021-030_a
1. Governor cup
2. Slider shoes
3. Sliding sheave Tmr2013-071-012_a
4. Guides
1. Punch
2. Vice
NOTE: The following procedure is not neces-
sary except if roller must be removed. Refer to
INSPECTING THE DRIVE PULLEY before pro-
ceeding.
Remove slider shoes out of each bearing sleeve.
Use a flat screwdriver if necessary.
219100971-014 9
Tmr2013-071-013_a
1. Removal direction
2. Assembly direction
NOTE: Whenever removing a governor cup with 1. Lock nut

2. Centrifugal lever pivot bolt
already two marked boxes replace it by a NEW 3. Centrifugal lever
one. 4. Thrust washers
5. Sliding plates (models with turbo and intercooler)
6. Thin lock nuts (models with turbo and intercooler)
Remove spring cover.
WARNING
Spring cover is under high clutch spring
preload. Never attempt to remove spring
cover without the recommended tools.
REQUIRED TOOL
PULLEY SPRING
Tmr2013-071-014_a
COMPRESSOR TOOL
1. Marked boxes (P/N 529 036 012)
Sliding Sheave Install support guide of spring compressor in a

This drive pulley is equipped with 6 levers. vice.
NOTE: The following procedure is not necessary
except if centrifugal lever and/or sliding plates (if
applicable) must be removed. Refer to INSPEC-
TION before proceeding.
Remove:
1
– Centrifugal levers
– Sliding plates (models with turbo and inter-
cooler).
A03D3EA
10 219100971-014
NOTE: The support guide will prevent bushing

damage.
Place sliding sheave on support guide.
Place support cup over spring cover and tighten
nut.
Remove spring cover screws.
tmr2016-120-017_a
1. Hub
2. Thrust washers
3. Fixed sheave
mmr2008-041-110_a
Cleaning the Drive Pulley
TYPICAL Clean pulley faces and shaft with fine steel wool
and dry cloth.
Remove service tool.
SERVICE PRODUCT
Remove the following components from the slid-
ing sheave.
CLUTCH AND PULLEY FLANGE CLEANER
PRO S1 (P/N 779244)
Using a paper towel with cleaning solvent, clean:

– Crankshaft tapered end
– Crankshaft threads
– Taper on the fixed sheave
– Threads of drive pulley screw.
NOTICE Avoid contact between cleaner and
crankshaft seal because damage may occur.
Remove all hardened oil deposits that have baked
tmr2016-120-025_a
on crankshaft and pulley tapered surfaces with
1. Spring cover coarse or medium steel wool and/or sand paper
2. Spring no. 600.
3. Spring seat
4. Sliding sheave NOTICE Do not use any other type of abra-
Fixed Sheave sive.
Remove the following components from the fixed Reclean mounting surfaces with paper towel and
sheave. solvent.
SERVICE PRODUCT
PRO S1 (P/N 779244)
Wipe off the mounting surfaces with a clean, dry

paper towel.
NOTICE Mounting surfaces must be free of
any oil, cleaner or towel residue.
219100971-014 11
tmr2016-120-018_a tmr2016-120-021_a
1. Taper of fixed sheave, crankshaft side 1. Bushing

2. Tapered end of fixed sheave shaft 2. Spring cover
3. Sliding sheave
Only use petrol base cleaner when cleaning bush-
ings of sliding sheave. Inspecting the Drive Pulley
NOTICE Do not use acetone to clean bush- Bushings
ing. For bushing inspection, refer to SLIDING SHEAVE
AND SPRING COVER in this subsection.
Governor Cup
Check governor cup for cracks or other visible
damage. Replace if necessary.
Roller
NOTICE Whenever replacing rollers and
slider shoes, always replace all rollers and
slider shoes at the same time.
Check if rollers move freely.
Check roller outer width and inner diameter, re-
place if it is out of specification.
tmr2016-120-020_a
1. Bushing
2. Sliding sheave
Tmr2013-071-045_a
A. Roller flat spot width

B. Roller inner diameter
ROLLER FLAT SPOT WIDTH

Service limit 8.50 mm (.335 in)
12 219100971-014
ROLLER INNER DIAMETER

8.025 mm to 8.175 mm
New
(.3159 in to .3219 in)
Sliding Sheave and Slider Shoes

NOTICE Always replace all slider shoes and
O-rings at the same time.
Check slider shoes for visible wear. If chamfer is
worn out, replace slider shoes and O-rings.
tmr2017-021-032_a
SLIDER SHOES AT LOWEST POSITION

1. Guides
2. Slider shoes
3. Measure here
GAP BETWEEN SLIDER SHOES AND GUIDES

Up to 0.2 mm (.0079 in) Inspect occasionally
0.2 mm to 0.35 mm
(.0079 in to .0138 in) Replace slider shoes
with old slider shoes
Over 0.35 mm (.0138 in) Replace governor cup
with new slider shoes and sliding sheave
Tmr2013-071-044_a
1. Roller
2. Slider shoe Centrifugal Lever Pivot Bolt
3. Chamfer
Measure diameter of centrifugal lever pivot bolt,
replace if it is out of specification.
R610tran12A A 1
A. Measure diameter here
CENTRIFUGAL LEVER PIVOT BOLT DIAMETER

6.063 mm to 6.091 mm
New
(.2387 in to .2398 in)
tmr2017-021-034_a
3 O-RINGS AT 120°
Measure the gap between slider shoes and Centrifugal Lever

guides with slider shoe at their lowest position Check bushing diameter in the centrifugal lever for
into guides wear. Replace centrifugal lever if necessary.
219100971-014 13
tmr2011-015-007_a
TYPICAL
1. Centrifugal lever
2. Bushing
A. Bushing inner diameter
CENTRIFUGAL LEVER BORE DIAMETER

6.000 mm to 6.120 mm RTX903CARBSSV-008-002_b
New
(.236 in to .241 in)
Sliding Sheave and Spring Cover
Service limit 6.200 mm (.244 in) Check sliding sheave for cracks and sliding con-
tact surface for excessive wear. Replace sliding
Replace centrifugal lever, thrust washers, cen- sheave if necessary.
trifugal lever pivot bolts and lock nuts if the
contact surfaces show heavy visible wear. Measure centrifugal lever pivot bolt bores. Re-
place sliding sheave if bores are out of specifica-
tion or otherwise damaged.
tmr2016-120-016_b
1. Lock nut
2. Centrifugal lever pivot bolt tmr2016-120-019_a
4. Contact surface to the roller A. Centrifugal lever pivot bolt bore diameter
5. Thrust washers
CENTRIFUGAL LEVER PIVOT BOLT BORE
WARNING DIAMETER
Whenever replacing centrifugal levers, al- 6.113 mm to 6.171 mm
New
ways replace all lever at the same time. (.241 in to .243 in)
Otherwise, unbalanced drive pulley will oc- Service limit 6.300 mm (.248 in)
cur because of levers difference.
Measure bushing diameters of sliding sheave.
Sliding Plate
Check sliding plate contact surface for visible REQUIRED TOOL
wear and replace if damaged. Dial bore gauge
MEASURING POINT
At least 5 mm (1/4 in) from bushing edge
14 219100971-014
Replace fixed sheave if required.

Check fixed sheave contact surface with the hub
for discoloration, polished area or pitting. If so, the
hub needs to be replaced.
tmr2016-120-020_b
1. Bushing on fixed sheave side

A. Bore diameter of bushing
SLIDING SHEAVE LARGE BUSHING

46.950 mm to 47.130 mm RTX19_1010RS-010-007_a
New 1. Contact surface to governor cup
(1.848 in to 1.856 in)
2. Sheave plate
47.160 mm (1.857 in) 3. Contact surface with hub.
Service limit
Hub
Check for:
– Brittle, hard or damaged seals
– Discoloration on the edges of the bearing
– Corrosion on the needles and/or the outter ring
– Flat spots on the needles.
If any of these damages appear, replace the hub.
tmr2016-120-021_b
1. Bushing on governor cup side

A. Bore diameter of bushing
SLIDING SHEAVE SMALL BUSHING

32.010 mm to 32.135 mm
New
(1.26 in to 1.265 in)
tmr2016-120-027_a
Service limit 32.200 mm (1.268 in)
1. Oil seals
2. Needle bearing
Replace sliding sheave if one of the bushings is
out of specification. Visually inspect coatings. Assembling the Drive Pulley
Fixed Sheave The assembly is the reverse of the disassembly
Check: procedure. However, pay attention to following.
– Fixed sheave contact surface to the governor Hub
cup for scratches or other damages 1. Thoroughly clean the bearing. Remove all the
– Fixed sheave plate for marks or scratches. grease with a pulley cleaner or a brake cleaner.
219100971-014 15
SERVICE PRODUCT
PRO S1 (P/N 779244)
2. Dry the inside of the bearing with compressed

air.
3. Apply grease in the middle of needles.
SERVICE PRODUCT
Isoflex Grease Topas NB 5051 (P/N 420298031)
(1 g (.035 oz))
NOTICE Do not use any other type of grease.

RTX903CARBSSV-008-002_c
NOTE: All the content of the pouch is required.
Keep seals free of grease. 2. Thrust washers
4. Lock nut
NOTICE Centrifugal levers must move easily

after installation.
M o de ls w ith Turbo an d Interc oo le r
Install sliding plates with longer offset on top.
Install NEW thin lock nuts and tighten them to
specification.
TIGHTENING TORQUE
1.5 N•m ± 0.1 N•m
Sliding plate lock nuts
tbg2016-005-052_a
4. Spin the needles until grease is spread evenly.

5. Put the bearing back on the shaft.
6. Spray cleaner on a clean rag to wipe grease ex-
cess on the shaft and the pulley sheaves.
NOTE: New hub comes with appropriate grease
and quantity of grease.
Sliding Sheave
Install centrifugal levers with their thrust washers.
Install NEW lock nuts and tighten them to speci-
fication.
RTX903CARBSSV-008-002_d
TIGHTENING TORQUE
1. Sliding plate
2. Longer offset
Centrifugal lever lock 8 N•m ± 1 N•m 3. Thin lock nuts
nuts (71 lbf•in ± 9 lbf•in)
Governor Cup
Rebuild governor cup with new bearing sleeves,
rollers and slider shoes.
NOTICE Final position has to be aligned with
the contact surface of the slider shoes (no pro-
trusion).
16 219100971-014
Install conical spring washer with its concave

side towards drive pulley then install drive pulley
screw.
Tmr2013-071-025_a
1. Punch
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 tmr2017-021-010_b
of the governor cup may appear. 1. Conical spring washer

2. Drive pulley screw
WARNING
Never substitute conical spring washer
and/or screw with jobber ones. Always use
BRP genuine parts for this particular case.
Lock the drive pulley as per removal procedure.
Tmr2013-071-026_a
1. Punch
NOTICE Rollers must move easily after in-

stallation.
Insert slider shoes into governor cup to properly
slide in guides.
Installing the Drive Pulley

cedure. However pay attention to the following. tmr2017-021-009_a
1. Clutch holder
2. Drive pulley screw
WARNING
Do not apply antiseize or any lubricant on Tighten drive pulley screw to specified torque.
crankshaft and drive pulley tapers.
NOTICE Never use any type of impact
wrench for drive pulley installation.
NOTICE Never use any type of impact
wrench at drive pulley removal and instal-
lation.
Clean mounting surfaces as described in CLEAN-
ING above.
Install drive pulley on crankshaft extension.
219100971-014 17
TIGHTENING TORQUE 5.3 Tighten the puller/locking tool until driven

pulley is free.
120 N•m ± 8 N•m
Drive pulley screw 5.4 Remove tools from the driven pulley.
DRIVEN PULLEY
Removing the Driven Pulley
REQUIRED TOOLS
CLUTCH HOLDER (P/N 529

036 432)
PULLER/LOCKING TOOL
(P/N 529 000 088)
DRIVEN PULLEY ADAPTER

(P/N 708 200 720) tmr2017-021-015_a
1. Driven pulley adapter

2. Puller/locking tool
1. Remove:
– CVT cover Disassembling the Driven Pulley
– Drive belt. Removing the Cam and Spring
2. Install the clutch holder. To remove the cam and the spring, always use the
3. Remove: following tools.
– Driven pulley screw (discard it)
– Collar washer. WARNING
Cam is under high clutch spring preload.
Never attempt to remove the cam without
the recommended tools.
REQUIRED TOOLS
PULLEY SPRING
COMPRESSOR TOOL
(P/N 529 036 012)
DRIVEN PULLEY
SPACER (P/N 529
036 351)
1. Install the driven pulley on the spring compres-

sor tool.
tmr2017-021-014_a 1.1 Secure the spring compressor tool rod in a
1. Clutch holder vice.
2. Driven pulley screw (discard)
3. Collar washer 1.2 Install the support cup, the driven pulley
4. Remove the clutch holder. spacer, the driven pulley (with the cam to-
wards the vice), the support guide and the
5. Pull the driven pulley out of the vehicle. handle.
5.1 If removed, reinstall the driven pulley 1.3 Screw in the handle to remove all play.
adapter.
5.2 Screw in the driven pulley extractor in the
center hole of the driven pulley adapter.
18 219100971-014
tmr2017-021-016_a
1. Fixed sheave
2. Sliding sheave
3. Spring support
4. Spring
5. Cam
tmr2015-022-700_a
Removing the Driven Pulley Roller
TYPICAL
1. Pulley spring compressor tool 1. Remove screw locking the bearing pin.
2. Support cup
3. Driven pulley spacer
4. Support guide
5. Handle
2. Remove and discard the three (3) Torx cam re-

taining screws.
tmr2017-021-017_a
2. Remove bearing pin.

REQUIRED TOOL
A stud-pulling head
tmr2017-021-031_a A slide hammer
TYPICAL - PULLEY SPRING COMPRESSOR TOOL IS STILL
INSTALLED Extractor adapter M4
3. Remove the driven pulley assembly from the

spring compressor tool.
4. Separate parts.
mmr2009-023-032
1. Stud-pulling head
2. Slide hammer
3. Extractor adapter M4
219100971-014 19
tmr2017-021-018_a tmr2017-021-020_a
1. Contact surfaces
3. Remove:
– Thrust washer 2. Ensure circlip properly locks the inner bushing.
– Roller. Replace part if necessary.
tmr2017-021-021_a
tmr2017-021-019_a
1. Thrust washer
3. Measure the inner diameter of cam bushing.
2. Roller
REQUIRED TOOL
4. Proceed with removal of other roller. Dial bore gauge
Inspecting the Driven Pulley MEASURING POINT
Cam At least 5 mm (1/4 in) from bushing edge
1. Verify all contact surfaces of cam for visible
damages.
20 219100971-014
DRIVEN PULLEY INNER HALF BUSHING

41.278 mm to 41.363 mm
New
(1.625 in to 1.628 in)
Replace the sliding sheave if the inner diameter of

bushing is out of specification.
Fixed Sheave
tmr2017-021-021_b
A. Inner diameter of cam bushing
CAM BUSHING INNER DIAMETER

41.278 mm to 41.363 mm
New
(1.625 in to 1.628 in)
Replace the cam if the inner diameter of bushing

is out of specification.
Sliding Sheave tmr2017-021-022
1. Inspect pulley sheave for marks or scratches. Replace fixed sheave and countershaft if one of
2. Ensure circlip properly locks the inner bushing. the following problem is detected:
Replace part if necessary. – Marks or scratches on pulley sheave
3. Measure the inner diameter of sliding sheave – Bent, twisted or otherwise damaged counter-
bushing. shaft
– Defective splines and threads at the end of
REQUIRED TOOL
countershaft.
Dial bore gauge
MEASURING POINT
At least 5 mm (1/4 in) from bushing edge
tmr2016-120-042_a
Driven Pulley Roller

1. Check the rollers for flat spots, cracks or other
visible damages. Replace if necessary (as a
tmr2016-120-039_a
set).
1. Circlip
A. Inner diameter of sliding sheave bushing 2. Measure inner and outer diameter of rollers.
219100971-014 21
friction. So it is normal to see gray teflon deposit

on cam or countershaft. Do not remove this de-
posit.
When a dust deposit has to be removed from the
cam or the countershaft, use dry cloth to avoid
removing transferred teflon.
Assembling the Driven Pulley

mmr2008-044-009_a
Installing the Driven Pulley Roller
A. Inner diameter
B. Outer diameter 1. Using a hand wire brush, clean locking screw
threads.
DRIVEN PULLEY
SERVICE LIMIT 2. Insert:
ROLLER
Inner diameter 8.5 mm (.335 in) – Roller
– Thrust washer.
Outer diameter 21.5 mm (.846 in)
3. Install spring pin.
3. Measure the roller thickness.
mmr2008-044-010_a
tmr2017-021-023_a
A. Thickness of roller
1. Roller
DRIVEN PULLEY 2. Thrust washer
SERVICE LIMIT 3. Spring pin
ROLLER
Thickness 14.75 mm (.581 in) 4. Tighten locking screw as specified.
TIGHTENING TORQUE
If a roller is out of specifications, replace all rollers
at the same time. 3.5 N•m ± 0.4 N•m
Locking screws
Cleaning the Driven Pulley
SERVICE PRODUCT
PRO S1 (P/N 779244)
Use cleaner and a clean rag to clean pulley

sheaves.
Cam and Spring
During break-in period, teflon from bushing moves
to cam or countershaft surface. A teflon over
teflon running condition occurs, leading to low
tmr2017-021-017_a
22 219100971-014
Assembling the Sheaves and Cam

1. Engage spring in the proper engagement bore
in the cam.
1. Arrow on cam
2. Arrow on fixed sheave
SLIDING SHEAVE BACKSIDE
ENGINE TYPE ARROW ON CAM
Turbo with Intercooler A
ENGINE TYPE ENGAGEMENT BORE
Turbo without Intercooler C
Turbo with Intercooler Position 4
Naturally-Aspirated C
Turbo without Intercooler Position 2
Naturally-Aspirated Position 2 6. Tighten the handle until the cam is completely
pressed against the sliding sheave.
2. Install the cam with the spring on the spring
compressor tool, over the support cup and the
driven pulley spacer.
3. Install:
– Spring support
– Fixed sheave
– Sliding sheave.
4. Complete with the support guide and the han-
dle.
5. Before tightening the handle, align the proper
arrow on cam and the sliding sheave with the
one on the fixed sheave.
219100971-014 23
NOTICE Make sure to position the large di-

ameter of the thrust washer against the conical
side of the spring washer.
Install the clutch holder.
REQUIRED TOOL
CLUTCH HOLDER (P/N 529

036 432)
Tighten driven pulley screw as specified.

TIGHTENING TORQUE
70 N•m ± 5 N•m
Driven pulley screw
tmr2015-022-700_a Remove the clutch holder.

1. Pulley spring compressor tool Install drive belt. Refer to DRIVE BELT in this sub-
2. Support cup
3. Driven pulley spacer section.
4. Support guide
5. Handle NOTICE After the repair procedure is fin-
ished, allow vehicle to sit for 6 hours for
7. From the back of the sliding sheave, install
threadlocker curing.
three (3) NEW cam screws.
TIGHTENING TORQUE CVT AIR GUIDE
61 N•m ± 6 N•m
Cam screw
Removing the CVT Air Guide
Remove:
8. Remove the driven pulley from the tool. – DRIVE PULLEY
– DRIVEN PULLEY.
Installing the Driven Pulley
Unscrew the clamps retaining the CVT air hoses.
cedure. However pay attention to the following. Remove CVT air guide.
Remove and discard O-rings.
NOTICE This assembly uses a stretch screw.
Always install a NEW screw.
SERVICE PRODUCT
XPS BRAKES AND PARTS CLEANER (P/N 219
701 776) or XPS BRAKES AND PARTS CLEANER
(USA) (P/N 219 701 705)
Clean threads of gearbox countershaft and NEW

driven pulley screw.
NOTICE Threads must be free of oil and
grease. Lubricants in threads will create too
high preload to tightened driven pulley screw.
Install the driven pulley onto the countershaft.
Make sure to align splines.
Install driven pulley screw with collar washer. tmr2017-021-024_a
1. Retaining screws
2. CVT air guide
3. O-rings
24 219100971-014
Inspecting the CVT Air Guide

Clean CVT air guide from contamination
Installing the CVT Air Guide

Install NEW O-rings.
tmr2017-021-025_a
TIGHTENING TORQUE
10 N•m ± 1 N•m
CVT air guide retaining
+
screws
LOCTITE 243 (BLUE)
(P/N 293 800 060)
219100971-014 25
Subsection XX (GEARBOX AND 4X4 COUPLING UNIT)
GEARBOX AND 4X4 COUPLING UNIT

SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 8
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ....................................... 6, 10
HANDLE ........................................................................................ 420 877 650 ........................................... 12
M34 SOCKET ................................................................................ 529 036 388 ..................................... 20, 25
OIL SEAL GUIDE........................................................................... 529 036 433 ............................... 13, 23, 36
OIL SEAL INSTALLER (COUNTERSHAFT) .................................... 529 036 391 ........................................... 12
OIL SEAL INSTALLER (DIFFERENTIAL OUTPUT) ........................ 529 036 390 ........................................... 13
OIL SEAL INSTALLER (GEARBOX) ............................................... 529 035 758 ........................................... 12
PUNCH .......................................................................................... 529 036 425 ........................................... 18
SPLINES SOCKET 1/2" .................................................................. 529 036 389 ..................................... 20, 25

BACK PROBE TEST WIRES .......................................................... 529 036 063 ......................................... 6, 8
SERVICE PRODUCTS
COPASLIP...................................................................................... 420 297 430 ........................................... 31
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ....... 14, 16, 19, 23, 33–34, 36
LOCTITE 5910 ............................................................................... 293 800 081 ............................... 10, 23, 25
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ............................... 24–25, 34
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ........................................... 23
PETAMO GREASE GHY 133N ...................................................... 420 899 271 ........................................... 12
SUPER LUBE GREASE.................................................................. 293 550 030 ....................................... 7, 10
tmr2017-022 1
See tightening procedure

30 ± 3 N•m
(22 ± 2 lbf•ft)
Loctite 243
Engine oil
30 ± 3 N•m
(22 ± 2 lbf•ft)
Loctite 243
Loctite 243
30 ± 3 N•m
(22 ± 2 lbf•ft)
Loctite 243
30 ± 3 N•m
(22 ± 2 lbf•ft)
NEW
Petamo grease
GHY 133 N
tmr2017-022-001_a
2 tmr2017-022
See 10 ± 1 N•m
tightening (89 ± 9 lbf•in)
sequence
10 ± 1 N•m
10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243
Petamo grease Super Lube
NEW GHY 133 N Grease
Engine oil
9 ± 1 N•m
(80 ± 9 lbf•in)
NEW
Engine oil
Loctite 648
170 ± 10 N•m
(125 ± 7 lbf•ft)
NEW
Petamo grease Petamo

GHY 133 N grease
GHY 133 N
1,5 - 2 N•m
(13 - 18 lbf•in)
Loctite 5910 10 ± 1 N•m
(89 ± 9 lbf•in)
NEW
10 ± 1 N•m
(89 ± 9 lbf•in)
Super Lube
Grease
NEW
See
tightening
sequence
30 ± 3 N•m 10 ± 1 N•m
(22 ± 2 lbf•ft) (89 ± 9 lbf•in)
NEW
Engine oil Loctite 5910 Petamo grease

GHY 133 N
tmr2017-022-002_a
tmr2017-022 3
See
tightening
sequence
10 ± 1 N•m
(89 ± 9 lbf•in) 25 ± 3 N•m
(18 ± 2 lbf•ft)
Engine oil
25 ± 3 N•m
(18 ± 2 lbf•ft) Engine oil
NEW
Copaslip
Engine oil
Copaslip
Engine oil
NEW
Loctite 243 Copaslip
10 ± 1 N•m
(89 ± 9 lbf•in) 10 ± 1 N•m
Copaslip Engine (89 ± 9 lbf•in)
Loctite 5910 oil
Copaslip
Engine oil
Copaslip
Engine oil
6 ± 0,7 N•m Loctite 648
(53 ± 6 lbf•in) 170 ± 10 N•m
Loctite 243 See (125 ± 7 lbf•ft)
10 ± 1 N•m
tightening (89 ± 9 lbf•in)
Engine oil sequence
Engine oil

tmr2016-121-099_b
4 tmr2017-022
GENERAL 3. Damaged or worn gears.

- Inspect gears for damages or missing teeth. Re-
GEARBOX OVERVIEW place respective gears.
GEAR INDICATION FAILS

1. Defective gearbox position sensor (GBPS).
- Perform a gearbox position sensor test.
- Damaged wires. Repair as required.
GEAR(S) IS (ARE) HARD TO SHIFT

1. Incorrect shifter cable adjustment.
- Adjust shifter cable (refer to SHIFTER CABLE in
SHIFTER subsection.
4 WHEEL DRIVE INDICATION FAILS

1. 4WD indicator switch failure.
- Test 4WD indicator switch. Replace as required.
tmr2017-022-003_a
- Bad contact. Check for corrosion or loose con-
1. Vehicle speed sensor (VSS) nector.
2. Shift shaft
3. Gearbox oil dipstick - Damaged wires. Repair as required.
4. 4WD actuator
6. Drive gear 4 WHEEL DRIVE DOES NOT ENGAGE OR
DISENGAGE
1. Defective 4WD switch.
- Check 4WD switch operation.
2. Defective 4WD actuator.
- Test 4WD actuator.
3. Damaged or worn shifting fork or sleeve.
- Remove 4WD actuator and inspect shifting fork
and sleeve.
PROCEDURES
tmr2016-121-006_a
VEHICLE SPEED SENSOR (VSS)
1. 4WD coupling sleeve
2. 4WD indicator switch VSS Location
3. Gearbox position sensor (GBPS)
4. Drive gear The vehicle speed sensor is located on the rear
5. Countershaft top side of the left gearbox housing.
TROUBLESHOOTING
UNUSUAL GEARBOX NOISE AND/OR
VIBRATIONS
1. Low oil level in gearbox.
- Oil leakage from gearbox. Replace damaged gas-
ket(s) and/or oil seal(s).
2. Defective bearings.
- Bearing(s) do(es) not turn smoothly. Replace
bearing(s).
tmr2017-022 5
If voltage is not as specified, test positive and

ground separately.
Testing the VSS Signal

1. Lift rear of vehicle so that rear wheels are off
the ground.
2. Set transmission to 2WD and to Neutral.
3. Turn ignition switch ON.
4. Back-probe the VSS connector and measure
voltage while slowly rotating rear wheels by
hand.
REQUIRED TOOLS
tmr2017-022-004_a
VEHICLE SPEED SENSOR (VSS)

BACK PROBE TEST WIRES
VSS Wire Identification (P/N 529 036 063)
COLOR SENSOR
FUNCTION PIN
CONNECTOR
12-volt input from fuse F5 A RED FLUKE 115 MULTIMETER
(P/N 529 035 868)
Speed signal
B WHITE
(to ECM-A E1)
Ground (to ECM-A D4) C BLACK VSS SIGNAL TEST
RESULT
VSS Circuit Protection TEST PROBES (WHILE ROTATING
WHEELS)
CONDITION CIRCUIT PROTECTION
PIN B PIN C Alternate reading
Supplied with main Fuse 5 of fuse block 2 (WHITE (BLACK between battery
relay activated (from main relay R2) wire) wire) voltage and 0 Vdc
NOTE: Since we measure pulsating voltage, the

Testing the VSS Input Voltage numeric display will continuously change. The
1. Turn ignition switch ON. analog display may be easier to follow.
2. Back-probe the VSS connector and measure
voltage.
REQUIRED TOOLS

(P/N 529 036 063)

(P/N 529 035 868)
smr2005-056-010_a
1. Analog display
VSS INPUT VOLTAGE TEST
RESULT
Removing the VSS
TEST PROBES Disconnect VSS connector.
(KEY ON)
PIN A PIN C Remove:
Battery voltage
(RED wire) (BLACK wire) – Retaining screw
– VSS.
6 tmr2017-022
GBPS Reset
When replacing the gearbox position sensor
(GBPS), it is required to reset (re-zero) 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 version
of the BRP diagnostic software, refer to COM-
tmr2017-022-005_a
MUNICATION TOOLS AND B.U.D.S. subsec-
SEVERAL PARTS REMOVED FOR CLARITY
1. Screw tion.
2. VSS
2. In the software, select the following:
Installing the VSS – Setting page
– ECM button
Pay attention to the following. – Initialization tab.
Lubricate VSS O-ring. 3. Set shift lever in NEUTRAL position.
4. In the Reset Gear Position Sensor field.
VSS O-RING
A message will be displayed if the operation is
SUPER LUBE GREASE successful.
Service product
(P/N 293 550 030)
If an error occurred or the GBPS is not within the
Tighten retaining screw to specification. allowed range while resetting, the ECM will gen-
erate a fault code and will not accept the setting.
TIGHTENING TORQUE
5. If a fault message is displayed, follow the in-
10 N•m ± 1 N•m structions in the message(s).
VSS retaining screw
6. Check for fault codes.
If a fault code is generated:
GEARBOX POSITION SENSOR – Carry out the service action.
(GBPS) – Reset the fault code.
GBPS Location – Repeat the reset procedure.
7. Close and disconnect the BRP diagnostic soft-
ware.
NOTE: Do not turn ignition key OFF.
8. Verify gears engagement.
8.1 With the vehicle on ground and in NEU-
TRAL position, start engine.
8.2 During 4-5 seconds, rev engine to 2500 ±
200 RPM.
8.3 Let engine returns to idle.
8.4 Select an other position (P, R, H or L). Re-
peat substeps 8.2 and 8.3 until all position
are verified.
tmr2017-022-200_a
NOTE: The vehicle must be in movement to
complete the procedure on R, H and L posi-
tion.
tmr2017-022 7
Testing the GBPS Input Voltage Testing the GBPS Communication Link
NOTE: Prior to conduct testing, check fault codes Continuity
in B.U.D.S. Unplug connector “A” from ECM and connect it
Set shift lever in NEUTRAL position. to the ECM adapter tool.
Back-probe the GBPS connector. REQUIRED TOOL
REQUIRED TOOL
#ECM ADAPTER TOOL
(P/N 529 036 166)
(P/N 529 036 063)
MULTIMETER PROBE RESISTANCE @
POSITIONS 20°C (68°F)
Test as follow:
GBPS connector (pin 1) and
MULTIMETER PROBE ECM adapter tool (pin F4)
VOLTAGE
POSITIONS
PIN 2 and PIN 3 of the
Below 1
GBPS connector
5 volts
If resistance is out of specification, check wires

and connectors. Repair and reset fault codes.
If resistance is good and the other tests suc-
If voltage is adequate, check GBPS signal wire. ceeded, replace the GBPS and reset fault codes.
If there is no voltage, check each GBPS input as NOTE: The GBPS must be reset.
follows.
MULTIMETER PROBE Removing the GBPS
VOLTAGE
POSITIONS Set shift lever in NEUTRAL position.
GBPS connector (pin 3) and Unplug GBPS connector.
battery ground
Remove screws and withdraw GBPS.
5 volts
GBPS connector (pin 2) and

battery + terminal
Battery voltage
If there is no voltage, check wires and connector

pins. Replace or repair defective parts and reset tmr2016-121-009_a
1. Screws
fault codes. 2. Gearbox Position Sensor (GBPS)
Installing the GBPS

8 tmr2017-022
Shift lever must be in the NEUTRAL position.

Align GBPS with the flat on the shift drum shaft.
NOTE: Do not force to install GBPS if shaft flat
is not properly aligned. If alignment is incorrect,
check shift rod adjustment.
tmr2017-022-006_a
ENGINE MAG SIDE
Measure switch resistance as follows.

SWITCH
SWITCH WIRE RESISTANCE
POSITION
BLACK/ Engine
tmr2016-121-010_a 2WD Infinite (OL)
BEIGE ground
Reset the GBPS. Refer to GBPS RESET in this
subsection. If the resistance is out of specification, replace the
4WD indicator switch.
4WD INDICATOR SWITCH Removing the 4WD Indicator Switch
4WD Indicator Switch Location Disconnect 4WD indicator switch connector and
unscrew 4WD indicator switch.
tmr2017-022-201_a
tmr2017-022-007_a
Testing the 4WD Indicator Switch

Disconnect 4WD indicator switch connector. Installing the 4WD Indicator Switch
Take care do not damage indicator switch threads
during installation.
Apply carefully some sealant on threads of indica-
tor switch.
NOTICE Do not apply Loctite 5910 on switch
plunger, as it will lead to switch malfunction.
tmr2017-022 9
TIGHTENING TORQUE
Service product
800 081)
1.5 N•m to 2 N•m
4WD indicator switch
(13 lbf•in to 18 lbf•in)
4WD ACTUATOR
4WD Actuator Location
Testing the 4WD Actuator
Check if the 2WD/4WD selector works properly.
tmr2017-022-016_a
Unplug 4WD actuator connector.

Turn ignition key ON. Place a drain pan under 4WD actuator.
Measure voltage as follows. Remove the 4WD actuator.
REQUIRED TOOL

(P/N 529 035 868)
SWITCH
SWITCH WIRE VOLTAGE
POSITION
2WD Battery
WHITE WHITE/BLUE
4WD voltage
If the selector is out of specifications, check

wires, connectors and replace the selector if nec-
essary. tmr2017-022-008_a
1. Screws
If the selector is good, check the vehicle harness. 2. 4WD actuator
If the vehicle harness is good, replace the 4WD
actuator. Installing the 4WD Actuator
Lubricate 4WD actuator O-ring.
Removing the 4WD Actuator
4WD ACTUATOR O-RING
Before beginning any servicing on the 4WD actu-
ator, make sure the vehicle is in 4WD position. SUPER LUBE GREASE
Service product
(P/N 293 550 030)
Remove engine bracket (MAG side).
10 tmr2017-022
Rotate the 4WD actuator counterclockwise until it

orients itself to mounting position.
NOTICE Do not cut or break the 4WD actuator
O-ring.
Install all 4WD actuator screws and tighten them.
TIGHTENING TORQUE
10 N•m ± 1 N•m
4WD actuator screws
Connect 4WD actuator.

Vmr2015-123-003_a
Set gearbox to PARK position.
1. 4WD actuator O-ring Lift the front of vehicle.
Ensure coupling fork is in 4WD position (toward Turn front wheels. The front propeller shaft
the front of vehicle). should not turn.
If the front propeller shaft turns, the 4WD actuator
is not installed correctly. Remove 4WD 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 propeller shaft does not turn, the 4WD
actuator is not installed correctly. Remove 4WD
actuator and reinstall it.
NOTICE Refill missing gearbox oil, refer to
GEARBOX OIL REPLACEMENT in PERIODIC
tmr2017-022-009_a
Align the 4WD actuator fork with the pin on cou-
pling fork then push the 4WD actuator in the hous- GEARBOX OIL SEALS
ing. See the following illustration to position the
4WD actuator correctly. Replacing Gearbox Oil Seal
Replace oil seals if they are brittle, hard or dam-
aged.
A small flat screwdriver can be used to remove
most of these oil seals.
NOTICE Avoid scoring parts during oil seal
removal.
When replacing an oil seal, take this opportunity
to inspect the following:
– Check bearings behind each oil seal for contam-
ination and/or metal shavings.
– Check oil seal running surfaces for scratches.
tmr2017-022-010_a
1. 4WD actuator fork

2. Coupling fork pin
tmr2017-022 11
Lubricating Oil Seal

When installing or reinstalling oil seals, use
PETAMO GREASE GHY 133N (P/N 420 899 271) to:
– Lubricate sealing lips all around.
– Fill up the room between sealing lips halfway
around the perimeter.
tmr2016-121-022_a
1. Countershaft oil seal

2. Oil seal installer
Shift Shaft Oil Seal

Remove the shift plate. Refer to SHIFTER subsec-
tion.
The shift shaft oil seal can be removed without
vmr2013-020-001_a removing the gearbox from the vehicle.
1. Sealing lips
2. Room between sealing lips
Countershaft Oil Seal

To replace the countershaft oil seal, remove:
– Drive and driven pulleys
– CVT air guide.
tmr2017-022-012_a
Use a suitable tube with the proper diameter to

install the oil seal.
If gearbox housing is apart, use following tools for
shift shaft oil seal installation.
tmr2017-022-011_a
REQUIRED TOOL
OIL SEAL INSTALLER
Install countershaft oil seal. (GEARBOX) (P/N 529 035 758)
REQUIRED TOOL
HANDLE (P/N 420 877 650)
OIL SEAL INSTALLER
(COUNTERSHAFT) (P/N 529 NOTICE Oil seal must be installed with seal-
036 391)
ing lip toward gearbox.
12 tmr2017-022
Shift Drum Shaft Oil Seal

To replace the shift drum shaft oil seal, remove
the GBPS (GEARBOX POSITION SENSOR). See
procedure in this subsection.
tmr2016-121-026_a
LEFT SIDE
Punch a sharp screwdriver through oil seal for re-

moval.
Place oil seal on output shaft and install it using
tmr2016-121-010_b
the following tools.
Use a suitable tube with the proper diameter to REQUIRED TOOL
install the oil seal.
OIL SEAL GUIDE (P/N 529
NOTICE Oil seal must be installed with seal- 036 433)
ing lip toward gearbox.
Drive Gear Oil Seals OIL SEAL INSTALLER
(DIFFERENTIAL OUTPUT)
Remove the appropriate drive shaft. Refer to (P/N 529 036 390)
REAR DRIVE subsection.
tmr2017-022-013_a tmr2016-121-027_a
RIGHT SIDE 1. Output shaft oil seal

2. Oil seal guide
3. Oil seal installer
GEARBOX ASSEMBLY
Removing the Gearbox Assembly
Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION for the proce-
dure.
tmr2017-022 13
Refer to CONTINUOUSLY VARIABLE TRANSMIS-

SION (CVT) subsection to remove following parts:
– CVT cover
– Drive and driven pulleys
– CVT air guide.
Drain gearbox oil. Refer to REPLACING THE
GEARBOX OIL in PERIODIC MAINTENANCE
Remove gearbox bracket.
tmr2017-022-017_a
Detach gearbox with engine bracket (PTO side)

from the engine.
Installing the Gearbox Assembly

Pay attention to following.
Loosely install engine bracket (PTO side) retaining
screws.
ENGINE BRACKET (PTO SIDE) RETAINING
tmr2017-022-015_a
SCREWS
1. Retaining screws
2. Gearbox bracket LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
Remove engine bracket (MAG side).
tmr2017-022-017_a
tmr2017-022-016_b
1. Retaining screws M8 x 35 (3x) Loosely install engine bracket (MAG side) retain-
2. Retaining screws M8 x 45 (4x)
3. Engine bracket (MAG side) ing screws.
Remove screws retaining the engine bracket ENGINE BRACKET (MAG SIDE) RETAINING
(PTO side) to the cylinder block. SCREWS
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
14 tmr2017-022
tmr2017-022-032_a
tmr2017-022-016_b
1. Countershaft
1. Retaining screws M8 x 35 (3x) 2. CVT screw
2. Retaining screws M8 x 45 (4x)
3. Engine bracket (MAG side) Tighten engine bracket (PTO side) retaining
Align gearbox assembly with engine: screws to specification.
1. Measure distance from shift shaft to oil tank rib
2. Measure distance from countershaft to CVT
screw.
REQUIRED TOOL
Deep gauge
DISTANCE FROM SHIFT SHAFT TO OIL TANK RIB

280.5 mm ± 1 mm (11.04 in ± .04 in)
tmr2017-022-017_a
Tighten engine bracket (PTO side) retaining

screws to specification.
TIGHTENING TORQUE
30 N•m ± 3 N•m
Retaining New gearbox
screws
M8 x 45 27 N•m ± 2 N•m
Reused gearbox
tmr2017-022-018_a
1. Shift shaft
2. Rib
3. Oil tank
DISTANCE FROM COUNTERSHAFT TO

CRANKSHAFT/CVT SCREW
265.2 mm ± 1 mm (10.44 in ± .04 in)
tmr2017-022 15
TIGHTENING TORQUE
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
Engine bracket (MAG 30 N•m ± 3 N•m
side) retaining screws (22 lbf•ft ± 2 lbf•ft)
After installation refill gearbox oil, refer to PERI-

tion.
ENGINE BRACKET (PTO SIDE)

AND DRIVE SHAFT
tmr2017-022-031_a
RETAINING SCREWS M8 X 45 (4X)

Removing the Engine Bracket (PTO
Side)
TIGHTENING TORQUE Remove gearbox assembly from engine, see pro-
Retaining screws M8 30 N•m ± 3 N•m cedure in this subsection.
x 35 (22 lbf•ft ± 2 lbf•ft) Unscrew engine bracket (PTO side) retaining
screws.
tmr2017-022-031_b tmr2017-022-019_a
RETAINING SCREWS M8 X 35 (3X) GEARBOX LH SIDE
Install gearbox bracket.
tmr2017-022-020_a
GEARBOX RH SIDE
tmr2017-022-015_b
1. Gearbox bracket Separate engine bracket (PTO Side) from gearbox.

2. Retaining screws
16 tmr2017-022
Inspecting the Drive Shaft Remove oil seal.

Replace oil seal if brittle, hard or damaged.
Check oil seal running surface of the drive shaft
for scratches. Replace if necessary.
Check drive shaft bearings for contamination
and/or metal shavings. Check if bearings turn
freely and smoothly. Replace if necessary.
tmr2017-022-029_a
Remove retaining rings.
tmr2017-022-030_a
tmr2017-022-025_a
tmr2017-022-025_b
Check drive shaft splines for wear or damages.
Removing the Drive Shaft

Remove cover washer.
tmr2017-022-030_b
Press shaft with bearing out of engine bracket

(PTO side).
If necessary remove the remaining bearing out of
the engine bracket (PTO side).
Check drive shaft for cracks, bend, pitting or other
visible damages.
tmr2017-022-028_a
tmr2017-022 17
Installing the Drive Shaft

The following tool is required to install bearings,
the oil seal and the cover washer.
REQUIRED TOOL
PUNCH (P/N 529 036 425)
Install bearing (gearbox side).
tmr2017-022-024_a
Install retaining ring.
tmr2017-022-022_a
Install:
– Drive shaft
– Retaining ring.
tmr2017-022-025_a
Install oil seal.
tmr2017-022-030_b
Install bearing (engine side).

tmr2017-022-026_a
Install NEW cover washer.

NOTE: Groove must face outwards the engine
bracket.
18 tmr2017-022
tmr2017-022-027_a tmr2017-022-019_a
COVER WASHER INSTALLATION

A. 2 mm to 3 mm (.079 in to .118 in)
Installing the Engine Bracket (PTO

Side)
Before engine bracket (PTO Side) installation
check O-ring if brittle, hard or damaged. Replace
if necessary.
Lubricate O-ring.
O-RING LUBRICATION
Service product Engine oil
tmr2017-022-020_a
GEARBOX HOUSING
Disassembling the Gearbox Housing
See procedures in this subsection to remove:
– ENGINE BRACKET (PTO SIDE)
– 4WD ACTUATOR
– GBPS (GEARBOX POSITION SENSOR).
Remove bearing cover.
tmr2017-022-021_a
Tighten engine bracket (PTO Side) retaining

screws to specification.
TIGHTENING TORQUE
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
Engine bracket (PTO 30 N•m ± 3 N•m
Side) retaining screws (22 lbf•ft ± 2 lbf•ft)
tmr2017-022 19
tmr2016-121-031_a tmr2016-121-032_a
1. Retaining screws 1. M34 socket

2. Bearing cover 2. Spline socket
3. Countershaft
Remove countershaft nut.
Remove nuts of main shaft and intermediate
NOTE: Heat up nut with a heat gun to break shaft.
threadlocker.
CAUTION Nut can loosen abruptly.
tmr2016-121-033_a
1. Main shaft nut

2. Intermediate shaft nut
tmr2016-121-029_a
Refer to GEARBOX AND SHIFTING MECHANISM
REQUIRED TOOL in this subsection and remove:
– Parking lock gear
– Index washer.
M34 SOCKET (P/N 529 036 388) Remove all gearbox housing screws:
1. Start removing the M6 screws.
2. Then remove the M8 screws.
SPLINES SOCKET 1/2"
(P/N 529 036 389)
NOTICE Turn spline socket clockwise to

loosen the nut.
20 tmr2017-022
tmr2016-121-037
tmr2017-022-014_a
1. 11 screws M6 x 45
2. 10 screws M8 x 45
3. 2 screws M8 x 65
tmr2016-121-038
If necessary, refer to procedures in this subsec-

tion and remove:
tmr2016-121-035_a
– GEARBOX AND SHIFTING MECHANISM
1. 2 screws M6 x 45
– OUTPUT SHAFT AND COUPLING MECHA-
Separate gearbox housing, use 2 big screw- NISM
drivers. – DRIVE GEAR.
Inspecting the Gearbox Housing

Check gearbox ball bearings for: contamination
and/or metal shavings.
Check if ball bearings turn freely and smoothly.
Replacing Bearing
If necessary heat housing up to 100°C (212°F) be-
fore removing ball bearings.
WARNING
Clean oil, outside and inside, from housing
tmr2016-121-036
before heating.
tmr2017-022 21
NOTICE Always support gearbox housings

properly when ball bearings are removed.
Housing damages may occur if this procedure
is not performed correctly.
Use a blind hole bearing puller to remove ball bear-
ings of:
– Countershaft (right cover)
– Intermediate shaft (right cover).
Remove retaining plate securing the main shaft
and intermediate shaft bearings in the left hous-
ing.
Remove screw securing the main shaft bearing in tmr2016-121-108_a
the right cover. LEFT GEARBOX HOUSING
1. Screws
Use a suitable puller to remove ball bearings of: 2. Retaining plate
– Main shaft (right and left cover) 3. Ball bearing main shaft
4. Ball bearing intermediate shaft
– Countershaft (left cover) 5. Ball bearing drive gear
– Intermediate shaft (left cover)
– Drive gear ball bearings (right and left cover).
.
tmr2016-121-041_a
LEFT GEARBOX HOUSING

1. Ball bearing countershaft
tmr2016-121-107_a
Unless otherwise instructed, never use hammer
RIGHT GEARBOX HOUSING
1. Ball bearing countershaft to install ball bearings. Use press machine only.
2. Ball bearing main shaft
3. Screw If necessary heat housings up to 100°C (212°F)
4. Ball bearing intermediate shaft before installing ball bearings.
5. Ball bearing drive gear
WARNING
Clean oil, outside and inside, from housing
before heating.
Place new bearing in freezer for 10 minutes be-

fore installation.
Use a suitable installer for installing ball bearings
of countershaft, main shaft and intermediate
shaft.
NOTE: Place gearbox housings on a wood stand
before installing ball bearings.
22 tmr2017-022
TIGHTENING TORQUE GEARBOX HOUSING MATING SURFACE

SEALANT
10 N•m ± 1 N•m
Retaining plate screws
(89 lbf•in ± 9 lbf•in) LOCTITE 5910 (P/N 293
Service product
800 081)
TIGHTENING TORQUE
Use a plexiglass plate and apply some sealant
LOCTITE 243 (BLUE)
Service product on it. Use a soft rubber roller (50 mm - 75 mm
(P/N 293 800 060)
(2 in - 3 in)), available in arts products suppliers for
Retaining screw main printing, and roll the sealant to get a thin uniform
10 N•m ± 1 N•m
shaft bearing (right coat on the plate (spread as necessary). When
cover) ready, apply the sealant on gearbox housing mat-
ing surfaces.
Install new oil seals with the proper installer (refer
to GEARBOX OIL SEALS in this subsection).
Assembling the Gearbox Housing

Clean all metal components in a solvent.
Gearbox housing mating surfaces are best
cleaned using a combination of LOCTITE CHISEL
(GASKET REMOVER) (P/N 413 708 500) and a brass
brush. Brush a first pass in one direction then
make the final brushing perpendicularly (90°) to
the first pass cross (hatch).
NOTICE Do not wipe with rags. Use a new
clean hand towel only.
IMPORTANT: When beginning the application of
the gear housing sealant, the assembly and the F12R17A
first torquing should be done within 10 minutes.
It is suggested to have all you need on hand to Do not apply in excess as it will spread out inside
save time. gearbox housing.
Place sleeve installer on drive gear. NOTE: It is recommended to apply this specific
REQUIRED TOOL sealant as described here to get a uniform appli-
cation without lumps. If you do not use the roller
OIL SEAL GUIDE (P/N 529 method, you may use your finger to uniformly dis-
036 433) tribute the sealant (using a finger will not affect
the adhesion).
tmr2016-121-109_a
tmr2016-121-014_a
Apply sealant on mating surface. 1. Apply sealant here
tmr2017-022 23
During installation of the right gearbox housing

align the coupling fork with the groove in the
coupling sleeve.
tmr2017-022-014_c
tmr2016-121-066_a
1. Coupling fork
2. Coupling sleeve
Install all gearbox housing screws.

Tighten M8 gearbox housing screws as per follow-
ing sequence.
TIGHTENING TORQUE
M8 gearbox housing 25 N•m ± 3 N•m
tmr2016-121-035_b
Refer to GEARBOX AND SHIFTING MECHANISM

in this subsection to install:
– Index lever
– Index washer
– Parking lock gear
– Parking lock lever.
Tighten main shaft and intermediate shaft nuts to
specification.
TIGHTENING TORQUE
tmr2017-022-014_b
LOCTITE 648 (GREEN)
Service product
(P/N 413 711 400)
Tighten M6 gearbox housing screws as per follow-
ing sequence. Main shaft and 170 N•m ± 10 N•m
intermediate shaft nuts (125 lbf•ft ± 7 lbf•ft)
TIGHTENING TORQUE
M6 gearbox housing 10 N•m ± 1 N•m
24 tmr2017-022
tmr2016-121-033_a tmr2016-121-032_a
1. Main shaft nut 1. M34 socket

2. Intermediate shaft nut 2. Spline socket
3. Countershaft
Tighten countershaft nut to specification.
Apply sealant on mating surface of bearing hous-
ing.
BEARING HOUSING MATING SURFACE
SEALANT
Service product
800 081)
Install bearing housing screws and tighten them

as per following sequence.
TIGHTENING TORQUE
10 N•m ± 1 N•m
Bearing housing screws
tmr2016-121-029_a
TIGHTENING TORQUE
LOCTITE 648 (GREEN)
Service product
(P/N 413 711 400)
170 N•m ± 10 N•m
Countershaft nut
REQUIRED TOOL
M34 SOCKET (P/N 529 036 388)

tmr2016-121-042_a
GEARBOX AND SHIFTING

SPLINES SOCKET 1/2" MECHANISM
(P/N 529 036 389)
Disassembling the Gearbox and
Shifting Mechanism
NOTICE Turn spline socket counterclockwise During gearbox and shifting mechanism disas-
to tighten the nut. sembly, inspect the condition of each part closely.
tmr2017-022 25
Index Lever, Index Washer and Parking Lock

Lever
Remove:
– Retaining screws
– Gearbox cover
– Gasket (discard it).
tmr2016-121-045_a
1. Pin
2. Park locking lever
Remove screw retaining the index washer to the

shift drum.
tmr2016-121-043_a
1. Retaining screws
2. Gearbox cover
3. Gasket
Remove:
– Nut
– Spring washer
– Park locking gear.
tmr2016-121-046_a
1. Screw
2. Index washer
Insert a flat screwdriver in the slot of index lever.

Turn screwdriver clockwise and remove index
washer.
tmr2016-121-044_a
1. Nut
2. Spring washer
3. Park locking gear
Remove:
– Pin
– Park locking lever.
tmr2016-121-047_a
1. Index washer
2. Index lever
26 tmr2017-022
Remove the index lever with washer, step ring

and spring.
tmr2016-121-111_a
Remove:
– Bearing pin
tmr2016-121-048_a
1. Screw
– Reverse intermediate gear
2. Washer – Needle bearing
3. Index lever
4. Step ring – Thrust washers.
5. Index spring
NOTE: Take care not to lose lower thrust washer
Shift Shaft Assembly during removal.
Separate gearbox housing, refer to GEARBOX
HOUSING in this subsection.
Withdraw shift shaft assembly.
tmr2016-121-112_a
1. Bearing pin
2. Thrust washers
3. Needle bearing
4. Reverse intermediate gear
tmr2016-121-110_a
Pinion Drive Shaft and Intermediate Shaft

Countershaft and Reverse Intermediate Gear
Separate gearbox housing, refer to GEARBOX HOUSING in this subsection.
Remove:
Use a soft hammer to push out countershaft from
1. Pinion drive shaft
gearbox housing CVT side.
2. Intermediate shaft.
NOTE: Bevel gear and distance shim remain in
gearbox housing.
tmr2017-022 27
tmr2016-121-113_a tmr2016-121-115_a
1. Pinion drive shaft 1. Free pinion LOW range gear

2. Intermediate shaft 2. Needle bearing
3. Thrust washer
Main Shaft, Shift Fork Shaft Assembly and
Shift Drum Disassembling the Shift Fork Shaft Assembly
Separate gearbox housing, refer to GEARBOX NOTICE Springs are not identical. Mark them
HOUSING in this subsection. to reinstall them in their original position.
See procedures in this subsection to remove: Remove:
– Pinion drive shaft – Snap rings (discard them)
– Intermediate shaft – Spring seats
– Countershaft – Springs
– Reverse intermediate gear. – Shift forks
Remove main shaft assembly together with shift – Shifting block.
fork shaft assembly and shift drum.
tmr2016-121-055_a
tmr2016-121-114_a
1. Snap rings
1. Main shaft assembly 2. Spring seat
2. Shift fork shaft assembly 3. Outer springs
3. Shift drum 4. Shift fork HIGH
5. Shifting block
6. Center spring
Remove: 7. Shift fork LOW/REVERSE
– LOW range gear 8. Shift fork shaft
– Needle bearing
Inspecting the Gearbox and Shifting
– Thrust washers.
Mechanism
Always verify for the following when inspecting
gearbox components:
– Gear teeth damage
– Worn or scoured bearing surfaces
28 tmr2017-022
– Rounded engagement dogs and slots

– Worn shift fork engagement groove
– Worn splines on shafts and shifting sleeves.
Bearings
When gearbox is removed check gearbox ball
bearings for contamination and/or metal shav-
ings.
Check if ball bearings turn freely and smoothly.
Replace if necessary, refer to GEARBOX HOUS-
ING in this subsection.
Shifting Sleeves
Check shifting sleeves for worn inner splines and
rounded or damaged engagement dogs.
Tmr2013-020-001_a
TYPICAL
1. Shifting sleeve
A. Width of shift fork engagement groove
WIDTH OF SHIFT FORK ENGAGEMENT GROOVE

5.30 mm to 5.40 mm
NEW
(.209 in to .213 in)
Shafts
Check bearing pin of reverse intermediate gear for
wear.
vmr2012-020-009_a
TYPICAL
1. Inner splines
2. Engagement dogs
Measure the width of shift fork engagement

groove.
tmr2016-121-056_a
1. Bearing pin
A. Outer diameter
BEARING PIN OUTER DIAMETER

24.987 mm to 25.000 mm
NEW
(.9837 in to .9843 in)
Check countershaft bearing journals for wear.
tmr2017-022 29
Check shift shaft spring for damages.

Shift Drum
NOTICE Do not disassemble shift drum.
Check shift drum tracks for scouring or heavy
wear, like rounded engagement slots.
tmr2016-121-057_a
A. MAG side
B. Bearing journal CVT side
COUNTERSHAFT BEARING JOURNALS

MAG SIDE
19.977 mm to 19.990 mm
NEW
(.7865 in to .787 in)
tmr2016-121-059_a
1. Track for the low/reverse range gear shift fork
CVT SIDE 2. Track for the shifting block
3. Track for the high range gear shift fork
24.977 mm to 24.990 mm 4. Shift drum gear
NEW
(.9833 in to .9839 in)
Shift Forks
SERVICE LIMIT 24.970 mm (.9831 in) Check both shift forks for visible damage, wear or
bent shift fork claws.
Check main shaft for wear.
Check engagement rollers for wear and smooth
movement.
Measure the shift fork claw thickness.
tmr2016-121-058_a
A. Bearing journal MAG side

B. Bearing journal CVT side
MAIN SHAFT BEARING JOURNAL vmr2006-022-075_a
CVT/MAG SIDE TYPICAL

1. Micrometer
16.980 mm to 16.991 mm A. Shift fork claw thickness
NEW
(.6685 in to .6689 in)
Shift Shaft
Check shift shaft for worn splines and gears.
30 tmr2017-022
SHIFT FORK CLAW THICKNESS

5.10 mm to 5.20 mm
NEW
(.201 in to .205 in)
Shift Fork Shaft

Check shift fork shaft for visible damage or wear.
Check if shift fork shaft is straight.
Index Lever and Parking Lever
Index lever with roller must move freely.
Check parking lever for cracks or other damages. tmr2016-121-055_a
1. Snap rings
2. Spring seat
Assembling the Gearbox and Shifting 3. Outer springs
Mechanism 4.
5.
Shift fork HIGH
Shifting block
The assembly of gearbox is essentially the reverse 6. Center spring
7. Shift fork LOW/REVERSE
of disassembly procedure. However, pay atten- 8. Shift fork shaft
tion to the following details.
Main Shaft, Shift Fork Shaft Assembly and
Prior to assembly lubricate ball bearing seats of: Shift Drum
– Main shaft
Install shifting sleeve, thrust washer and LOW
– Countershaft gear pinion on main shaft assembly.
– Intermediate shaft.
NOTE: Check if shifting sleeve engages correctly
BALL BEARING SEATS LUBRICATION in reverse gear.
COPASLIP (P/N 420
Service product
297 430)
Assembling the Shift Fork Shaft Assembly

NOTICE Springs are not identical.
Install:
– NEW snap rings
– Spring seats
– Springs
– Shift forks
– Shifting block.
tmr2016-121-060_a
1. Main shaft assembly

2. Reverse gear
3. Shifting sleeve
4. Thrust washer
5. Needle bearing
6. LOW gear pinion
7. Thrust washer
Install shift fork shaft assembly, shift drum and

main shaft assembly together into gearbox hous-
ing.
tmr2017-022 31
tmr2016-121-116_a tmr2016-121-118_a
1. Main shaft assembly 1. Pinion drive shaft

2. Shift fork shaft assembly 2. Bevel gear splines
3. Shift drum
Countershaft and Reverse Intermediate Gear
Pinion Drive Shaft and Intermediate Shaft
Install:
Ensure distance shim and bevel gear are placed
– Reverse intermediate gear
on the pinion drive shaft bearing in gearbox hous-
ing. – Needle bearing
– Thrust washers
– Bearing pin.
tmr2016-121-117_a
1. Distance shim
2. Bevel gear
tmr2016-121-112_b
1. Thrust washers
Install: 2. Reverse intermediate gear
1. Intermediate shaft 3. Needle bearing
4. Bearing pin
2. Pinion drive shaft.
Carefully fit pinion drive shaft into inner splines of Install countershaft.
bevel gear.
32 tmr2017-022
tmr2016-121-111_a tmr2016-121-048_b
1. Index spring
Shift Shaft Assembly 2. Step ring
3. Index lever
Install shift shaft assembly. 4. Washer
5. Screw
TIGHTENING TORQUE
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
Index lever retaining 10 N•m ± 1 N•m
Install index washer on shift drum.

Insert a flat screwdriver in the slot of the index
lever, turn screwdriver clockwise and engage
lever in index washer in NEUTRAL position as per
following illustration.
tmr2016-121-110_a
Align mark on shift shaft with marks on shift drum

gear.
tmr2016-121-074_a
1. Index lever
2. Index washer
3. Neutral position
tmr2016-121-063_a Install screw retaining the index washer to the

1. Mark on shift shaft shift drum.
2. Marks on shift drum gear
Index Lever, Index Washer and Parking Lock

Lever
Fit step ring into index lever.
tmr2017-022 33
Install gearbox cover with NEW gasket.

Tighten gearbox cover screws as per following se-
quence.
TIGHTENING TORQUE
10 N•m ± 1 N•m
Gearbox cover screws
tmr2016-121-046_a
1. Screw
2. Index washer
TIGHTENING TORQUE
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
Index washer retaining 10 N•m ± 1 N•m
tmr2016-121-075_a
Install:
– Park locking gear OUTPUT SHAFT AND 4X4
– Spring washer COUPLING MECHANISM
– Nut
– Pin
Removing the Output Shaft and 4X4
– Park locking lever.
Coupling Mechanism
Drain gearbox oil. Refer to REPLACING THE
Set gearbox to PARK position. GEARBOX OIL in PERIODIC MAINTENANCE
Remove 4WD ACTUATOR, refer to procedure in
this subsection.
Detach GEARBOX ASSEMBLY from engine, refer
to procedure in this subsection.
Remove:
– Screw
– Coupling fork shaft
– Coupling fork.
tmr2016-121-020_a
PARK LOCKING LEVER ENGAGED
Tighten nut to specification.

TIGHTENING TORQUE
LOCTITE 648 (GREEN)
Service product
(P/N 413 711 400)
170 N•m ± 10 N•m
Park locking gear nut
34 tmr2017-022
vmr2006-022-030_a
1. Inspect splines
Measure the coupling sleeve groove width.

tmr2016-121-064_a
1. Screw
2. Coupling fork shaft
3. Coupling fork
Pull out 4X4 coupling sleeve.
vmr2006-022-031_a
A. Groove width
COUPLING SLEEVE GROOVE WIDTH

5.25 mm to 5.35 mm
NEW
(.207 in to .211 in)
tmr2016-121-065_a
Coupling Fork
Inspecting the Output Shaft and 4X4 Check coupling fork for visible damage, wear or
Coupling Mechanism bent coupling fork claws.
Check coupling fork claw thickness.
Output Shaft
Check output shaft and its gear for cracks, bend,
pitting or other visible damages.
Check output shaft splines for wear or other dam-
ages.
Check if the output shaft bearings turn freely and
smoothly.
Replace oil seal if brittle, hard or damaged.
4X4 Coupling Sleeve
Check splines of coupling sleeve for wear or other
damages.
vmr2006-022-032_a
1. Coupling fork
2. Micrometer
tmr2017-022 35
COUPLING FORK CLAW THICKNESS

4.95 mm to 5.05 mm
NEW
(.195 in to .199 in)
Installing the Output Shaft and 4X4

Coupling Mechanism
Install coupling sleeve onto the output shaft.
Install:
– Coupling fork
– Coupling fork shaft tmr2016-121-119_a
– Screw.
Ensure that coupling fork engages into the cou- Installing the Drive Gear
pling sleeve groove. Install drive gear.
REQUIRED TOOL
OIL SEAL GUIDE (P/N 529

036 433)
tmr2016-121-067_a
1. Coupling fork
2. Coupling sleeve
TIGHTENING TORQUE
LOCTITE 243 (BLUE) tmr2016-121-120_a
Service product
(P/N 293 800 060) 1. Oil seal guide
2. Drive gear
Coupling fork shaft 6 N•m ± 0.7 N•m
DRIVE GEAR
Removing the Drive Gear
Remove drive gear.
36 tmr2017-022
Subsection XX (SHIFTER)
SHIFTER
NEW 15 ± 1.5 N•m
(133 ± 13 lbf•in)
NEW
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)
NEW 9 ± 1 N•m
(80 ± 9 lbf•in)
15 ± 1.5 N•m
(133 ± 13 lbf•in) NEW
15 ± 1.5 N•m
(133 ± 13 lbf•in)
NEW
24.5 ± 3.5 N•m

(18 ± 3 lbf•ft)

tmr2017-023-100_a
tmr2017-023 1
PROCEDURES
SHIFT LEVER
Removing the Shift Lever
1. Remove the shifter indicator. Refer to BODY
subsection.
2. Place shift lever in NEUTRAL position.
3. Secure vehicle using wheel blocks.
4. Unscrew shift lever handle.
tmr2017-023-003
8. Remove shift lever.
Inspecting the Shift Lever

Check shift lever for bending or cracks.
Check spring and bushing condition.
Replace all damaged parts.
Installing the Shift Lever

tmr2017-023-001
Tighten shift lever handle nut to specification.
5. Remove the console. Refer to BODY subsec-
TIGHTENING TORQUE
tion.
15.5 N•m ± 1.5 N•m
Shift lever handle Nut
Adjust shifter cable, refer to ADJUSTING THE

SHIFTER CABLE in this subsection.
Check if shift lever works properly in all positions.
SHIFTER CABLE
Adjusting the Shifter Cable
NOTICE Move vehicle back and forth to en-
tmr2017-023-002 sure gearbox is set in neutral position.
6. Detach shifter cable from shift lever. 2. Secure vehicle using wheel blocks.
7. Remove shift lever pivot bolt and nut. 3. Loosen cable adjustment nuts at engine end of
cable.
2 tmr2017-023
TIGHTENING TORQUE
24.5 N•m ± 3.5 N•m
Adjustment nuts
6. Move shift lever in R position then in H position.

8. Check if shift lever is properly centered in neu-
tral notch. Readjust as required.
NOTE: To properly check shift lever alignment
into notch, move shift lever toward the LH side
tmr2016-122-008 then let it return to position.
TYPICAL 9. Test the shifter to confirm that the system
4. Adjust cable nuts in order to center shift lever works properly in all positions.
in neutral notch.
WARNING
After adjustment, make sure that PARK posi-
tion works properly.
SHIFT PLATE
Removing the Shift Plate
NOTE: Do not remove shift plate needlessly.
1. Remove shifter cable from shift plate.
tmr2016-122-003
TYPICAL - CORRECT ADJUSTMENT

A. Shift lever centered in neutral notch
NOTE: UP and DOWN shifter arm freeplay must

be symmetrical about the center line of neutral
gate.
tmr2016-122-009
2. Index shift plate and shift shaft.
tmr2016-122-013_a
1. Center line
2. UP side of center line
3. DOWN side of center line
5. Tighten cable adjustment nuts to specification.
tmr2017-023 3
tmr2016-122-010_a
TYPICAL
tmr2016-122-012
1. Trace a mark on both parts
SHIFT PLATE ANGLE FROM 2 HOLES ON ENGINE
3. Remove shift plate nut and bolt. A. 23° ± 2.5°
Adjust shifter cable, refer to SHIFTER CABLE AD-

JUSTMENT in this subsection.
Tighten shift plate nut to specification.
TIGHTENING TORQUE
9 N•m ± 1 N•m
Shift plate nut
tmr2016-122-011
4. Remove shift plate.
Inspecting the Shift Plate

Check shift plate for:
– Cracks
– Bending
– Spline condition.
Installing the Shift Plate

Place gearbox in NEUTRAL position before shift
plate installation.
Install and align shift plate using marks previously
traced.
If shift plate is installed on a new engine, adjust it
as per the following illustration.
4 tmr2017-023
Subsection XX (TURBO CHARGER AND INTERCOOLER)
TURBO CHARGER AND INTERCOOLER

SERVICE TOOLS
ENGINE LEAK DOWN TEST KIT ................................................... 529 035 661 ........................................... 14
SMALL HOSE PINCHER ............................................................... 295 000 076 ........................................... 12
TURBO TEST KIT........................................................................... 529 036 321 ........................................... 14
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ..................................... 16, 19
RTX903CARBSSV-010 1
TURBOCHARGER
NEW
12 ± 1 N•m
Loctite 243
NEW
15 ± 2 N•m
(133 ± 18 lbf•in)
NEW
NEW
NEW
See
tightening
procedure See tightening procedure
10 ± 1 N•m
NEW (89 ± 9 lbf•in) NEW
NEW 15 ± 2 N•m
Engine (133 ± 18 lbf•in)
oil
9 ± 1 N•m
(80 ± 9 lbf•in)
Loctite 243
10 ± 1 N•m
(89 ± 9 lbf•in)
NEW
5 ± 0,6 N•m
(44 ± 5 lbf•in)
NEW
5 ± 0,6 N•m
(44 ± 5 lbf•in)

tmr2017-024-001_b
2 RTX903CARBSSV-010
INTERCOOLER
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
8 ± 1 N•m
(71 ± 9 lbf•in)
8 ± 1 N•m
(71 ± 9 lbf•in)
5.5 ± 0.5 N•m

(49 ± 4 lbf•in)
5.5 ± 0.5 N•m

(49 ± 4 lbf•in)
RTX903CARBSSV-010-200
RTX903CARBSSV-010 3
GENERAL Compressor
The compressor wheel spinning causes filtered air
TURBO CHARGER to enter through the compressor inlet. The air is
then compressed and exits through the compres-
sor outlet.
tmr2017-024-003_a
tmr2017-024-002_a
1. Compressor inlet Pressure Upstream Throttle Sensor

2.
3.
Compressor outlet
Turbine inlet
(PUTS)
4. Turbine outlet To ensure optimal engine operation in all con-
5. Pressure Upstream Throttle Sensor (PUTS)
6. Boost Control Valve (BCV) ditions, the ECM system requires 2 pressure
7. Waste gate actuator rod sensors: The PUTS and the MAPS. The PUTS
8. Actuator rod spring
9. Waste gate measures the air pressure upstream the throt-
tle plate and the MAPS measures the pressure
Turbine downstream the throttle plate.
The exhaust gases cause the turbine wheel to
spin and accelerate. The gases then exit through
the turbine outlet towards the mufflers.
The turbine wheel drives the compressor wheel
through the rotor shaft. When the turbine wheel
is spinning, the compressor wheel is spinning at
the same speed.
tmr2015-025-005_a
Refer to ELECTRONIC FUEL INJECTION (EFI)

subsection for testing and replacement.
Boost Control Valve (BCV)

The BCV controls the pressure acting on the
waste gate actuator rod spring. The ECM uses
pulse width modulation to control the BCV.
If too high boost pressure is measured by the
PUTS, the ECM will control the BCV and open
the waste gate when the actuation pressure has
been reached.
tmr2017-024-004_a
4 RTX903CARBSSV-010
tmr2017-024-034_a
Excess pressure may also be returned to the in- tmr2017-024-006_a

take hose before the compressor inlet. WASTE GATE OPENS
1. Compressed air
When the air pressure inside the actuator drops,

the spring will return the actuator rod to its initial
position and close the waste gate.
tmr2017-024-035_a
NOTE: A BCV malfunction will activate Limp

Home Mode.
Refer to ELECTRONIC FUEL INJECTION (EFI)
subsection for testing and replacement.
Waste Gate Actuator Rod and Spring tmr2017-024-005_a
WASTE GATE CLOSES

When the BCV allows compressed air to enter the 1. Compression spring inside actuator
waste gate actuator, the actuator rod will move to
open the waste gate. Waste Gate
The waste gate regulates turbine speed by allow-
ing exhaust gas to bypass the turbine.
RTX903CARBSSV-010 5
MAINTENANCE
The turbo charger is maintenance free. However
it is susceptible to damage caused by failures
from other systems. Refer to TROUBLE SHOOT-
ING in this subsection.
NOTICE If particles are suspected of entering
the exhaust system, take the proper actions to
remove them.
NOTICE Never operate engine without an air
filter.
NOTICE Engine oil change intervals and pro-
tmr2017-024-007_a cedure must be respected.
Air filter replacement should be adjusted accord-
INTERCOOLER ing to riding conditions as it is critical to ensure
proper engine performance and life span.
Air filter replacement frequency must be in-
creased for the following dusty conditions:
– Riding on dry gravel roads or similar conditions.
NOTE: Riding in a group in these conditions
would increase even more the air filter replace-
ment requirement.
For air filter replacement refer to PERIODIC
tmr2017-024-036_a
1. Intercooler PRECAUTIONS
2. Shroud
3. Air outlet hose Engine Warming and Cooling
4. Air inlet hose
Allow the vehicle to reach operating temperature
An exhaust gas turbocharger heats the air that it before placing high demand on the engine. This
compresses. allows oil to reach the correct viscosity to properly
The intercooler cools the hot compressed air from lubricate the turbo.
the compressor outlet. Allow the vehicle to idle for 2 minutes before turn-
ing it off. This will allow the lubrication system to
ADJUSTMENT gradually cool the turbo.
WASTE GATE
NEW turbocharger assembly are factory adjusted.
Do not try to adjust the waste gate.
WASTE GATE ACTUATOR ROD

NEW turbocharger assembly are factory adjusted.
Do not try to adjust the waste gate actuator rod.
6 RTX903CARBSSV-010
TROUBLESHOOTING 9. Intercooler malfunction.

- Check if intercooler is clogged or contaminated.
LACK OF POWER - Check for correct intercooler fan electric connec-
1. Cold start tion (direction of rotation).
- Allow vehicle to reach operating temperature up 10. Turbo charger blocked or damaged.
for turbo to be at maximum efficiency. - Check for excessive carbon build up on housing.
2. Clogged air filter. - Check for rotor radial clearance.
- Check air filter. Refer to PERIODIC MAINTE- - Check if rotor shaft bearing is worn out.
NANCE PROCEDURES subsection. - Check turbo charger housing if damaged or re-
3. Intake system collapsed, restricted or leaking. stricted.
- Check tightness of clamps and screws. NOISY PERFORMANCE
- Damaged or missing gaskets.
1. Support brackets, turbo charger flanges or
- Check for foreign object between air filter and
turbo charger. clamps are loose.
- Inspect parts for damage, cracks or obstructions. - Check tightness of clamps and screws.
Repair or replace. Refer to AIR INTAKE SYSTEM - Check if support brackets and parts connected to
and INTAKE MANIFOLD subsection. the turbo charger are not loose or damaged.
4. Exhaust system collapsed, restricted or leaking. 2. Foreign object in intake or exhaust system.
- Check if the exhaust system is blocked or dam- - Check and clean intake and/or exhaust system.
aged. Replace parts as necessary. Refer to EX-
HAUST SYSTEM subsection. 3. Intake system collapsed, restricted or leaking.
- Check exhaust manifold for cracks, blown or - Check tightness of clamps and screws.
missing gaskets. Replace parts as necessary. - Inspect parts for damage, cracks or obstructions.
Refer to EXHAUST SYSTEM subsection.
- Check for damaged or missing gaskets.
- Check for foreign object in the exhaust system.
4. Exhaust system collapsed, restricted or leaking.
5. Fuel pump malfunction.
- Check tightness of clamps and screws.
- Perform a fuel pump pressure test and check fuel
pump. Refer to FUEL TANK AND FUEL PUMP - Inspect parts for damage, cracks or obstructions.
subsection. - Check for damaged or missing gaskets.
6. Sensor or injector malfunction. 5. Turbo charger blocked or damaged.
- Check fault codes with B.U.D.S. system. Refer - Check for excessive carbon build up on housing.
ENGINE MANAGEMENT SYSTEM subsection. - Check for imbalance due to damaged or broken
- Check fuel injection system is in good condition rotor blades.
and correctly adjusted. Refer to ELECTRONIC - Check turbo charger housing if damaged or re-
FUEL INJECTION (EFI) subsection. stricted.
- Check Boost Pressure Sensor (PUTS). Refer to - Check for rotor radial clearance.
ELECTRONIC FUEL INJECTION (EFI) subsection.
- Check if rotor shaft bearing is worn out.
- Check Turbo Control Valve (BCV) function and for
correct installation. Refer to ELECTRONIC FUEL
INJECTION (EFI) subsection. BLUE SMOKE AND/OR OIL
CONSUMPTION
7. Engine damage or malfunction.
1. Clogged air filter.
- Check for proper valve timing. Refer to TIMING
CHAIN subsection. - Inspect air filter. Refer to PERIODIC MAINTE-
- Perform engine leak test. Refer to TOP END sub-
section. 2. Intake system collapsed, restricted or leaking.
8. Waste gate malfunction. - Check tightness of clamps and screws.
- Check waste gate actuator. Refer to procedure in - Inspect parts for damage, cracks or obstructions.
this subsection. - Check for damaged or missing gaskets.
- Check waste gate for smooth movement.
3. Use of unsuitable engine oil type.
- Check Turbo Control Valve (BCV) function and for
correct installation. Refer to ELECTRONIC FUEL - Replace engine oil by the recommended engine
INJECTION (EFI) subsection. oil.
RTX903CARBSSV-010 7
4. Excessive carbon build up on housing. 2. Exhaust system collapsed, restricted or leaking.

- Check for excessive pressure in crankcase and - Check tightness of clamps and screws.
correct function of crankcase ventilation system. - Inspect parts for damage, cracks or obstructions.
- Check if the oil return hose is clean and not re- - Check for damaged or missing gaskets.
stricted.
- Check for foreign object in the exhaust system.
EXCESSIVE ENGINE OIL IN TURBO 3. Turbo charger blocked or damaged
CHARGER
- Check for excessive carbon build up on housing.
1. Worn out bearings of rotor shaft. - Check for rotor radial clearance.
- Perform a pressure drop test, see procedure in - Check if rotor shaft bearing is worn out.
this subsection.
- Check turbo charger housing if damaged or re-
- Note that oil some traces are normal. stricted.
2. Blocked oil return hose. 4. Oil supply hose and/or oil return hose blocked.
- Check if oil return hose is free. - Check and/or replace oil hoses, refer to proce-
dures in this subsection.
3. Plugged crankcase ventilation system.
- Check if crankcase ventilation system is blocked. 5. Too little warm up time.
- Extend warm up period.
4. Intake system collapsed or restricted.
- Check tightness of clamps and screws. EXCESSIVE RADIAL AND/OR AXIAL
- Check for damaged or missing gaskets. CLEARANCE OF ROTOR SHAFT
- Check for foreign object between air filter and 1. Intake system leaking.
turbo charger.
- Inspect parts for damage, cracks or obstructions. turbo charger.
5. Exhaust system collapsed, restricted or leaking. - Inspect air filter. Refer to PERIODIC MAINTE-
- Check tightness of clamps and screws. NANCE PROCEDURES subsection.
- Inspect parts for damage, cracks or obstructions. - Inspect parts for damage, cracks or obstructions.
- Check for damaged or missing gaskets. 2. Exhaust system collapsed, restricted or leaking.
- Check for foreign object in the exhaust system. - Check tightness of clamps and screws.
6. Support brackets, turbo charger flanges or - Inspect parts for damage, cracks or obstructions.
clamps are loose. - Check for damaged or missing gaskets.
- Check tightness of clamps and screws. - Check for foreign object in the exhaust system.
- Check if support brackets and parts connected to 3. Insufficient lubrication or oil lag at start up.
the turbo charger are not loose or damaged.
- Inspect oil pressure hose if restricted, blocked or
7. Excessive carbon build up on housing. leaking.
- Check if crankcase ventilation system is blocked. - Inspect engine oil filter if restricted or blocked, re-
fer to PERIODIC MAINTENANCE PROCEDURES
DAMAGED ROTOR OF TURBINE OR subsection.
COMPRESSOR - Check engine oil pressure, refer to LUBRICATION
SYSTEM subsection.
1. Intake system leaking.
4. Engine oil contaminated or unsuitable engine
turbo charger. oil type.
- Inspect air filter. Refer to PERIODIC MAINTE- - Replace engine oil and filter, refer to PERIODIC
NANCE PROCEDURES subsection. MAINTENANCE PROCEDURES subsection.
- Check tightness of clamps and screws. 5. Excessive carbon build up on housing.
- Inspect parts for damage, cracks or obstructions. - Check if crankcase ventilation system is blocked.
6. Worn out bearings of rotor shaft.
- Perform a pressure drop test, see procedure in
this subsection.
8 RTX903CARBSSV-010
PROCEDURES Removing the Oil Pressure Hose

1. Disconnect oil pressure switch.
OIL PRESSURE HOSE 2. Remove:
– Threaded nipple with oil pressure switch
– Gasket rings (discard them).
tmr2017-024-037
Oil Pressure Hose Access

Refer to the appropriate subsection and remove:
tmr2017-024-008_a
– Rear service cover 1. Threaded nipple with oil pressure switch
– Front CVT hose outlet. 2. Gasket rings
3. Place hose over a drain pan to catch up oil

spillage.
4. Remove:
– Threaded nipple
– Gasket rings (discard them)
– Hose nipple.
tmr2017-024-038
tmr2017-024-009_a
1. Threaded nipple
2. Gasket rings
3. Hose nipple
tmr2017-024-039
5. Pull oil pressure hose out of the turbo charger.
NOTICE Prevent debris from entering the tur- 6. Remove retaining clamp nut.
bocharger. block all openings.
RTX903CARBSSV-010 9
tmr2017-024-038
tmr2017-024-010_a
7. Cap and pull hose out of vehicle.

NOTICE Clean all spilled oil.
Installing the Oil Pressure Hose

Reverse the removal procedure.
Refer to exploded view for service products and
torques.
Refill engine with recommended engine oil. Re-
fer to OIL LEVEL VERIFICATION in the PERIODIC
tmr2017-024-039
Removing the Oil Return Hose
OIL RETURN HOSE 1. Remove:
– Retaining screws
– Oil tube
– Gasket (discard it).
tmr2017-024-040
Oil Return Hose Access

Refer to appropriate subsection and remove:
– Rear service cover
– Front CVT outlet hose tmr2017-024-012_a
1. Retaining screws
2. Oil tube
3. Gasket
2. If necessary remove and discard Oetiker clamp

and withdraw hose from oil tube.
10 RTX903CARBSSV-010
tmr2017-024-041_a
Refer to exploded view for service products and

torques.
fer to OIL LEVEL VERIFICATION in the PERIODIC
tmr2015-025-008_a
1. Oetiker clamp
2. Oil tube TURBO CHARGER
3. Remove and discard Oetiker clamp and with- Turbo Charger Access
draw hose from oil sump cover.
1. Remove the rear service cover. Refer to BODY
subsection.
Removing the Turbo Charger

In order to make room to work comfortably, it is
recommended to remove the passenger door and
both seats and seat rails.
1. Remove the CVT air outlet hose and its bracket.
tmr2017-014-018_a
Installing the Oil Return Hose

The installation is the revers of the removal proce-
dure. However, pay attention to the following.
Make sure the engine harness is not trapped be-
tween the oil return hose and the engine.. tmr2017-024-039
RTX903CARBSSV-010 11
tmr2017-024-042 tmr2017-024-045
2. Remove OIL PRESSURE HOSE from turbo. Re- 6. Remove clamp and upper coolant hose con-
fer to procedure in this subsection. nected to the coolant tube.
3. Remove clamps and disconnect BCV hoses 6.1 Install a hose pincher on each hoses.
from turbo.
REQUIRED TOOL
SMALL HOSE
PINCHER (P/N 295
000 076)
tmr2017-024-043
4. Remove the waste gate actuator and its bracket

from turbo.
tmr2017-024-046_a
6.2 Remove clamp and disconnect upper

coolant hose.
tmr2017-024-044
5. Loosen clamps and disconnect air inlet and out-

let hoses.
tmr2017-024-047
7. Remove the exhaust pipe clamps.
tmr2017-024-048 tmr2017-024-051
8. Remove coolant tube retaining nut and screw. 12. Remove the turbo retaining screws and wash-
ers.
tmr2017-024-049_a
tmr2017-024-052
9. Move the coolant tube aside.

13. Remove turbo charger.
10. Remove heat shield retaining screws.
Inspecting the Turbo Charger
Check turbo charger:
– for any damages or cracks
– for corrosion
– for any oil leak
– for contamination and/or oil coking at oil inlet
and outlet
– if rotor shaft turns smooth and easily.
tmr2017-024-050_a
11. Remove lower heat shield.
tmr2017-024-025_a tmr2017-024-027_a
1. Rotor shaft
2. Turbine rotor Connect leak tester to adequate air supply.
3. Waste gate
Set needle of measuring gauge to zero.
Testing the Rotor Shaft Bearing Leakage NOTE: All testers have specific instructions on
REQUIRED TOOL gauge operation and required pressure.
Supply turbo charger with air pressure.
ENGINE LEAK DOWN TEST NOTICE During leakage test apply slightly a
KIT (P/N 529 035 661) alternating radial pressure onto the shaft to
achieve a proper test result.
ROTOR SHAFT BEARING LEAKAGE TEST
TURBO TEST KIT (P/N 529 SERVICE LIMIT 50%
036 321)
Waste Gate Lever and Waste Gate
Block the oil return bore. Remove retaining clip.
Check for waste gate actuator rod play on lever
pin.
Disconnect the waste gate actuator rod from the
waste gate lever.
Check counter nut of waste gate actuator rod for
tightness.
NOTICE Do not open counter nut of waste
gate actuator rod. Length of waste gate actu-
ator rod assembly must not change.
tmr2017-024-026_a
1. O-ring
2. Cover plate of turbo test kit
3. Screw
Install gauge adapter into previously cleaned the

oil supply bore.
tmr2017-024-030_a
tmr2017-024-028_a
TURBINE ROTOR
1. Retaining clip
2. Waste gate actuator rod Step 1: Push slightly
3. Counter nut 1. Rotor
4. Waste gate lever 2. Shaft
3. Feeler gauge
Check the waste gate lever for free movement.
Check waste gate and its seat for wear or dam-
age.
tmr2017-024-029_a
1. Waste gate lever

2. Waste gate
tmr2015-025-028_a
Rotor of Turbine and Compressor COMPRESSOR ROTOR
Step 1: Push slightly
Check rotor visually for: 1. Rotor
– bent blades 2. Shaft
3. Feeler gauge
– any damages
– thermal stress (turbine rotor). REQUIRED TOOL
Apply slightly a radial pressure onto the shaft to Feeler gauge 0.1 mm (.004 in)
minimize the gap between rotor and housing.
Check radial clearance of the rotors in the com- ROTOR RADIAL CLEARANCE
plete circumference. Minimum of 0.1 mm
SERVICE LIMIT
(.004 in)
Rotor Shaft
Check discoloration of the shaft due to overheat-
ing.
MOVEMENT OF WASTE GATE ACTUATOR ROD

ENGINE AIR PRESSURE MOVEMENT
1 mm ± 0.5 mm
27 kPa (3.92 PSI)
Without (.039 in ± .02 in)
Intercooler 5 mm ± 0.5 mm
42 kPa (6.09 PSI)
(.197 in ± .02 in)
1 mm ± 0.5 mm
49 kPa (7.11 PSI)
With (.039 in ± .02 in)
Intercooler 5 mm ± 0.5 mm
63 kPa (9.14 PSI)
(.197 in ± .02 in)
tmr2017-024-031_a
If movement of the waste gate actuator rod is out
1. Shaft
of specification perform following adjustment pro-
2. Oil return bore cedure:
Waste Gate Actuator 1. Remove retaining clip.
Apply air pressure to the actuator. 2. Loosen counter nut of waste gate actuator rod.
Measure movement of waste gate actuator rod at
specified air pressure.
REQUIRED TOOL
Dial gauge
(P/N 529 021 800)
1. Retaining clip
2. Counter nut
3. Disconnect the waste gate actuator rod from

the waste gate lever.
4. Adjust length of the waste gate actuator rod:
If movement of the waste gate actuator rod was
below the specification screw out the adjustment
rod.
If movement of the waste gate actuator rod was
tmr2017-024-032_a
above the specification screw in the adjustment
ALIGN DIAL BORE GAUGE WITH WASTE GATE ACTUATOR rod.
ROD
1. Actuator
2. Fitting for air pressure supply
3. Waste gate actuator rod
4. Dial gauge
Installing the Turbo Charger

Tighten turbo charger retaining screws according
to the sequence.
TIGHTENING TORQUE
Turbo charger
5 N•m ± 0.6 N•m
retaining STEP A
screws
5. Tighten counter nut to specification.

TIGHTENING TORQUE
10 N•m ± 1 N•m
Counter nut
6. Engage the waste gate actuator rod on the

waste gate lever.
7. Install a NEW retaining clip.
8. Repeat measurement of waste gate rod move- tmr2017-024-052_a
ment.
TIGHTENING TORQUE
Turbine Flange Surface Turbo charger
23 N•m ± 3 N•m
Check warpage of turbine flange. retaining STEP B
screws
REQUIRED TOOL
Straight edge
Feeler gauge 0.1 mm (.004 in)
tmr2017-024-052_b
Fill turbo charger at oil supply bore with engine

oil and turn rotor shaft until turbo charger is filled
completely.
tmr2017-024-033_a Then immediately install oil return hose and oil
1. Turbine flange supply hose, refer to procedures in this subsec-
2. Straight edge tion.
3. Feeler gauge
TURBINE FLANGE WARPAGE fer to OIL LEVEL VERIFICATION in the PERIODIC
Maximum of 0.1 mm MAINTENANCE PROCEDURES subsection.
SERVICE LIMIT
(.004 in)
Start the engine and let it idle for a few minutes

to ensure proper turbo charger lubrication.
INTERCOOLER
Intercooler Access
Refer to BODY subsection and remove:
– Rear service cover
– Air box cover
– Intercooler grille
Removing the Intercooler tmr2017-024-055
NOTICE When removing the intercooler, al- 4. Remove the intercooler retaining screws.
ways plug the turbo charger hoses with clean
rags to prevent dirt from entering the turbo.
1. Loosen the clamp and disconnect the inter-
cooler air outlet hose.
tmr2017-024-056
tmr2017-024-053
2. Loosen the clamp and disconnect the inter-

cooler air inlet hose from the turbo.
tmr2017-024-057_a
5. Remove intercooler.
tmr2017-024-054
3. Cut locking tie and disconnect fan connector.
If there is a pressure drop, first spray tool, hoses

and adapters with a soapy water solution to en-
sure they are not leaking. If they are not leaking,
replace the intercooler.
Installing the Intercooler

Reverse removal procedure.
INTERCOOLER FAN
Intercooler Fan Access
tmr2017-024-058 Remove intercooler. Refer to procedure in this
subsection.
Inspecting the Intercooler
NOTE: When vehicle is running at operating tem-
Inspecting the Intercooler Fan
perature, intercooler outlet air temperature should Fan must be easy to turn by hand.
be lower than inlet air temperature. The temper- Refer to WIRING DIAGRAM.
ature difference will vary with atmospheric condi-
tions. INTERCOOLER FAN SPECIFICATIONS
Check radiating fins for clogging or damage. At wide open throttle
Commanded on by ECM
and as needed
Remove insects, mud or other obstructions with
Speed(s) 1
compressed air or low pressure water.
Monitored in BUDS2 No
Intercooler Leak Test
Activated in BUDS2 Yes, ECM tab
Block outlet hose.
Unplug the inlet hose from the intercooler. Resistance Approximately 2.8
Install the VACUUM/PRESSURE PUMP (P/N 529 021 Power (+) Battery voltage
800) with an adaptor on inlet fitting. Ground (-) Permanent ground
If battery voltage is not present when fan is acti-

vated in B.U.D.S., refer to WIRING DIAGRAM and
test fuse(s), relay and harness.
For ground location on vehicle, refer to POWER
DISTRIBUTION AND GROUNDS subsection.
Replacing the Intercooler Fan
Remove fan screws and replace the fan.
TIGHTENING TORQUE
3.5 N•m ± 0.5 N•m
529021800 Fan screw
Pressurize the intercooler.

NOTICE Testing at higher pressures can
damage the system.
PRESSURE TEST
100 kPa (14.5 PSI) for 2 minutes minimum
Subsection XX (ENGINE MANAGEMENT SYSTEM (EMS))
ENGINE MANAGEMENT SYSTEM (EMS)
TCV ING COILS (3)

CAPS
BPS INJ (3)
ETA/TPS LS
MAPTS
CTS
VSS
CPS
4WD ACTUATOR
tmr2017-025-100_a
tmr2017-025 1
KS
OPS
GBPS
ECM
tmr2017-025-101_a
TCV = Turbo Control Valve

BPS = Boost Pressure Sensor
CAPS = Camshaft Position Sensor
CPS = Crankshaft Position Sensor
CTS = Cooling Temperature Sensor
ECM = Engine Control Module
ETA = Electric Throttle Actuator
GBPS = Gearbox Position Sensor
IGN COIL = Ignition coil
INJ = Injector
MAPTS = Manifold Air Pressure/Temperature Tensor
LS = Lambda Sensor
OPS = Oil Pressure Switch
TPS = Throttle Position Sensor
VSS = Vehicle Speed Sensor
2 tmr2017-025
GENERAL Diagnostic Mode

The ECM features a self-diagnostic mode that is
SYSTEM DESCRIPTION activated on system power up (ignition key ON)
for certain systems and components, and when
The ECM ensures a high power output with clean the engine is running for others. Refer to DIAG-
combustion. NOSTIC AND FAULT CODES subsection for more
There are 7 main systems that are controlled by information.
the ECM:
1. Electronic Fuel Injection (EFI) Monitoring System
2. Intelligent throttle control (iTC) The MONITORING SYSTEM monitors various
3. Cooling system (cooling fan) electrical and electronic components of the en-
4. Ignition system gine control systems such as the:
5. Starting system – ETA (Electric Throttle Actuator)
6. Fuel system – TPS (Throttle Position Sensor)
7. D.E.S.S. – TAS (Throttle Accelerator Sensor)
– ECM (Engine Control Module).
NOTE: For further information related to these
systems, refer to the applicable subsection. The engine management system provides for re-
dundancies in these components should a failure
The ECM is the central point of the engine man-
or partial failure occur to which it will adjust sys-
agement system.
tem operation to protect the vehicle and most of
importantly, the driver.
Should the engine management system not re-
spond (or not respond correctly) to a failure, then
the monitoring system will react to ensure vehicle
and driver safety.
The monitoring system therefore ensures the en-
gine management system is functioning correctly.
Limp Home Mode

When a major component of the EMS is not oper-
ating properly, limp home mode will be set.
tmr2017-025-001
Engine RPM will be limited and/or engine behav-
ECM LOCATION ior and control may be modified depending on the
cause of the failure.
The ECM reads input signals from various
LIMP HOME will be displayed in the multifunction
switches, controls, and sensors, that it compares
gauge and the CHECK ENGINE light symbol will
to predetermined parameters, makes computa-
be on in the gauge.
tions, and provides control signal outputs required
for proper engine management. A failure of any of the following major components
will force the vehicle into LIMP HOME MODE:
The ECM also interacts through CAN bus with
other electronic modules for various functions, – TPS / ETA / TAS
information exchange and display of messages. – GBPS
Refer to CONTROLLER AREA NETWORK (CAN). – Injectors
The ECM also features a permanent memory that – Low oil pressure
will store the information on the various ignition – High engine coolant temp
keys programmed to the vehicle, fault codes, cus- – MAPTS signal fault.
tomer information, and other engine information,
even when the battery is removed from the vehi-
cle.
tmr2017-025 3
Subsection XX (CONTROLLER AREA NETWORK (CAN))
CONTROLLER AREA NETWORK (CAN)

GENERAL
SYSTEM DESCRIPTION
The CAN (Controller Area Network) protocol is an
ISO standard for serial data communication.
The CAN bus, which is composed of a
pair of twisted wires (WHITE/BEIGE and
WHITE/BLACK), is the nervous system of the
engine management system (EMS). It links the
electronic modules (ECUs) together, allowing
them to communicate and interact with each
other as required.
If a component or system malfunction is de-
tected, a module may generate a fault code,
which it transmits through the CAN bus as a
signal. The fault signal may be used for various
functions such as triggering the display of an error
message in the multifunction gauge display, turn-
ing on a fault indicator light, limiting or inhibiting
vehicle or engine operation, or viewed using the
BUDS2 software for troubleshooting.
Using B.U.D.S., technicians may also communi-
cate through the diagnostic connector (DB) with
the ECM (Engine Control Module) and the multi-
function gauge for various reasons such as:
– Extracting data
– Programming a module
– Changing settings
– Viewing fault codes
– and for various other functions.
CAN-HI
WHITE/BEIGE
B-C1 DPS 1-C DB-1 CI-19
CLUSTER
DPS
B-C2 DPS 1-D DB-2 CI-18
WHITE/BLACK
CAN-LO
tmr2016-124-001
CLUSTER: Multifunction Gauge

DB: Diagnostic Connector
DPS: Dynamic Power Steering
ECM: Engine Control Module
tmr2017-026 1
Subsection 03 (COMMUNICATION TOOLS)
COMMUNICATION TOOLS
SERVICE TOOLS
12 V BATTERY SUPPLY CABLE .................................................... 529 035 997 ........................................... 1
DIAGNOSTIC CABLE .................................................................... 710 000 851 ........................................... 1
MPI-2 INTERFACE CARD .............................................................. 529 036 018 ........................................... 1
MPI-3 INTERFACE CARD .............................................................. 529 036 353 ........................................... 1
POWER INTERFACE ..................................................................... 515 177 223 ........................................... 1
GENERAL REQUIRED TOOLS

Refer to the B.U.D.S. directory on KNOWLEDGE MANDATORY TOOLS
CENTER for all BUDS related information, includ- A personal computer (laptop or desktop)
ing:
– User manual (Navigation through menus, pro- MPI-2 INTERFACE CARD
gramming keys, reading fault codes, writing (P/N 529 036 018)
data to modules, etc.)
– Installation instructions OR
– BRP BUDS chart
MPI-3 INTERFACE CARD (P/N 529
Search keyword: "BUDS". 036 353)
DIAGNOSTIC CABLE
(P/N 710 000 851)
POWER INTERFACE (P/N 515 177

223)
Knowledge Center Key Word

12 V BATTERY SUPPLY CABLE
(P/N 529 035 997)
Download and install the software on a PC.
Connect the vehicle to the BRP diagnostic soft-
OPTIONAL TOOL
ware (BUDS2).
Extension cable
available at electronic retail outlets.
Do not exceed 7.5 m (25 ft)
Multi-Purpose Interface Card (MPI-2 or

MPI-3)
The Multi-Purpose Interface (MPI) in conjunction
with the diagnostic cable is used with BUDS2
to communicate with the engine control module
(ECM) and other modules.
The MPI card uses the power from the PC com-
puter's USB port.
Power Interface
The power interface and power supply cable al-
lows the connection of a fully charged external
battery to provide stable voltage to the unit and
BUDS2.
219100916-010 1
Stable voltage is essential to prevent update

crashes.
Do not use a charger on the battery (unit or exter-
nal) during software updates.
tmr2017-027-001
TROUBLESHOOTING
tbs2018-004-001
DIAGNOSTIC TIPS
The power interface and power supply cable
connected to external battery can be used for IMPORTANT: Make sure all connections are
extended diagnostic time. made and vehicle is powered up before starting
the BRP diagnostic software (BUDS2) to allow
proper communication between the vehicle and
BUDS2.
MPI Connection Troubleshooting

MPI Status Lights
The MPI card includes 2 status lights that indicate
the connection condition: USB and CAN. Both
lights must be GREEN to function properly. Oth-
erwise, refer to the following charts.
mbs2018-006-002
TYPICAL
The power interface with or without the power

supply cable will keep the unit powered even if the
ignition switch is turned off or the D.E.S.S. key is
removed.
vdd2006-001-151_b
The power interface has a fuse protected volt- MPI-2 CARD

meter included and an extra fuse to protect from
polarity inversion of the power supply cable.
Diagnostic Connector Location

The diagnostic connector is located inside the
glove box compartment.
2 219100916-010
COMMUNICATION PROBLEM (CAN)

STATUS WHAT TO DO
USB – BUDS2 does not communicate with

the vehicle.
– Check connections from computer to
CAN CAN
vehicle.
Light is
OFF – Check if BUDS2 is started.
– Check if vehicle is powered: Is cluster
turned ON? If it is not ON, install the
vmr2016-128-001_a D.E.S.S. key on the D.E.S.S. post.
MPI-3 CARD
This occurs when BUDS2 looses
Prerequisite for USB Communication: communication with vehicle.
– Computer turned on. – Check connections from computer to
CAN vehicle.
– MPI card connected to computer. Light is
RED – Check if vehicle is powered: is cluster
COMMUNICATION PROBLEM (USB) turned ON? If not, install the D.E.S.S.
key on the D.E.S.S. post.
STATUS WHAT TO DO
– Check if ignition key is in ON position.
Check USB connection between
Light is MPI card and computer. CAN – Connections are GOOD.
OFF Check USB operation on computer Light is BUDS2 communicates normally
(hardware or USB drivers) GREEN with the vehicle.
Connections are GOOD.

Light is
Communication can take place
GREEN
on USB side
Prerequisite for CAN Communication:

– MPI card connected to diagnostic connector on
vehicle.
– Computer turned ON
– The D.E.S.S. key installed on the engine
D.E.S.S. post (if applicable).
– ECM is powered.
– Ignition key installed and turned to ON (electri-
cal system powered up without engine started).
– BUDS2 started and logged on.
219100916-010 3
Subsection XX (DIAGNOSTIC AND FAULT CODES)
DIAGNOSTIC AND FAULT CODES

GENERAL
MONITORING SYSTEM
The ECM features a monitoring system that self-diagnoses various electrical and electronic components.
This mode becomes active when the ignition key is turned ON.
NOTE: Some components require the engine to be running to be monitored (fuel injectors for example).
The monitoring system continuously validates that the components (control modules, sensors and actu-
ators) are not faulty or defective. When a malfunction is detected, the related electronic module(s):
– Sets an active fault code.
– Adapts the proper protection strategy according to the failure.
– Sends out signals to the multifunction gauge to inform the rider of a particular condition.
If a minor fault occurs, the engine and vehicle will continue to operate without noticeable loss of perfor-
mance.
If a more important fault occurs, engine RPM may be limited. The engine/vehicle will continue to operate
with reduced performance.
If a major component of the Engine Management System (EMS) fails, engine RPM will be limited as well
as vehicle speed. Refer to LIMP HOME MODE in the ENGINE MANAGEMENT SYSTEM subsection.
These strategies are used to protect engine/electrical system from damage and to maintain safe opera-
tion of the vehicle. In extreme cases, the engine may also be completely shut down.
Messages in Gauge for Problematic Conditions

If an abnormal condition occurs, the gauge will display one of the following messages. It can be com-
bined with a pilot lamp.
MESSAGE DESCRIPTION
All active or previously activated faults that require attention.
CHECK ENGINE
No engine limitation engaged.
Critical faults requiring diagnostic as soon as possible.
LIMP HOME
An engine limitation is engaged and/or the engine behavior is modified.
LO BATT VOLT Low battery voltage detected by ECM.
HIGH BATT VOLT High battery voltage detected by ECM.
LOW OIL Low oil pressure detected by the ECM.
D.E.S.S. KEY NOT
D.E.S.S. KEY is not recognized by ECM.
RECOGNIZED
HI TEMP High temperature detected by the ECM.
ECM CRC ERROR Error message from ECM.
TPS FAULT TPS (throttle position sensor) fault, generally followed by a Limp Home message.
BRAKE SWITCH FAULT Brake signal fault.
ECM NOT RECOGNIZED Message displayed when the gauge is unable to identify the ECM.
tmr2017-028 1
MESSAGE DESCRIPTION
TRANSMISSION Gearbox position sensor fault active.
SIGNAL FAULT "E" is also displayed in the gear display.
When one or both sensor of the TAS (throttle accelerator sensor) is/are faulty, erratic
PPS FAULT or out of range or that the ratio between the two is incorrect, the message will be
displayed and the check engine pilot lamp will be lit.
When the TAS Limp Home (throttle accelerator sensor) is engaged, the message
MANUAL LIMP HOME
will be displayed.
Limp Home Mode

Refer to LIMP HOME MODE in the ENGINE MANAGEMENT SYSTEM subsection.
FAULT CODES Once the fault condition(s) of the active fault is no

longer present, its state will change to "occurred".
Fault Code Categories
A fault code consists of an alphanumeric designa- Occurred Fault Codes
tor followed by a hexadecimal number of 3 digits. An occurred fault code indicates a fault that was
The alphanumeric designator defines the category active, but no longer is.
of the fault code while the hexadecimal number The occurred fault does not presently affect sys-
refers to a unique fault. tem or component operation but is retained as a
FAULT CODE CATEGORIES history of the faults that were detected.
EXAMPLE The fault may have been generated due to a
ALPHANUMERIC MODULE/ system or component that was momentarily op-
OF FAULT
DESIGNATOR SYSTEM erating outside normal parameters. Repeated
CODE
occurred faults of this type should be considered
From P0 to P3 Power train P0116 when troubleshooting a problem, and may require
Communication that maintenance action be taken.
From U0 to U3 between module U0073 An occurred fault may also be generated when
and sensors disconnecting and reconnecting a component, re-
placing a burnt fuse, when the software update of
RELATED MODULE AND FAULTS
an electronic module has been carried out, or may
FAULT CODE be due to a momentary high or low voltage.
MODULE
CATEGORY
Inactive Fault Codes
ECM P and U
An inactive fault code represents a fault code that
Cluster P and U is neither active, nor occurred. It is simply part of
DPS P and U a list of all possible faults that can be monitored
by the ECM and multifunction gauge, which may
become active or occurred if the monitoring sys-
Fault Code States tem detects an applicable fault. These codes can
Fault codes have 3 possible states: be viewed in BRP diagnostic software BUDS2.
– Active
– Occurred
Reading and Clearing Fault Codes
– Inactive. Refer to COMMUNICATION TOOLS subsection.
For more information pertaining to the faults code
Active Fault Codes status and report, refer to BUDS2.
An active fault code is an indication of a fault that
is currently triggered. How to Read Fault Codes Using the
The active fault may or may not compromise Multifunction Gauge
normal operation of the system(s). Service ac- Refer to the applicable GAUGE subsection.
tion should be taken to correct the problem that
caused the fault code.
2 tmr2017-028
NOTE: A fault code must be in an "Active" state FAULT CODE DIAGNOSTIC

to be displayed in the multifunction gauge. BRP
diagnostic software BUDS2 must be used to read Diagnostic Tips
all fault codes states. To see the last two minutes of operating condi-
tions, click on the Summary tab in BUDS2 and
How to Find Fault Code Descriptions select Statistics.
Connect BUDS2 to the vehicle. Refer to COM- NOTE: The page displays data whatever there is
MUNICATION TOOLS subsection. fault code(s) or not.
Navigate to the Faults page.
Browse lists of active/occurred and inactive fault
codes.
GENERAL GUIDELINES TO SOLVE FAULT CODES
CONDITION ACTION
Use BUDS2 to:

Read fault codes.
Display "Active" faults to see components currently not operating normally.
Display "Occurred" faults to troubleshoot intermittent problems.
Monitor system(s), sensor(s), switches and actual conditions.
Troubleshooting vehicle
Activate component(s) for troubleshooting.
Set components (resets etc).
Know the last minute of operating conditions by using the "History" page.
Know the operating conditions, if available, when a fault code occurred by
using the "More details" button in the fault page.
Check sensor connections or mixed up connections.
Before vehicle maintenance:

Read the electronic modules with BUDS2
Save and print the BUDS2 file (keep faults option only).
New fault(s) appear after a vehicle
maintenance or repair After vehicle maintenance:
Read the electronic modules with BUDS2
Compare the fault code(s) before and after the maintenance
using the printed copy and the current reading.
Investigate only the newly fault codes.
Clear all occurred faults
Read the fault description in BUDS2
Sensor "Active" fault
Check related fuse(s) and relay.

Check related power and ground wires.
Low system voltage
Check for common power supply to several sensors/modules
on one module.
(refer to POWER DISTRIBUTION AND GROUNDS).
Power problem on sensor(s)
NOTE: Some sensors are supplied by the battery while others are
supplied by a module.
Low system voltage
Check battery condition and connections.
on several modules
(several communication faults
Check voltage regulator/rectifier.
will also appear)
A battery charger has likely been used to substitute the vehicle battery.
High system voltage on several
Clear all occurred faults and check again.
modules
Check voltage regulator/rectifier.
Check the module that is reported as missing.
When all modules report that a
module is missing
Check related power and ground wires.
tmr2017-028 3
GENERAL GUIDELINES TO SOLVE FAULT CODES
CONDITION ACTION
When several modules are in fault Search for a common problem such as a faulty sensor.
When several modules and sensors report that a module is missing.
The missing module may report CAN bus off.
Check related CAN wires (continuity, short to ground, short between CAN
CAN buss OFF
low and high).
Check module pins and wiring terminals.
Then, the other modules should stop reporting that module is missing.
May have been generated due to a system or component that was
momentarily operating outside normal parameters.
May be generated when disconnecting and reconnecting a component,
replacing a burnt fuse, or may be due to a momentary high or low voltage.
Before being "Occurred", a fault has always been "Active" for a certain time,
Occurred fault(s) indicating that an unexpected condition or problem has been present during
the driving cycle.
A frequent momentarily fault or an intermittent fault may never be seen as
"Active" in BUDS2 while there is still a pending problem.
This type of malfunctions can be discovered by looking at the "Occurred"
faults and then by evaluating the fault count.
As long as a fault is present, it is displayed as "Active".
Low value: Suggests handling problems (connections, terminal contact/
Fault count shape etc.).
(0 - 255) High value: Suggests a frequent and unsolved problem.
The problem should be investigated.
Fault conditions
Look for abnormal, excessive values.
When the basic troubleshooting has been done and the fault code(s)
persists, often the problem is related to the wiring harness, connections or
electromechanical components.
Hard to find problems Short to ground, to battery or between wires.
Wire splices, chafing, terminal problems (pulled out, bent, out of shape,
corroded etc.).
Bad contacts in switch or relay.
ECUs share information and their systems may interact with each other. Certain faults may cause more
than one ECU to set a fault code or indication (pilot lamp or message) as the failure of some components
may affect the operation of several systems.
4 tmr2017-028
SPECIFIC FAULTS
TPS Fault
A TPS fault may be considered to be a major fault
as the TPS provides the most important feedback
(2 signals) to the ECM on throttle position.
A TPS fault affects engine control as the throttle
plate is moved by the ETA (electric throttle actua-
tor) which, is controlled by the ECM (see INTEL-
LIGENT THROTTLE CONTROL (ITC) subsection).
A TPS fault is generally followed by LIMP HOME
mode and the engine is brought back to idle, or
may be completely shutdown.
Low Battery Voltage Fault

If the 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 being discharged, and to allow nor-
mal system operation.
TAS Fault
If one TAS (throttle accelerator sensor) signal is
missing, LIMP HOME MODE will be activated and
the check engine light will come ON. Pressing and
holding the OVERRIDE button will allow normal
control of the accelerator pedal.
If both sensors in the TAS are at fault, a TAS
FAULT message will appear in the gauge, the
check engine light will come ON and the engine
will run at idle. The accelerator pedal will not
have any affect on engine RPM. However, the
vehicle may be driven in LIMP HOME MODE by
pressing the OVERRIDE button.
When limp home mode is engaged using the
override button, a MANUAL LIMP HOME mes-
sage will appear in the gauge. The OVERRIDE
button can then be used as the accelerator,
vehicle speed is controlled by pressing and/or
releasing the button.
BRAKE ACTIVATION Fault Message in

Gauge
If a brake signal is received continuously for 15
seconds above 5 km/h (3 MPH), a BRAKE mes-
sage will be displayed in the gauge.
tmr2017-028 5
DIAGNOSTIC AND FAULT CODES

GENERAL
FAULT CODE TABLE
PCODE MODULE DESCRIPTION CAUSE ACTION
change dps if condition
ROTOR ENCODER SPI internal comm fail error or
C0051 DPS GLOBE still active after key-on
COM FAIL damaged DPS
cycle
ROTOR INCODER internal INCODER fail or
C0052 DPS GLOBE still active after key-on
VARIANCE damaged DPS
cycle
TORQUE SENSOR OUT
C1203 DPS GLOBE internal error or damaged DPS still active after key-on
OF RANGE
cycle
TORQUE SENSOR
C1304 DPS GLOBE internal error or damaged DPS still active after key-on
LINEARITY CHECK FAIL
cycle
verify with customer
DPS temp upper range due to
C1309 DPS GLOBE TEMPERATURE HIGH condition when dps ovr
excessive use of DPS
show-up
verify with customer
DPS temp exceed due to
C1310 DPS GLOBE TEMPERATURE OVER condition when dps ovr
excessive use of DPS
show-up
C1318 DPS GLOBE SEPIC LOW internal error or damaged DPS change DPS
C1319 DPS GLOBE SEPIC HIGH internal error or damaged DPS change DPS
Open SCM Activation
If pressure threshold not
page in BUDS, performe
Release Valve Activation reach after calibrated time
C2109 SCM a combined test in
delay Exceed delay (When release valve
System self test
activated)
sequence section
If the suspension valve Open SCM Activation
maximum allowed activation page in BUDS, performe
Suspension Valve
C210A SCM time in a specific time window a combined test in
Activation time Exceed
is exceeded for (counter > System self test
CntExceed). sequence section
If the suspension valve Open SCM Activation
maximum allowed activation page in BUDS, performe
Outlet Valve Activation
C210B SCM time in a specific time window a combined test in
time Exceed
is exceeded for (counter > System self test
CntExceed). sequence section
Open SCM Activation
Pressure sensor signal Sensor input voltage < 0.5V
C2111 SCM a pressure sensor test
Invalid for hardcoded debounce time
in System self test
sequence section
tmr2015 1

If pressure threshold not reach
Open SCM Activation
after calibrated time delay
Pressure threshold not (threshold change in function
C21D0 SCM a combined test in
Reach outlet adjustment of compressor temperature)
System self test
(When outlet pressure
sequence section
adjustment activated)
Open SCM Activation
Compressor over If over temp threshold reach
C21D2 SCM a pressure test in
temperature condition for time delay
System self test
sequence section
Open SCM Activation
C21D3 SCM Over pressure detected If pressure > 350PSI a pressure sensor test
in System self test
sequence section
reach after calibrated time Open SCM Activation
Pressure threshold not delay (threshold change page in BUDS, performe
C21E0 SCM reach Rear suspension in function of compressor a combined test in
adjustment temperature) (When Rear System self test
suspension adjustment sequence section
activated)
Open SCM Activation
If maximum number of page in BUDS, performe
Air Leak Plausibility check
C21E1 SCM readjustment for rear a combined test in
Rear suspension
suspension is reach System self test
sequence section
reach after calibrated time Open SCM Activation
Pressure threshold not delay (threshold change page in BUDS, performe
C21F0 SCM reach Front suspension in function of compressor a combined test in
adjustment temperature) (When front System self test
suspension adjustment sequence section
activated)
Open SCM Activation
C21F3 SCM readjustment for front right a combined test in
Front Right suspension
sequence section
Open SCM Activation
C21F4 SCM readjustment for front left a combined test in
Front left suspension
sequence section
2 tmr2015

Check related fuse(s)
Disconnect the 1st
oxygen sensor (FRONT
cylinder) and measure
his resistance (Expected
value: 7 to 12 Ohms)
Measure the voltage
of the harness power
wire relative to ground
(Expected value:
Internal fault path number Damaged O2 sensor, Battery voltage)
for Signal error : power damaged circuit wires, Disconnect the
P0030 ECM
stage of heater of Sensor damaged connector or associated ECM
upstream catalyst damaged ECM output pins. connector and
measure resistance
between harness
wires and ground
(Expected value: open)
Measure the resistance
of the harness wires,
between the ECM
and sensor connectors
(Expected value < 2
Ohms)
Disconnect the 1st
Measure the voltage
(Expected value:
for Min error : power damaged circuit Disconnect the
P0031 ECM
stage of heater of Sensor wires,damaged connector associated ECM
upstream catalyst or damaged ECM output pins. connector and
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
tmr2015 3

Disconnect the 1st
Measure the voltage
(Expected value:
for Max error: power damaged circuit Disconnect the
P0032 ECM
stage of heater of Sensor wires,damaged connector associated ECM
upstream catalyst or damaged ECM output pins. connector and
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
Disconnect the 2nd
oxygen sensor (REAR
Measure the voltage
(Expected value:
Blown fuse, damaged or
Internal fault path number Battery voltage)
disconnected O2 sensor,
for Min error : power Disconnect the
P0037 ECM damaged or disconnected
stage of heater of Sensor associated ECM
circuit wires, damaged ECM
upstream catalyst, LSU 2 connector and
output pins.
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
4 tmr2015

Disconnect the 2nd
oxygen sensor (REAR
Measure the voltage
(Expected value:
for Max error: power Disconnect the
output pins.
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
Make sure sensor
connector is
well inserted
Disconnect the sensor,
measure the voltage
Damaged sensor,
Manifold Absolute damaged circuit wires,
wires (Expected value:
P0106 ECM Pressure circuit damaged connector or
4.8 to 5.1 Volts)
range/performance damaged ECM pins, ECM
voltage supply
between the ECM
(Expected value < 2
Ohms)
Make sure sensor
connector is
well inserted
measure the voltage
Damaged sensor,
damaged circuit wires,
Manifold Air Pressure wires (Expected value:
P0107 ECM damaged connector or
Sensor voltage too Low 4.8 to 5.1 Volts)
damaged ECM pins, ECM
voltage supply Low
between the ECM
(Expected value < 2
Ohms)
tmr2015 5

Make sure sensor
connector is
well inserted
measure the voltage
Damaged sensor, wires of the harness power
Manifold Air Pressure shorted to battery +, wires (Expected value:
P0108 ECM
Sensor voltage too High ECM voltage supply too 4.8 to 5.1 Volts)
High. Measure the resistance
between the ECM
(Expected value < 2
Ohms)
Make sure sensor
connector is
well inserted
measure the voltage
Damaged sensor,
Intake Air Temperature wires (Expected value:
Sensor 1 circuit Low 4.8 to 5.1 Volts)
voltage supply Low
between the ECM
(Expected value < 2
Ohms)
Make sure sensor
connector is
well inserted
measure the voltage
Intake Air Temperature shorted to battery +, wires (Expected value:
P0113 ECM
Sensor 1 circuit High ECM voltage supply too 4.8 to 5.1 Volts)
High. Measure the resistance
between the ECM
(Expected value < 2
Ohms)
6 tmr2015

Disconnect the sensor
and check for a change
in the fault code. If
the fault code stays
the same, look for a
short circuit on the
harness. If the fault
code is different,
replace the sensor
Engine Coolant Damaged sensor, wires
Measure the sensor
P0116 ECM Temperature Sensor 1 shorted to battery +,
resistance (Expected
circuit range/performance ECM voltage supply.
value: 2280 to 2736
Ohms at 19 to
21°C (66 to 70°F))
between the ECM
(Expected value < 2
Ohms)
Disconnect the sensor
and check for a change
in the fault code. If
the fault code stays
the same, look for a
short circuit on the
harness. If the fault
code is different,
replace the sensor
Engine Coolant Engine temperature sensor
Measure the sensor
P0117 ECM Temperature Sensor 1 or circuit wires shorted to
circuit Low ground.
value: 2280 to 2736
Ohms at 19 to
21°C (66 to 70°F))
between the ECM
(Expected value < 2
Ohms)
Make sure sensor
connector is
well inserted
Measure the sensor
value: 2280 to 2736
Engine Coolant
Disconnected sensor, or Ohms at 19 to
P0118 ECM Temperature Sensor 1
sensor resistance too High. 21°C (66 to 70°F))
circuit High
between the ECM
(Expected value < 2
Ohms)
tmr2015 7

Make sure sensor
connector is
well inserted
First Throttle Accelerator Damaged circuit wires, Measure the resistance
P0122 ECM Sensor (TAS) Short circuit damaged sensor or damaged of the harness wires,
to GND ECM pins. between the ECM
(Expected value < 2
Ohms)
Make sure sensor
connector is
well inserted
First Throttle Accelerator Damaged circuit wires, Measure the resistance
P0123 ECM Sensor (TAS) shorted to damaged sensor or damaged of the harness wires,
battery + ECM pins. between the ECM
(Expected value < 2
Ohms)
Intake Air Temperature
P0127 ECM Air Temperature in intake High
too High
Disconnect the 1st
Measure the voltage
(Expected value:
ECU int. fault path no.: Damaged O2 sensor, Battery voltage)
electrical diagnosis for damaged circuit wires, Disconnect the
P0130 ECM
lambda sensor upstream damaged connector or associated ECM
catalyst. npl-error damaged ECM output pins. connector and
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
8 tmr2015

Disconnect the 1st
Measure the voltage
(Expected value:
P0131 ECM
cat. min-error damaged ECM output pins. connector and
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
Disconnect the 1st
Measure the voltage
(Expected value:
P0132 ECM
cat. max-error damaged ECM output pins. connector and
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
tmr2015 9

Disconnect the 1st
Measure the voltage
(Expected value:
Damaged O2 sensor, Battery voltage)
ECU int. fault path no.:
damaged circuit wires, Disconnect the
P0133 ECM diagnosis lambda sensor
damaged connector or associated ECM
upstream catalyst
damaged ECM output pins. connector and
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
Disconnect the 1st
Measure the voltage
(Expected value:
P0135 ECM lambda sensor heating
upstream cat.
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
10 tmr2015

Disconnect the 2nd
oxygen sensor (REAR
Measure the voltage
(Expected value:
P0136 ECM
second lambda sensor damaged connector or associated ECM
upstream cat. npl-error damaged ECM output pins. connector and
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
Disconnect the 2nd
oxygen sensor (REAR
Measure the voltage
(Expected value:
P0137 ECM
upstream cat. min-error damaged ECM output pins. connector and
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
tmr2015 11

Disconnect the 2nd
oxygen sensor (REAR
Measure the voltage
(Expected value:
P0138 ECM
upstream cat. max-error damaged ECM output pins. connector and
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
Disconnect the 2nd
oxygen sensor (REAR
Measure the voltage
(Expected value:
ECU int. fault path Damaged O2 sensor, Battery voltage)
no.: diagnosis lambda damaged circuit wires, Disconnect the
P0139 ECM
sensor upstream catalyst damaged connector or associated ECM
(exhaust bank2) damaged ECM output pins. connector and
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
12 tmr2015

Disconnect the 2nd
oxygen sensor (REAR
Measure the voltage
(Expected value:
P0141 ECM lambda sensor heating
upstream cat.
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
Open ECM ACTIVATION
page in BUDS.
Power stage sig error ECM injector power stage
P0201 ECM Activate injector and
injector 2 error
check if injector is
reacting as expected
Open ECM ACTIVATION
page in BUDS.
Power stage sig error ECM injector power stage
P0202 ECM Activate injector and
injector 1 error
check if injector is
reacting as expected
Check for coolant
fluid leak and
Engine Coolant over Coolant fluid temperature too coolant fluid level
P0217 ECM
temperature condition high Check radiator condition
Check for other fault,
Check thermostat
Make sure sensor
connector is
well inserted
2nd Throttle Accelerator Damaged circuit wires, Measure the resistance
P0222 ECM Sensor (TAS) shorted to damaged sensor, or damaged of the harness wires,
GND ECM pins. between the ECM
(Expected value < 2
Ohms)
tmr2015 13

Make sure sensor
connector is
well inserted
2nd Throttle Accelerator Damaged circuit wires, Measure the resistance
P0223 ECM Sensor (TAS) shorted to damaged sensor, or damaged of the harness wires,
battery + ECM pins. between the ECM
(Expected value < 2
Ohms)
Disconnect the
fuel pump and
measure his winding
value < 2 Ohms)
Measure the voltage
disconnected fuel pump,
Fuel Pump circuit shorted (Expected value:
P0231 ECM damaged circuit wires,
to ground, or open circuit Battery voltage)
damaged connectors or
Disconnect
damaged ECM output pins.
the associated
ECM connector
of the harness wire,
between the ECM and
fuel pump connectors
(Expected value < 2
Ohms)
Disconnect the
fuel pump and
measure his winding
value < 2 Ohms)
Measure the voltage
Damaged fuel pump, wire relative to ground
Fuel Pump circuit shorted damaged circuit wires, (Expected value:
P0232 ECM
to battery + damaged connectors or Battery voltage)
damaged ECM output pins. Disconnect
the associated
ECM connector
between the ECM and
fuel pump connectors
(Expected value < 2
Ohms)
14 tmr2015

Disconnect injector
1 and measure his
Measure the voltage
(Expected value:
Blown fuse, damaged or Battery voltage)
Cylinder 1 injector open disconnected injector, Disconnect
P0261 ECM circuit or shorted to damaged or disconnected the associated
ground circuit wires, damaged ECM ECM connector
output pins. Measure the resistance
of the harness
wire, between the
ECM and injector 1
connectors (Expected
value < 2 Ohms)
Check if HIC connector
is connecting the engine
harness to the vehicle
harness
Disconnect injector
1 and measure his
Measure the voltage
(Expected value:
Battery voltage)
Disconnect
the associated
Damaged injector,
ECM connector
Cylinder 1 injector shorted damaged circuit wires,
P0262 ECM Verify the isolation
to battery + damaged connector or
between harness
injectors signals
of the harness
wire, between the
ECM and injector 1
value < 2 Ohms)
harness
tmr2015 15

Disconnect injector
2 and measure his
Measure the voltage
(Expected value:
Blown fuse, damaged or Battery voltage)
Cylinder 2 injector open disconnected injector, Disconnect
P0264 ECM circuit or shorted to damaged or disconnected the associated
ground circuit wires, damaged ECM ECM connector
output pins. Measure the resistance
of the harness
wire, between the
ECM and injector 2
value < 2 Ohms)
harness
Disconnect injector
2 and measure his
Measure the voltage
(Expected value:
Battery voltage)
Disconnect
the associated
Damaged injector,
ECM connector
Cylinder 2 injector shorted damaged circuit wires,
P0265 ECM Verify the isolation
to battery + damaged connector or
between harness
injectors signals
of the harness
wire, between the
ECM and injector 2
value < 2 Ohms)
harness
Make sure sensor
Damaged knock sensor,
connector is fully
Diagnostic Fault Code for damaged circuit wires,
P0324 ECM inserted and check
min error of knock sensor damaged connector or
knock system.
16 tmr2015

Make sure sensor
Damaged knock sensor,
connector is fully
Diagnostic Fault Code for damaged circuit wires,
P032A ECM inserted and check
min error of knock sensor damaged connector or
knock system.
Make sure sensor

connector is
well inserted
Disconnect
Damaged CPS, the associated
Crankshaft Position damaged circuit wires, ECM connector
P0335 ECM
Sensor damaged connector or Measure the resistance
damaged ECM output pins. of the harness wires,
between the ECM
(Expected value < 2
Ohms)
Open the ECM
Activation page in BUDS
Perform an ignition
coil activation and
check if ignition coil
is reacting as expected
Measure the voltage
(Expected value:
Battery voltage)
Disconnect
Damaged ignition coil,
the associated
P0359 ECM Ignition coil ECM connector
damaged connector or
between the ECM
and tested device
value < 2 Ohms)
is connecting the
engine harness to
the vehicle harness
Refer to the service
manual for detailed
ignition coil testing
procedure
tmr2015 17

Open the ECM
Perform an ignition
coil activation and
Measure the voltage
(Expected value:
Battery voltage)
Disconnect
the associated
P0360 ECM Ignition coil ECM connector
between the ECM
and tested device
value < 2 Ohms)
is connecting the
engine harness to
the vehicle harness
manual for detailed
procedure
Open the ECM
Perform an ignition
coil activation and
Measure the voltage
(Expected value:
Battery voltage)
Disconnect
the associated
Ignition coil damaged circuit wires,
P0361 ECM ECM connector
range/performance damaged connector or
between the ECM
and tested device
value < 2 Ohms)
is connecting the
engine harness to
the vehicle harness
manual for detailed
procedure
18 tmr2015

Open the ECM
Perform an ignition
coil activation and
Measure the voltage
(Expected value:
Battery voltage)
Disconnect
the associated
Ignition coil damaged circuit wires,
P0362 ECM ECM connector
range/performance damaged connector or
between the ECM
and tested device
value < 2 Ohms)
is connecting the
engine harness to
the vehicle harness
manual for detailed
procedure
Disconnect relay
and measure his coil
Disconnect the
associated ECM
connector and
disconnected relay, damaged
measure resistance
P0480 ECM Radiator cooling fan relay circuit wires or connectors,
between harness
damaged ECM output pins,
wires and ground
damaged Relay.
between the ECM
and tested device
value < 2 Ohms)
tmr2015 19

Check if vehicle speed
is available in BUDS
Monitoring page
Disconnect the
No vehicle speed available &
sensor, measure the
Vehicle is in (H or L Gear) with
voltage of the harness
Engine RPM over 4000RPM.
Invalid or missing vehicle power wire relative
P0500 DPS Damaged Vehicle Speed
speed to ground (Expected
sensor circuit, Damaged
value: Battery voltage)
sensor, Wrong mounting
position of speed sensor.
between the ECM
(Expected value < 5
Ohms)
is available in Monitoring
page in BUDS
Disconnect the
sensor, measure the
Vehicle speed not Vehicle speed correlation power wire relative
P0501 ECM
plausible check failed to ground (Expected
between the ECM
(Expected value < 5
Ohms)
Open the ECM
Monitoring
page in BUDS.
Brake signal correlation check Check fuse
P0504 ECM Brake signal not plausible
failed Press on brake pedal.
Ensure that brake switch
light comes on ECM
Monitoring page
Measure voltage
between harness
connector SS1 and
Damaged or disconnected ground (Expected
relay, damaged circuit wires, value: 11 to 13 volts)
P0512 ECM Starter control circuit
damaged connectors or Measure resistance
damaged ECM output pins. from connector:
ECMB-L4 to SS2
(Expected value: < 2
ohms)
Use a stored access
A non stored access key was key to turn key switch.
Invalid Access Key
P0513 ECM detected when key switch If no stored access keys
Detected
was turned to ON. are available program
one and try again
20 tmr2015

Measure resistance
between harness
connector EOP and
ground When engine
stopped. (Expected
value < 2 Ohms)
Measure resistance
between harness
Damaged switch, connector EOP and
damaged circuit wires, ground When engine
Engine oil pressure sensor
P0520 ECM damaged connector, running. (Expected
circuit malfunction
damaged ECM pins. value = open)
Measure resistance
from harness
connector: EOP to
ECMA-E3 (Expected
value: < 2 Ohms)
is properly connected
(engine harness to the
vehicle harness).
Measure resistance
between harness
connector EOP and
ground When engine
stopped. (Expected
value < 2 Ohms)
Measure resistance
between harness
connector EOP and
Damaged switch,
ground When engine
Engine oil pressure sensor running. (Expected
P0523 ECM damaged connector,
sticking value = open)
damaged ECM pins.
Measure resistance
from harness
connector: EOP to
ECMA-E3 (Expected
value: < 2 Ohms)
(engine harness to
the vehicle harness).
tmr2015 21

Measure resistance
between harness
connector EOP and
ground When engine
stopped. (Expected
value < 2 Ohms)
Measure resistance
between harness
connector EOP and
Damaged switch, ground When engine
damaged circuit wires, running. (Expected
Engine oil pressure too
P0524 ECM damaged connector, value = open)
Low
damaged ECM pins. Measure resistance
from harness
connector: EOP to
ECMA-E3 (Expected
value: < 2 Ohms)
(engine harness to the
vehicle harness)
External troubleshooting
is not possible
TORQUE_SENSOR_
P0551 DPS Damaged DPS Clear the Fault. If Fault
OPEN
becomes Active Replace
the DPS
is not possible
TORQUE_SENSOR_
SHORT_GND
the DPS
is not possible
TORQUE_SENSOR_
SHORT_5V
the DPS
Measure battery
voltage with engine
stopped. (Expected
value: 11 to 13 volts)
Battery failure, voltage Measure battery
regulator failure, voltage with engine
damaged circuit wires running. (Expected
Non-plausibility error on
P0560 ECM or connection, damaged value: 13 to 14.7 volts)
system voltage
magneto generator. Check connections
An external battery charger on voltage regulator.
may have been used. Check ground
and positive
connections on battery.
Check ground on vehicle
frame
22 tmr2015

Measure battery
voltage with engine
stopped (Expected
value: 11 to 13 Volts)
Check ground
Blown fuse, battery low
and positive
(damaged magneto/regulator),
connections on battery
P0562 DPS System voltage low damaged circuit wires or
Validate that all the DPS
connection, Intense usage of
connectors are secured
WINCH
On the DPS power
connector, measure
the voltage between
the two harness wires
(Expected value: Battery
voltage)
Measure battery
voltage with engine
stopped (Expected
Check ground
and positive
Validate that all the DPS
Battery low (damaged
On the DPS power
magneto/regulator), damaged
P0562 DPS GLOBE BATTERY LOW connector pins, measure
circuit wires or connection.
the voltage between
Intense usage of WINCH
the two harness
power wires (Expected
between the DPS power
connector and ground
(Expected value < 2
Ohms)
Measure battery
voltage with engine
stopped. (Expected
Blown fuse FC, battery failure,
Measure battery
voltage regulator failure,
voltage with engine
damaged circuit wires
running. (Expected
or connection, damaged
P0562 ECM System voltage low value: 13 to 14.7 volts)
magneto generator.
Check connections
An external battery charger
on voltage regulator.
may have been used. Intense
Check ground
usage of WINCH
and positive
frame
tmr2015 23

Measure battery
voltage with engine
stopped. (Expected
Measure battery voltage
with engine Running at
Rectifier failure, damaged
P0563 DPS system voltage high 3500RPM. (Expected
value: 13 to 14.7 volts)
Check connections
Check ground and
positive connections on
battery.
Measure battery
voltage with engine
stopped. (Expected
Measure battery voltage
Rectifier failure, damaged
with engine Running at
circuit wires or connection./
P0563 DPS GLOBE BATTERY HIGH 3500RPM. (Expected
Improper battery charger
could raise that fault
Check connections
Check ground and
positive connections on
battery.
Measure battery
voltage with engine
stopped. (Expected
Measure battery
voltage with engine
Damaged regulator. running. (Expected
P0563 ECM System voltage high An external battery charger value: 13 to 14.7 volts)
may have been used. Check connections
Check ground
and positive
frame
DPS not calibrated or damage
P0601 DPS CALIBRATION FAULT Try updating the DPS
DPS
P0601 SCM SCM calibration fault Calibration Checksum err Update SCM
Manufacturing CRC change dps if condition
P0602 DPS GLOBE Internal error or damaged DPS
Programming Error always active
EEPROM is not possible
Last minute memory or last
P0605 SCM COMMUNICATION Check for
modes memory check
FAULT communication fault
using BUDS
P0606 DPS GLOBE Application CRC(boot) Application CRC(boot) reflash DPS
24 tmr2015

Try updating the
ECM calibration
Faulty calibration
If the problem
P0606 ECM Control Module Processor Faulty programming
persists, reflash ECM
Damaged ECM
If the problem persists,
replace the ECM.
Measure battery
voltage with engine
stopped (Expected
Check ground
and positive
Battery low (damaged
magneto/regulator), damaged
P0607 DPS GLOBE Boot Count(boot) Validate that all the DPS
Intense usage of WINCH
On the DPS power
connector, measure
the voltage between
the two harness power
wires (Expected value:
Battery voltage)
Make sure sensor
connector is
well inserted
Disconnect
Throttle Accelerator the associated
Sensor (TAS) Throttle Accelerator Sensors ECM connector
P060D ECM
synchronistic error (TAS) plausibility check error Measure the resistance
between sensor 1 and 2 of the harness wires,
between the ECM
(Expected value < 2
Ohms)
Disconnect
the associated
ECM connector
Throttle position
P060E ECM TPS plausibility check error of the harness wires,
performance
between the ECM
(Expected value < 2
Ohms)
Try updating the ECM
variant or calibration
Faulty variant coding
If the problem
P0610 ECM Variant Coding error Faulty programming
Wrong ECM after replacement
replace ECM.
still active after
internal error or damaged
P062F DPS GLOBE EEPROM SPI key-on cycle external
DPS, EEPROM SPI
troobleshooting not
possible
tmr2015 25

Faulty calibration or variant
Internal control module If the problem
P062F ECM Faulty programming
EEPROM error persists, reflash ECM
Damaged ECM
replace ECM.
EXCESSIVE ERROR
P0635 DPS GLOBE internal error or damaged DPS change DPS
CURRENT
is not possible
MOTOR LOW CURRENT
P0636 DPS Internal error or damaged DPS Clear the Fault. If Fault
FAULT
the DPS
is not possible
MOTOR HIGH CURRENT
P0637 DPS Internal error or damaged DPS Clear the Fault. If Fault
FAULT
the DPS
short-circuit in motor/ internal
P0637 DPS GLOBE OVER CURRENT change DPS
error
is not possible
DPS motor supply
P0658 DPS PHASE A_LOW Clear the Fault. If Fault
Damaged DPS
the DPS
is not possible
DPS motor supply
P0659 DPS PHASE A_HIGH Clear the Fault. If Fault
Damaged DPS
the DPS
High temperature of the DPS.
P0666 DPS HIGH TEMPERATURE Let the unit cool down.
Extreme usage of the unit.
Disconnect Accessories
and Lights relays, turn
key switch (on w/lights)
Measure coil resistance
of both relays (Expected
Measure the voltage of
Blown fuse, damaged
the harness power wires
or disconnected relay,
of both relays relative
P0685 ECM Accessory relay circuit damaged circuit wires,
to ground (Expected
damaged connectors or
damaged ECM output pins
Disconnect
the associated
ECM connector
between the ECM and
both relays (Expected
value < 2 Ohms)
26 tmr2015

Blown fuse, damaged
the harness power wires
Accessory relay circuit or disconnected relay,
of both relays relative
P0686 ECM shorted to ground or open damaged circuit wires,
to ground (Expected
circuit damaged connectors or
damaged ECM output pins
Disconnect
the associated
ECM connector
between the ECM and
value < 2 Ohms)
Damaged relay, the harness power wires
Accessory relay circuit damaged circuit wires, of both relays relative
P0687 ECM
shorted to battery + damaged connector or to ground (Expected
damaged ECM output pins. value: Battery voltage)
Disconnect
the associated
ECM connector
between the ECM and
value < 2 Ohms)
Disconnect radiator fan
relay and measure his
coil resistance (Expected
Measure the voltage
wire of relay relative
Radiator fan circuit disconnected fan relay,
to ground (Expected
P0691 ECM shorted to ground or damaged circuit wires,
open circuit damaged connectors or
Disconnect
the associated
ECM connector
between the ECM and
relay (Expected value <
2 Ohms)
tmr2015 27

Disconnect radiator fan
relay and measure his
coil resistance (Expected
Measure the voltage
Damaged fan relay, wire of relay relative
Radiator fan circuit damaged circuit wires, to ground (Expected
P0692 ECM
shorted to battery + damaged connector or value: Battery voltage)
damaged ECM output pins. Disconnect
the associated
ECM connector
between the ECM and
relay (Expected value <
2 Ohms)
Open the ECM
Monitoring
Damaged switch,
page in BUDS.
P0790 ECM Check of Override Button Press on
damaged connector, damaged
Override button.
ECM pins.
Ensure that the 2 switch
light change of state.
Check clutch for proper
P0811 ECM Clutch slippage detected Excessive clutch slippage
clutch behavior
Disconnect the
2nd oxygen sensor
and measure his
Measure the voltage
(Expected value:
for Signal error : power Disconnect the
output pins.
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
Wrong Throttle
Wrong TPS sensor position.
P1120 ECM Accelerator Sensor (TPS) Check TAS adjustment.
Both TPS position failed test.
position
28 tmr2015

Disconnect the 1st
Measure the voltage
(Expected value:
P1130 ECM
cat. Sig-error damaged ECM output pins. connector and
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
Disconnect the 2nd
oxygen sensor (REAR
Measure the voltage
(Expected value:
P1136 ECM
upstream cat. Sig-error damaged ECM output pins. connector and
measure resistance
between harness
wires and ground
between the ECM
(Expected value < 2
Ohms)
tmr2015 29

Injection and fuel
supply system.
Adaptation of the air charge
reaching the limits (min
and max) based on the
lambda sensors feedback.
Too much variation in the
Diagnostic Fault code for engine itself in reference
Check injector and fuel
P1171 ECM Fuel Supply System (ORA to a nominal engine. It can
supply system.
Max Fault) Exhaust Bank1 be cause by an engine that
has been modified or out
of spec (airbox, air filter,
injectors, exhaust system,
valve clearance, etc.) or
any other components that
can influence the engine
performance.
Injection and fuel
supply system.
supply system.
Min Fault) Exhaust Bank1 be cause by an engine that
performance.
Injection and fuel
supply system.
supply system.
Max Fault) Exhaust Bank2 be cause by an engine that
performance.
30 tmr2015

Injection and fuel
supply system.
supply system.
Min Fault) Exhaust Bank2 be cause by an engine that
performance.
backup phase detection
Signal fault at phase
P1339 ECM strategies not able to find the
determination
correct phase
Check for ECM fault
P1606 ECM Control Module Processor Internal ECM problem External troubleshooting
not possible
Disconnect ETC
Damaged ETC,
Electrical Throttle of the harness wires,
P160E ECM Actuator (ETA) control between the ECM
fault and tested device
value < 2 Ohms)
Disconnect ETC
Damaged ETC,
P1610 ECM Actuator (ETA) shorted to between the ECM
V+ and tested device
value < 2 Ohms)
Disconnect ETC
Damaged ETC,
P1611 ECM Actuator (ETA) shorted to between the ECM
ground and tested device
value < 2 Ohms)
Disconnect ETC
Damaged ETC,
P1612 ECM Actuator (ETA) signal between the ECM
not plausible and tested device
value < 2 Ohms)
tmr2015 31

Disconnect ETC
Damaged ETC,
Electrical Throttle damaged circuit wires,
P1613 ECM between the ECM
Actuator (ETA) damaged connector or
and tested device
value < 2 Ohms)
Check throttle
mechanical adjustment.
Check idle stop for wear.
Ensure throttle plate is
Throttle mechanical against throttle stop.
adjustment Check throttle
Throttle idle position
P1614 ECM No initialization angle at idle.
failure on throttle release
after throttle body/ Perform THROTTLE
ECM replacement POSITION SENSOR
RESET in BUDS with
throttle completely OFF.
manual for more details.
Check throttle
against throttle stop.
Throttle mechanical
Check throttle
adjustment
TPS position deviation angle at idle.
P1615 ECM No initialization
fault Perform THROTTLE
after throttle body/
POSITION SENSOR
ECM replacement
INITIALIZATION in
BUDS with throttle
completely OFF.
Check throttle
Throttle mechanical stop Check throttle
Throttle No initialization angle at idle.
P1616 ECM
limp-home-position failed after throttle body/ Perform THROTTLE
ECM replacement POSITION SENSOR
INITIALIZATION in
BUDS with throttle
completely OFF..
32 tmr2015

Check THROTTLE
cable adjustment.
Wrong throttle body
mechanical position
P1619 ECM TPS adaptation failure during reset of closed TPS
Perform THROTTLE
or no initialization after ECM
POSITION SENSOR
replacement.
INITIALIZATION in
BUDS with throttle
completely OFF.FF.
Check cable adjustment.
Wrong throttle body Make sure throttle plate
mechanical position is against throttle stop.
P1620 ECM TPS adaptation failure during reset of closed TPS Perform THROTTLE
or no initialization after ECM POSITION SENSOR
replacement. INITIALIZATION in
BUDS with throttle
completely OFF.
Check throttle
Throttle mechanical stop
TPS adaptation cancelled angle at idle.
No initialization
P1621 ECM lower mechanical stop Perform THROTTLE
failed POSITION SENSOR
ECM replacement
INITIALIZATION in
BUDS with throttle
completely OFF.
against throttle stop..
Check throttle
Throttle mechanical stop
angle at idle.
No initialization
P1622 ECM TPS adaptation failed Perform THROTTLE
POSITION SENSOR
ECM replacement
INITIALIZATION in
BUDS with throttle
completely OFF.
ECU ADC plausibility Monitoring plausibility check
P16C0 ECM Check for ECM fault
check failed
Monitoring plausibility check
P16C1 ECM ECU ADC test failed Check for ECM fault
failed
P16C2 ECM ECU monitoring error Check for ECM fault
failed
Throttle Accelerator
P16C3 ECM Sensors (TAS) monitoring Check for ECM fault
failed
check fault
tmr2015 33

Engine speed monitoring Monitoring plausibility check
check fault failed
Safety fuel cut-off
P16C5 ECM activated monitoring Check for ECM fault
failed
check level 1
Safety fuel cut-off
P16C6 ECM activated monitoring Check for ECM fault
failed
check level 2
Throttle valve plausibility Monitoring plausibility check
check failed failed
Permitted throttle valve
P16C8 ECM position monitoring check Check for ECM fault
failed
exceeded
Reset fault, If fault
Motor short circuit or power
P1F01 DPS Power output overload re-occur, replace DPS
output failed
unit
Measure battery
voltage with engine
stopped. (Expected
Power output overload Measure battery
P1F02 DPS High voltage at the unit input.
(18V). voltage with engine
running. (Expected
test charging system as
per shop manual
Fault may become
Active in extreme
use situations.
Electronic Circuit Hi temperature detected by Reset fault and let
P1F03 DPS
Overheat on board temperature sensor. DPS cool down.
If fault re-occur in normal
riding conditions, replace
DPS unit
is not possible
Motor current sensor Motor input vs output Current
P1F05 DPS Clear the Fault. If Fault
range/performance correlation check failed
the DPS
Damaged circuit wires, Disconnect main relay
Main relay de-energized damaged connectors or and measure his coil
P20EB ECM
too late or sticking damaged ECM output pins. resistance (Expected
Damaged relay value: 70 to 90 Ohms)
34 tmr2015

Make sure sensor
connector is
well inserted
Disconnect the
Damaged TPS, sensor and associated
2nd Throttle Accelerator damaged circuit wires, ECM connector
P212C ECM
Sensors (TPS) low damaged connector or Measure the resistance
between the ECM
(Expected value < 2
Ohms)
Make sure sensor
connector is
well inserted
Disconnect the
2nd Throttle Accelerator damaged circuit wires, ECM connector
P212D ECM
Sensors (TPS) high damaged connector or Measure the resistance
between the ECM
(Expected value < 2
Ohms)
Make sure sensor
connector is
well inserted
measure the voltage
Damaged sensor,
Ambient pressure sensor wires (Expected value:
shorted to ground 4.8 to 5.1 Volts)
voltage supply low
between the ECM
(Expected value < 2
Ohms)
Make sure sensor
connector is
well inserted
measure the voltage
Ambient pressure sensor shorted to battery +, wires (Expected value:
P2229 ECM
short to V + ECM voltage supply too 4.8 to 5.1 Volts)
high. Measure the resistance
between the ECM
(Expected value < 2
Ohms)
Intake or throttle body
P2279 ECM Intake Air System leak Check for cracked plenum
air leak
tmr2015 35

If the accelerator pedal
and the brake are activated
Throttle and break pedal
P2299 ECM simultaneously for a delay
are used at the same time
time and the vehicle is moving
faster than Speed-threshold
Wrong O2 sensor position
exchanged lambda
P2416 ECM after O2 replacement Swap O2 sensor wires.
sensors upstream catalyst
or wire replacement.
Check ignition key
Ignition switch state not Ignition key switch connection
P2530 ECM contacts and wire
plausible or internal switch fault
connections
Throttle Accelerator
P2620 ECM Wrong TPS sensor position. Check TAS adjustment.
Sensors (TPS) position
Make sure sensor
connector is
well inserted
Disconnect the
First Throttle Accelerator damaged circuit wires, ECM connector
P2621 ECM
Sensor (TPS) low damaged connector or Measure the resistance
between the ECM
(Expected value < 2
Ohms)
Make sure sensor
connector is
well inserted
Disconnect the
First Throttle Accelerator damaged circuit wires, ECM connector
P2622 ECM
Sensors (TPS) high damaged connector or Measure the resistance
between the ECM
(Expected value < 2
Ohms)
is not possible
DPS motor supply
P2670 DPS PHASE B_LOW Clear the Fault. If Fault
Damaged DPS
the DPS
is not possible
DPS motor supply
P2671 DPS PHASE B_HIGH Clear the Fault. If Fault
Damaged DPS
the DPS
36 tmr2015

Open ECM Monitoring
page in BUDS,
Verify that gear position
information changes
with gear selection
changes on vehicle.
Disconnect GBPS
Measure voltage
between harness
Damaged circuit wires, connector 5-GBPS-1 and
Gear position sensor damaged gear position sensor, 5-GBPS-3. (Expected
P2801 ECM
invalid range damaged ECM pins or value: 4.8 to 5.1 Volts)
damaged transmission. Measure resistance
from connector:
5-ECM-B13 to
5-GBPS-2 (Expected
value: < 2 Ohms)
Measure resistance
from connector:
5-ECM-B22 to 5-GBPS-3
(Expected value: < 2
Ohms)
Open ECM Monitoring
page in BUDS,
Verify that gear position
information changes
with gear selection
changes on vehicle.
Disconnect GBPS
Measure voltage
between harness
connector 5-GBPS-1 and
Damaged circuit wires,
Gear position sensor 5-GBPS-3. (Expected
damaged gear position sensor,
P2806 ECM angle defined area vs value: 4.8 to 5.1 Volts)
damaged ECM pins or
position not plausible Measure resistance
damaged transmission.
from connector:
5-ECM-B13 to
5-GBPS-2 (Expected
value: < 2 Ohms)
Measure resistance
from connector:
5-ECM-B22 to
5-GBPS-3 (Expected
value: < 2 Ohms)
On the Diagnostic
connector, measure the
resistance between the
two CAN lines (Expected
CAN bus off, no Damaged circuit wires or
U0073 DPS Measure the resistance
messages damaged DPS pins.
of each CAN wire in
the harness, between
the Diagnostic and DPS
value < 5 Ohms)
tmr2015 37

On the Diagnostic
Damaged CAN Bus wires to value: 50 to 70 Ohms)
CAN LOSS/CANBUS
U0073 DPS GLOBE Network, damaged DPS pins Measure the resistance
FAILURE/CANBUSS OFF
or wires. of each CAN wire in
value < 5 Ohms)
On the Diagnostic
CAN-Bus failure, CAN-Bus Damaged circuit wires or
U0073 SCM Measure the resistance
OFF damaged SCM pins.
of each CAN wire in
the Diagnostic and SCM
value < 2 Ohms)
On the Diagnostic
Lost communication with
U0100 DPS ECM, damaged DPS/ECM Measure the resistance
ECM (lost of CAN ID’s)
pins. of each CAN wire in
the Diagnostic and ECM
value < 5 Ohms)
On the Diagnostic
ECM CAN
U0100 DPS GLOBE Network, damaged DPS pins Measure the resistance
COMMUNICATION OFF
or wires. of each CAN wire in
value < 5 Ohms)
On the Diagnostic
Missing CAN ID from ECM
Lost Communication With Internal module error
ECM (lost of CAN ID’s) Damaged circuit wires or
of each CAN wire in
damaged module pins.
value < 2 Ohms)
38 tmr2015

On the Cluster power
connector, measure
the voltage between
the two harness
power wires (Expected
Damage CAN Bus On the Diagnostic
wires to cluster connector, measure the
Lost communication with
U0155 DPS Damaged circuit wires or resistance between the
CLUSTER
damaged Cluster module two CAN lines (Expected
pins. value: 50 to 70 Ohms)
of each CAN wire in the
harness, between the
Diagnostic and Cluster
value < 2 Ohms)
With vehicle connected
to BUDS with MPI2,
check for CLUSTER
fault or ECM fault
Disconnect the
cluster connector
Measure the voltage
wires relative to
ground (Expected
Disconnect MPI2
from DB connector
Missing CAN ID
Lost communication with between the two
Module internal error
U0155 ECM CLUSTER (lost of CAN CAN lines (Expected
Damaged circuit wires or
ID’s) value: 50 to 70 Ohms)
Disconnect the
ECM connector
of each CAN wire in
value < 2 Ohms)
value < 2 Ohms)
tmr2015 39

With vehicle connected
to BUDS with MPI2,
check for CLUSTER
fault or ECM fault
Disconnect the
cluster connector
Measure the voltage
wires relative to
ground (Expected
Disconnect MPI2
from DB connector
Missing CAN ID
Lost communication with between the two
Module internal error
U0155 ECM CLUSTER (lost of CAN CAN lines (Expected
Damaged circuit wires or
ID’s) value: 50 to 70 Ohms)
Disconnect the
ECM connector
of each CAN wire in
value < 2 Ohms)
value < 2 Ohms)
Check for Cluster fault
Measure the voltage
of the cluster harness
power wires relative
to ground (Expected
On the Diagnostic
Missing CAN ID
Lost Communication With Module internal error
Cluster (lost of CAN ID’s) Damaged circuit wires or
of each CAN wire in
the Diagnostic and SCM
value < 2 Ohms)
value < 2 Ohms)
40 tmr2015

Check for dirty
or oxidized Key
contact. Clean key
contact if needed.
Check for broke
key contact
Ensure sensor
Lost communication The Vehicle Immobilizer is connector is
U0167 ECM with Vehicle Immobilizer reporting an electrical fault on fully inserted.
Control Module the communication line. Measure resistance
between ECMB-A1
and CC-C (Expected
value < 2 Ohms).
Measure resistance
between ECMB-C2 and
CC-E (Expected value <
2 Ohms).
Install the proper ECM
Invalid Security Exchange Incorrect ECM or CLUSTER, or CLUSTER on vehicle.
U0300 ECM
received Incorrect software version. Update security coding
using BUDS
Variant Coding, Faulty calibration or variant
If the problem
U0301 ECM software incompatibility Faulty programming
(DFC_MoFVar) Damaged ECM
replace ECM.
Variant Coding, Faulty calibration or variant
If the problem
U0302 ECM software incompatibility Faulty programming
(DFC_MTVARNPL) Damaged ECM
replace ECM.
Check in the
BUDS Tab "vehicle
Variant Coding failure Faulty variant coding configuration" if the
U0400 DPS
Software incompatibility Faulty programming DPS option is checked.
Reflash the DPS with
the latest software
look at BUDS vehicle
vehicle configuration error or
VARIANT config. check DPS for
U0400 DPS GLOBE DPS software mismatch or
IMCOMPATIBILITY reflash write config and
error
cycle on/off vehicle
Check if SCM is install
on a valid vehicle
Update SCM
SCM not install on Open Vehicle
Variant Coding failure
U0400 SCM expected vehicle Configuration in Setting
Software incompatibility
Faulty programming page in BUDS & if check
vehicle configuration is
set as expected for the
vehicle.
tmr2015 41

is available in Monitoring
page in BUDS
Remove the sensor
VEHICLE SPEED ERROR vehicle speed error value power wire relative
U0416 DPS GLOBE
VALUE received from ECM to ground (Expected
between the ECM
(Expected value < 5
Ohms)
Check for dirty
or oxidized Key
contact. Clean key
contact if needed.
Check for broke
key contact
Ensure sensor
Invalid Data Received The Vehicle Immobilizer could connector is
U0426 ECM From Vehicle Immobilizer not read the number of the fully inserted.
Control Module access key. Measure resistance
between ECMB-A1
and CC-C (Expected
value < 2 Ohms).
Measure resistance
between ECMB-C2 and
CC-E (Expected value <
2 Ohms).
Invalid Check Sum from is not possible
U220E ECM Check Sum error
CLUSTER message Check for
communication fault
Check the two
DPS fuses
Ensure DPS connector
Lost of power on DPS that can
is fully inserted.
Module improper be caused by damaged circuit
U3001 DPS Check for Damaged
shutdown wires or damaged DPS pins.
tail light, DPS,
Cluster circuit wires
Check for damaged DPS
pins.
Check fuse
Ensure SCM connector
Lost of power on SCM
Module improper is fully inserted.
U3001 SCM Damaged circuit wires or
shutdown Check for Damaged
damaged SCM pins.
circuit wires or damaged
SCM pins.
42 tmr2015
Subsection XX (INTELLIGENT THROTTLE CONTROL (iTC))
INTELLIGENT THROTTLE CONTROL

(iTC)
GENERAL the TPS that the throttle plate has reached the
targeted position, the ECM stops the throttle
SYSTEM DESCRIPTION actuator.
Depending on various conditions and the type of
The iTC is an electronic throttle control system
key used, the iTC can modify the ETA response,
that includes:
limit the engine torque or vehicle speed.
– Throttle accelerator sensor (TAS)
For torque limitation, the ECM processes the TAS
– Electric throttle actuator (ETA)
input differently depending on the specific mode.
– Throttle position sensor (TPS). In other words, the driver's demand may not nec-
essarily result in the corresponding throttle open-
ing.
For vehicle speed limitation, the iTC controls the
throttle opening to maintain a maximum set speed
even if the accelerator is pedal fully depressed.
SYSTEM MAIN FEATURES

The use of the iTC allows the following features:
– Key modes
– ECO/Sport modes
– Override functions.
tmr2017-029-001_a
ACCELERATOR PEDAL Key Modes

1. TAS
Normal Key
When a normal key is used and sport mode is
selected, engine delivers approximately 70% of
the accelerator pedal demand (less if ECO mode
is selected). Vehicle speed is limited to 70 km/h
(43 MPH).
Performance Key
When a performance key is used and sport mode
is selected, engine delivers 100% of the accel-
erator pedal demand (less if ECO mode is se-
lected). The vehicle speed is limited to 133 km/h
(83 MPH).
tmr2017-029-002
ETA WITH INTEGRATED TPS

ECO/Sport Modes
The TAS is part of the accelerator pedal module. When sport mode is selected, the full potential of
The ETA and TPS are comprised in the throttle the specific ignition key is deployed except when
body. gearbox is in reverse or low gear.
The iTC is often referred to as a "throttle by wire" When ECO mode selected, the full potential of the
system (no throttle cable is used). specific ignition key is not reached and the accel-
According to the accelerator pedal position and erator pedal response is smoother than in sport
other inputs, the ECM powers the ETA motor us- mode.
ing pulse width modulation (PWM), to control the
throttle plate. When the ECM detects through
tmr2017-029 1
Reverse Override Function In the above mentioned situations the electronic

In reverse gear, engine delivers less than the drive belt protection will help protect the CVT
accelerator pedal demand and vehicle speed is drive belt from being damaged by activating the
limited to 20 km/h (12 MPH). Also, the accelera- engine torque limiter. The gauge will also scroll
tor pedal response is smoother than in high gear. a LOW GEAR message, suggesting the operator
to immobilize the vehicle and set to LOW GEAR.
If the override button is depressed, vehicle speed
and engine acceleration are increased. Even with The ECM will temporarily deactivate and activate
the override is activated, the ECM will not allow cylinder(s) to vary engine speed. This results in
the engine to deliver 100% of the accelerator very apparent vehicle stuttering. The goal is to
pedal demand. move the drive belt to a cooler section of the CVT
drive and driven pulley sheaves.
SYSTEM OTHER FEATURES Low Range Operation
Driver's Seat Belt Monitoring When gearbox is in low range, engine delivers
If driver's seat belt not fastened, speed is limited less than the accelerator pedal demand and the
to approximately 20 km/h (12 MPH). accelerator pedal response is smoother than in
high gear.
Brake Monitoring
Engine Temperature Monitoring
If the ECM receives a brake switch signal while
gearbox is in gear and the vehicle moving, the If coolant gets too hot, engine will deliver less
ETA will decrease throttle plate opening and en- than the accelerator pedal demand. The limitation
gine speed will drop to idle. is proportional to the overheat degree.
NOTE: A defective brake light switch that would Battery Voltage Monitoring
stay in a closed position would force the engine to
run at idle. If the battery voltage gets low, the engine
idle RPM will be increased at approximately
Electronic Engine Braking 1500 RPM.
The ECM commands the throttle to open enough Drowned Mode
to bring engine RPM slightly above CVT drive belt
engagement speed. This keeps the drive pulley In case of a fuel flooded engine, the engine can
and belt engaged and allows for engine braking. be cranked without fuel injection.
The engine braking function stops when vehicle To enter the drowned mode, the TAS signals must
stops. indicate a throttle demand of at least 20% before
and during engine cranking.
Pressing on the brake pedal does not cancel the
electronic engine braking function. Limp Home Mode
Electronic Drive Belt Protection When certain faults are occurring, the ECM will
enter the limp home mode. In this mode, the en-
Electronic drive belt protection works in all modes gine will deliver less than the accelerator pedal de-
(ECO,Sport). mand.
This function is activated when riding at too slow
speed for the high range, such as in the following PROCEDURES
situations:
– Pulling SPORT/ECO SWITCH
– Pushing
– Hauling a load Sport/ECO Switch Wire Information
– 4X4 applications FUNCTION PIN COLOR
– Mud holes Signal (to ECM B pin D4) 1 BROWN/GREEN
– Water holes
Ground through ECM
– Crossing obstacles 2 ORANGE/VIOLET
(to ECM B pin A1)
– Climbing onto trailer
– Hill climbing
2 tmr2017-029
SEAT BELT SWITCH

Seat Belt Switch Wire Information
FUNCTION PIN COLOR
Signal (to ECM B pin E3) B YELLOW/GREY
Ground through ECM
A ORANGE/VIOLET
(to ECM B pin A1)
OVERRIDE SWITCH
Override Switch Wire Information tmr2017-029-701_a
PARTS REMOVED FOR CLARITY

FUNCTION PIN COLOR 1. retaining nuts
2. Coolant hoses
Normal position signal
1 VIOLET/YELLOW
(to ECM B pin D3) To install, reverse the removal procedure, how-
Ground through ECM ever pay attention to the following:
2 VIOLET/GREY
(to ECM B pin B1) Route and attach wires correctly.
Override position signal Tighten nuts to the specified torque.
3 VIOLET/ORANGE
(to ECM B pin F3)
TIGHTENING TORQUE
Accelerator pedal 13 N•m ± 1 N•m
THROTTLE ACCELERATOR retaining nuts (115 lbf•in ± 9 lbf•in)
SENSOR (TAS)
Carry out the ECM FIRST INITIALIZATION, refer to
TAS Description ELECTRONIC FUEL INJECTION (EFI) subsection.
The throttle accelerator sensor (TAS) is a double
hall effect sensor that sends a signal to the ECM TAS Wire Information
which is proportional to the accelerator pedal. The
FUNCTION PIN COLOR
redundancy is used for security purposes.
The voltage output of the hall effect sensors are Signal (E1) A GRAY/GREEN
different. Ground through ECM (K3) B GRAY/BLACK
Replacing the TAS Voltage input (5 volt) (K1) C GRAY/VIOLET
The TAS is part of the accelerator pedal. Voltage input (5 volt) (J3) D ORANGE/VIOLET
1. Note the wire routing and locking tie position. Signal (A3) E ORANGE/GREEN
2. Disconnect electrical connector. Ground through ECM (B3) F ORANGE/BLACK
3. Remove both accelerator pedal retaining nuts
outside the passenger compartment. Reach TAS Failure
nuts by the RH side of the vehicle above the If one TAS signal fails, the vehicle will enter the
rack and pinion, beside the coolant hoses. limp home mode. In this case, depressing the
override button will temporarily restore accelera-
tor pedal operation (while button is depressed).
If both TAS signals fail, the engine speed will drop
to idle. Depressing the override button will force
the ECM to open the ETA to an angle that allows
the vehicle to move.
Testing the TAS with BUDS2

Connect toBUDS2 software. Refer to COMMU-
NICATION TOOLS subsection.
Select the Measurements and ECM tabs.
tmr2017-029 3
Look at the TAS (%) window as you depress the

accelerator pedal.
The TAS signal should vary from near 0% to near
100% depending on the pedal position, which
confirms the TAS signal reaches the ECM.
If the TAS signal is above 2% with the accelera-
tor pedal at released, the MODE button will not
be able to select between ECO/Sport modes. Re-
place the accelerator pedal assembly.
4 tmr2017-029
Subsection XX (ELECTRONIC FUEL INJECTION (EFI))
ELECTRONIC FUEL INJECTION (EFI)

SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 1
FUEL HOSE DISCONNECT TOOL ................................................ 529 036 037 ........................................... 13
SERVICE PRODUCTS
DIELECTRIC GREASE ................................................................... 293 550 004 ........................................... 24
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 31
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ........................................... 33
GENERAL WARNING
The following tools are required to test most of Proceed with care and use appropriate safety
the electrical parts. equipment when working on the fuel system.
Wipe off any fuel spillage in the engine com-
REQUIRED TOOL partment. Do not allow fuel to spill on hot en-
gine parts and/or on electrical connectors.
(P/N 529 035 868) Cover the fuel line connection with an absorbent
shop rag before disconnecting them. Slowly dis-
connect the fuel hose to minimize spilling.
ECM ADAPTER TOOL WARNING

(P/N 529 036 166)
Replace any damaged, leaking or deterio-
rated fuel lines or connections. After work-
ing on the fuel system, always pressurize the
WARNING fuel system and check for fuel leaks. Refer
When electrically disconnecting or removing to FUEL SYSTEM PRESSURIZATION in FUEL
the throttle body from the intake manifold, al- TANK AND FUEL PUMP subsection.
ways remove the tether cord from the engine
cut-off switch and disconnect the battery. SYSTEM DESCRIPTION
The electronic fuel injection system (EFI) is com-
WARNING prised of various sensors used for detecting ongo-
Always disconnect battery prior to working ing operating conditions of the engine and vehicle,
on the fuel system. Always disconnect bat- and includes all the components that perform the
tery exactly in the specified order, BLACK required adjustments to the engine.
(-) cable first. Electrical connections should
be disconnected prior to disconnecting fuel
lines.
WARNING
Fuel is flammable and explosive under cer-
tain conditions. Wear safety glasses and
work in a well ventilated area. Do not smoke
or allow open flames or sparks in the vicinity.
219100971-015 1
Electrical System Refer to AIR INTAKE SYSTEM subsection for

more information.
ECM (Electronic Control Module)
Throttle Body ((ETC) Electronic Throttle
Control)
Air for combustion is drawn in by the engine. The
air flows through the throttle body (ETC) and is
controlled by a throttle plate.
The Electronic Throttle Control (ETC) is a heated
single 54 mm throttle body with integrated dual
throttle position sensors (TPS) and electric throttle
actuator (ETA) and is mounted on the intake man-
ifold.
The ETA allows the ECM to electronically control
the throttle plate opening which regulates the
tmr2017-030-016 amount of air that enters the engine, and there-
fore engine speed.
The ECM controls the engine operation and the
vehicle power management. To control the en- There is no idle air control valve (IACV).
gine, the ECM reads the inputs from the sensors
which it compares to predetermined parameters
stored in the ECM (fuel and ignition maps), makes
computations, and activates the outputs accord-
ingly (injectors, ignition coils etc.).
Refer to ENGINE MANAGEMENT SYSTEM (EMS)
subsection for more information.
EFI Sensors
To control the injection system, the engine man-
agement uses input signals from the following
sensors:
– Camshaft position sensor (CAPS)
– Crankshaft position sensor (CPS) tmr2017-030-001_a
– Manifold absolute pressure and temperature ELECTRONIC THROTTLE CONTROL (ETC)

1. Throttle body (ETC)
sensor (MAPTS) 2. Throttle plate
3. Dual Throttle Position Sensor (TPS)
– Boost pressure sensor (BPS) 4. Electric throttle actuator (ETA) (electric motor)
– Throttle position sensor (TPS) which is inte-
grated to the throttle body (Electronic Throttle Refer to INTELLIGENT THROTTLE CONTROL
Control (ETC)) (iTC) subsection for more information.
– Throttle accelerator sensor (TAS).
Fuel System
– Coolant Temperature Sensor (CTS)
Refer to ENGINE MANAGEMENT SYSTEM (EMS) Fuel Rail
subsection for more information. A fuel rail is mounted on the intake manifold. The
fuel rail, which is used to secure the injectors to
Air Intake System the manifold, also provides to the injectors the
fuel pressure that it receives from the fuel pump.
Air Filter
The fuel pressure applied to the fuel rail is regu-
Air, drawn into the air filter housing, first passes
lated by the fuel pressure regulator located in the
through an inlet duct.
fuel pump module.
After it passes through the air filter, an air duct
(intake adapter) is used to channel the air to the
turbocharger.
The intercooler then cools the air before going to
the throttle body.
2 219100971-015
In BUDS2, go to:
– Measurements page
– ECM button.
NOTE: The multifunction gauge and the BRP di-
agnostic software (BUDS2) use the same signal
to provide the engine RPM indication.
TROUBLESHOOTING
DIAGNOSTIC TIPS
Engine problems are not necessarily related to the
tmr2017-030-002_a fuel injection system.
Fuel Injectors It is important to ensure that the engine and
propulsion system, fuel delivery and electrical
Three fuel injectors are used to inject fuel into the
systems are functioning normally.
intake ports of the cylinder head. One injector is
used per cylinder. For diagnostics purposes, use the BRP diagnostic
software (BUDS2).
After a problem has been solved, be sure to clear
the fault(s) recorded in the ECM using the BRP
diagnostic software.
WARNING
Electrical actuators and electronic mod-
ules may be powered up as soon as the
START/STOP button is depressed. Always
disconnect the battery prior to disconnecting
any electrical or electronic parts.
Never use a battery charger to temporarily substi-

tmr2017-030-002_b
tute the battery as it may cause the ECM to func-
tion erratically, or not at all.
Fuel is injected in accordance with injection sig- Check related-circuit fuse solidity and condition
nals received from the ECM. with an ohmmeter. A visual inspection could lead
Fuel Pump to a false diagnosis.
An electric fuel pump with an integrated pressure Poor Idling
regulator and fuel system filters is used. For more
details on the fuel pump unit, refer to FUEL TANK If poor idling is experienced, check the following:
AND FUEL PUMP subsection. – Poor quality fuel or water in the fuel
– Fault codes using BUDS2
ADJUSTMENT – Throttle body cleanliness
– Engine leaks or other mechanical problem.
IDLE SPEED
Electrical Related Problems
Idle speed is not adjustable. The EMS (Engine It is important to check the following in the elec-
Management System) controls the idle speed of trical system:
the engine through the iTC system by control-
ling throttle plate opening using the ETA (electric – Battery voltage
throttle actuator). – Fuses
The engine RPM may also be verified using the – Ground connections
BRP diagnostic software (BUDS2). – Wiring and connectors.
219100971-015 3
Ensure that all electronic components are original

BRP recommended components. Any modifica-
tion to the wiring harness may lead to poor sys-
tem operation or generate fault codes.
Electrical Connections
Pay particular 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 lmr2010-022-002_a
intermittent connection that would be difficult to ECM CONNECTOR IDENTIFICATION - COOLING FINS FACING
OUT
troubleshoot. 1. Connector A
2. Connector B
NOTE: Do not apply dielectric grease or other lu-
bricants on the ECM connectors. The ECM connectors have 48 pins.
NOTE: For connector information, cleaning and
PROCEDURES probing, refer to WIRING HARNESS AND CON-
NECTORS subsection.
ENGINE CONTROL MODULE
(ECM) Quick Test to Validate ECM Operation
Briefly press START/STOP button.
NOTE: As a first troubleshooting step, always
check for applicable fault codes using the BRP This should wake up the ECM. The ECM will then
diagnostic software (BUDS2). activate relay 1 for approximately 12 seconds af-
ter which it will turn off all power. If the D.E.S.S.
Locating the ECM key is installed when the START/STOP button is
pressed, the power will stay on for approximately
The ECM is located behind the driver seat. 40 seconds.
QUICK INDICATION THAT ECM IS POWERED
(ASSUMING THE OBSERVED COMPONENT
IS WORKING)
Multifunction gauge comes ON.
Fuel pump turns on for approx. 2 seconds (if key on

D.E.S.S. post installed).
If ECM does not turn on, check the following:

– Fuse F6 and F8.
– Battery voltage. Refer to CHARGING SYSTEM
tmr2017-030-001 subsection.
– Relay R2
ECM Connector Identification – START/STOP switch. Refer to STARTING SYS-
There are 2 connectors connected to the ECM: TEM subsection.
– Engine harness connected to ECM-A – ECM power circuit wires and ground wires.
– Vehicle system control harness connected to For testing of fuses and relay R2, refer to POWER
ECM-B. DISTRIBUTION AND GROUNDS subsection.
NOTE: When relay 2 is not working, the ECM and
the complete vehicle electrical system will not be
powered.
4 219100971-015
ECM First Initialization If voltage is as per specification, refer to TESTING

This procedure performs a reset of the following THE ECM POWER SUPPLY in this subsection.
values in the ECM: If voltage is out of specification:
– TAS (Throttle Accelerator Sensor) – Test the START/STOP switch, refer to START-
– TPS (Throttle Position sensor) ING SYSTEM subsection.
– GBPS (Gearbox Position Sensor). – If the START/STOP switch tests good, test
wiring and connectors from battery to ECM.
This reset must be carried out whenever the ECM
Refer to WIRING DIAGRAM.
has been replaced.
This reset may be carried out whenever any of Testing the ECM Power Supply
the following components have been replaced in- 1. Disconnect ECM-B connector and connect it to
stead of their respective reset procedures: the ECM adapter tool.
– Throttle body (for TPS)
2. Install a jumper wire between B-H2 and B-M2
– GBPS (Gearbox Position Sensor). on the ECM adapter tool.
1. Connect the vehicle to the BRP diagnostic soft- 3. Turn the ignition switch to ON.
ware (BUDS2).
4. Set the multimeter to Vdc.
2. In B.U.D.S., select the following:
– Setting page 5. Check for voltage as follows.
– ECM button ECM
BATTERY VOLTAGE
– Setting tab ADAPTER
– ECM First Initialization B-M4 Negative post Battery voltage
3. In the ECM first initialization field, click on the
Reset button. If voltage is not measured, check the following:
– Main relay
4. Follow the instructions in the message boxes
– Wiring and connections, refer to the WIRING
that appear.
DIAGRAM.
If the operation is successful, a message will be
displayed stating that the reset was successful. Testing the Continuity of ECM Ground
If an error occurred or a component is out of Circuits
range, a message may be displayed. Follow the 1. Connect ECM-B connector on the ECM adapter
instructions in the message and repeat the pro- tool.
cedure.
2. Set multimeter to and probe adapter termi-
5. Check for fault codes. nals as per following table.
If a fault code is generated, carry out the service ECM
actions, reset the fault and repeat the reset pro- BATTERY READING
ADAPTER
cedure.
PIN TERMINAL
6. Start engine and make sure it operates normally
throughout its full engine RPM range. 1L
Negative
2M Close to 0
Testing the ECM Wake Up Circuit (Ground)
3M
1. Disconnect ECM-B connector and connect it to
the ECM adapter tool.
2. Set the multimeter to Vdc.
3. While pressing the START/STOP button, read
voltage as follows.
ECM
BATTERY READING
ADAPTER
PIN TERMINAL VOLTAGE
Negative
B-D1 Battery Voltage
(Ground)
219100971-015 5
Replacing the ECM

Prior to replacing an ECM, ensure that all the rec-
ommendations in the general introduction of this
subsection have been followed and all applicable
testing procedures have been carried out.
NOTE: Proceed with an ECM FIRST INITIALIZA-
TION as it may resolve the problem.
If the ECM is replaced, data must be transferred
into the new ECM.
smr2009-030-010_a
ECM Data Entry for ECM Replacement

If any measurement is out of specification refer to
POWER DISTRIBUTION AND GROUNDS subsec- Use one of the following 2 methods to collect the
tion and check the following: required information. The 1st being the easiest:
– Wiring and connections 1. Use BUDS2 to obtain the data from a saved
– Engine ground "*.buds2" file on your PC computer.
– Battery ground 2. Collect the information from the vehicle and on
the Knowledge Center.
– Frame ground.
Once the required information has been collected,
Removing the ECM refer to ENTERING THE COLLECTED INFORMA-
TION INTO THE ECM.
NOTE: If a new ECM is to be installed, first read
the procedures in ECM REPLACEMENT in this 1st Collecting Method: Obtaining the Data
subsection. from a Saved .buds2 File
1. Disconnect battery cables. 1. Start BUDS2.
NOTICE Always disconnect the BLACK (–) NOTE: It is not necessary to perform any connec-
battery cable first, then disconnect RED (+) tion. The PC computer can be used alone.
cable. 2. In BUDS2, click on the Open a BUDS2 file but-
ton.
2. Refer to appropriate subsection and remove the
driver seat. Make sure you are at: C:\Program
Files(x86)\BRP\BUDS2\Files.
Installing the ECM IMPORTANT: Be sure to use the file that specifi-
1. The installation is the reverse of the removal cally matches the vehicle you are servicing.
procedure. However, pay attention to the fol- NOTE: The file name structure is as follows:
lowing.
VIN_date read (yyyymmdd)_hour read (hhmmss).mpem
2. Install and secure the ECM.
Example:
TIGHTENING TORQUE
2.5 N•m ± 0.5 N•m 2BPSBK8C68V000168_20090206_111640.buds2
ECM screw
(22 lbf•in ± 4 lbf•in) Therefore:
3. Reconnect ECM connectors. VIN: 2BPSBK8C68V000168
4. Reconnect battery cables. Date: 2009 02 06
Hour: 11h 16m 40s
NOTICE Always reconnect the RED (+) bat-
tery cable first, then reconnect BLACK (–) 3. Select the Summary page then the Vehicle
cable. button and record (write down) the following
information.
5. If a new ECM is installed, refer to REPLACING
1. Vehicle serial number
THE ECM in this subsection.
2. Engine serial number
3. Vehicle model number
4. Customer name.
6 219100971-015
2nd Collecting Method: Collect the

Information from the Vehicle and BOSSWeb
1. Record engine serial number.
smr2014-026-005_a
1. Vehicle Serial Number here
3. Enter the recorded data in the new ECM as de-

tmr2017-030-002 tailed in ENTERING THE COLLECTED INFOR-
LH SIDE OF ENGINE MATION INTO THE ECM.
1. Engine serial number plate
2. Exhaust manifold Entering the Collected Information Into the
ECM
2. Record the following numbers from BOSSWeb.
Look in Sales menu and choose Unit history. 1. Connect the vehicle to the BRP diagnostic soft-
1. Vehicle serial number ware (BUDS2).
2. Vehicle model number 2. In BUDS2, click the Scan button to read the
3. Customer name. new ECM.
3. Select:
– Summary page
– Vehicle button.
4. Write all of the following information you
recorded previously.
1. Vehicle serial number (VIN)
2. Engine serial number
3. Vehicle model number
4. Customer name.
NOTICE . Enter only the appropriate product
model number as obtained when gathering the
information.
NOTICE Pay particular attention when typ-
smr2014-026-004_a
ing the V.I.N. and model numbers. Once Write
SERVICE, UNIT HISTORY
1. Click on SALES menu Data button is pressed, the data cannot be
2. Select Unit History modified.
5. Perform the THROTTLE POSITION SENSOR
INITIALIZATION procedure, refer to ADJUST-
MENTS in this subsection.
6. Start the engine and ensure proper operation.
7. Reinstall any remaining removed parts.
FUEL INJECTOR
Accessing the Fuel Injector Connector
Remove air box cover and intercooler grill.
219100971-015 7
tmr2017-011-005 tmr2017-030-015
Remove rear body module, refer to BODY subsec- Remove intercooler shroud.
tion
tmr2017-011-009
tmr2017-011-004
Unhook the coolant expansion tank and slide un-

der the intercooler shroud
tmr2017-030-004_a
1. Fuel Injectors
2. Fuel Injector connectors
tmr2017-011-008
Testing the Fuel Injector Operation

Unscrew the TCV. Using BUDS2 (Dynamic)
NOTE: As a first troubleshooting step, always
check for applicable fault codes using the BRP
diagnostic software (BUDS2).
1. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).
2. Start engine.
8 219100971-015
3. In BUDS2, select the following: MAXIMUM FUEL PRESSURE DROP ALLOWED

– Functions page BETWEEN FUEL INJECTORS
– ECM button. 10 kPa (1.5 PSI)
4. Select an injector and press the ACTIVE button.
If the pressure drop between fuel injectors is
5. Repeat for all injectors.
greater than the specification, replace the injector
If the engine RPM drops momentarily when click- with the least pressure drop, then repeat the test.
ing on a cylinder, the injector on this cylinder is
12. Using the valve on the fuel pressure gauge,
functioning normally.
release the pressure in the system (if so
If the engine RPM does not drop momentarily equipped).
when clicking on a cylinder, this cylinder is not
13. Remove fuel pressure gauge and reinstall re-
functioning properly. Check the following:
moved parts.
– Fuel injector operation. Refer to TESTING THE
FUEL INJECTOR BALANCE USING BUDS2 14. Crank engine in drowned mode (accelerator
held all the way in) to ventilate the engine of
– Spark plug and ignition coil. Refer to IGNITION
the fuel that was injected during the test.
SYSTEM subsection.
– Engine condition. WARNING
Testing the Fuel Injector Balance Using Always crank engine in drowned mode to
BUDS2 ventilate all fuel that was injected during the
test. Failure to do so may result in severe
NOTICE After fuel injector activation using engine damage and injury.
BUDS2, always crank engine in drowned mode
to ventilate the engine of fuel. Testing the Fuel Injector Leakage
1. Install a fuel pressure gauge as described in Test Setup
TESTING THE FUEL PUMP PRESSURE of 1. Ensure there is enough fuel in fuel tank.
FUEL TANK AND FUEL PUMP subsection.
2. Ensure fuel pressure from fuel pump is within
2. Connect the vehicle to the BRP diagnostic soft- specification. Refer to FUEL TANK AND FUEL
ware (BUDS2). PUMP subsection.
3. Press the Start button to activate the ECM. NOTE: Keep the pressure gauge installed for the
4. In BUDS2, select the following: leakage test.
– Functions page 3. Connect the vehicle to the BRP diagnostic soft-
– ECM button ware (BUDS2).
– Activate Fuel Pump. 4. In BUDS2, go to:
5. Click on the ACTIVATE button to activate fuel – Functions page
pump. – Vehicle or ECM button
6. Fuel pressure must be within specification. Re- – Functions tab
fer to FUEL TANK AND FUEL PUMP subsec- – Execute Fuel Pressure Relief.
tion. Re-activate fuel pump as necessary.
5. Remove fuel rail with injectors from engine.
7. In BUDS2, energize fuel injector no. 1. However, do not disconnect fuel pump pres-
8. Record the fuel pressure drop for injector no. 1. sure hose from fuel rail. Refer to FUEL INJEC-
9. Re-activate fuel pump. TORS in this subsection.
10. Repeat the procedure for fuel injector no. 2 6. Position fuel rail so that an appropriate con-
and no. 3 and record the pressure drop for tainer may be placed under the injectors to
each injector. collect any fuel leakage.
11. The maximum fuel pressure drop between in-
jectors should not exceed the following spec-
ification:
219100971-015 9
4. Check resistance value between fuse box and

ECM connector terminals as follows.
NOTE: It is not necessary to remove the fuse. Re-
fer to POWER DISTRIBUTION AND GROUNDS
subsection for fuse box information.
INJECTOR ECM FUSE BOX READING
@ 20°C
CYLINDER PIN TERMINAL
(68°F)
1 B2
2 K1 B4 11.4 - 12.6
3 J1
mmr2009-120-017
If resistance value obtained is correct, carry out
INJECTOR LEAKAGE TEST SETUP TESTING THE FUEL INJECTOR INPUT VOLTAGE
7. Install key on D.E.S.S. post. in this subsection.
If resistance value obtained is incorrect, repeat
Testing the Leakage test at HIC connector located beside the ECM.
1. In BUDS2, go to:
– Functions page
– Vehicle or ECM button
– Functions tab
– Activate Fuel Pump.
2. Check for fuel leakage from the injector noz-
zles.
3. Monitor fuel pressure at fuel pressure gauge.
If pressure drops below 372 kPa (54 PSI) during
the test, re-activate fuel pump as necessary.
FUEL INJECTOR LEAKAGE
tmr2017-030-003
TEST DURATION SPECIFICATION
1 drop per minute INJECTOR ECM HIC READING
2 minutes
maximum @ 20°C
CYLINDER PIN
(68°F)
If test is not within specification, replace the faulty
fuel injector. 1 B2
4. Properly reinstall fuel rail. Refer to FUEL RAIL 2 K1 D 11.4 - 12.6
in this subsection. 3 J1
5. Reinstall remaining removed components.
If resistance value obtained is incorrect, remove
WARNING injector connector and check resistance value be-
Wipe up any spilled fuel. tween injector pins as follows. Refer to FUEL IN-
JECTOR ACCESS in this subsection.
Testing the Fuel Injector Resistance
1. Ensure vehicle electrical power is off.
2. Disconnect connector “A” from the ECM, refer
to ECM CONNECTOR ACCESS in this subsec-
tion.
3. Remove cover from the fuse box and locate
fuse F5 (ign/inj/fuel pump fuse).
10 219100971-015
INJECTOR READING 6. Momentarily press the START/STOP button to

wake up the ECM without holding the brakes.
PIN @ 20°C (68°F)
NOTE: It is not necessary to activate the injector
1 2 11.4 - 12.6 since it is continuously powered when the ECM is
awake.
If readings are out of specifications, replace injec-
tor. 7. Set the multimeter to Vdc. Read voltage.
INJECTOR INJECTOR BATTERY READING
Testing the Fuel Injector Input Voltage
CYLINDER WIRE TERMINAL VOLTAGE
1. Ensure both ECM connectors are properly con-
nected. 1
VIOLET/ Battery
2. Ensure the HIC connector is properly con- 2 Vdc
BLUE Ground
nected. 3
3. Disconnect the fuel injector connector. Refer to
FUEL INJECTOR CONNECTOR ACCESS in this If injector input voltage is good, carry out the fol-
subsection. lowing:
– Circuit continuity test between injector and
ECM, refer to WIRING DIAGRAM.
– Test the injector signal, go to: TESTING THE
FUEL INJECTOR SIGNAL in this subsection
If injector input voltage is not good, check the fol-
lowing:
– Fuse F5
– Circuit continuity between fuse F5 and in-
jector. Refer to POWER DISTRIBUTION AND
GROUNDS subsection and WIRING DIAGRAM.
Testing the Fuel Injector Signal
1. Set multimeter to Vdc.
tmr2017-030-004_a
1. Fuel Injectors NOTE: Make sure multimeter is in the Auto

2. Fuel Injector connectors Range mode.
NOTE: Press against tab underneath connector
as illustrated to unlock it.
smr2009-030-028_a
PRESS HERE TO UNLOCK
4. Ensure fuse F5 (Ign/Inj/fuel pump) is properly

installed. mmr2009-120-020_a
5. Install key on D.E.S.S post. 2. Press the Hz button so that the display shows
Hz.
219100971-015 11
tmr2017-011-005
Remove rear body module, refer to BODY subsec-

tion.
mmr2009-120-020_b
3. Connect the multimeter probes as indicated in

the following table and using the BUDS2 soft-
ware, activate each injector and read the fre-
quency on the multimeter.
NOTE: The multimeter counts the pulses per sec-
onds (Hertz) of current the ECM sends to the in-
jector.
INJECTOR INJECTOR BATTERY READING
tmr2017-011-004
CYLINDER WIRE TERMINAL FREQ.

Unhook the coolant expension tank and slide un-
BROWN/ der the intercooler shroud.
1
RED
BROWN/ Battery
2 9 Hz
BLUE Ground
BROWN/
3
GREY
If reading is good, the control circuit is functional.

If there is no reading, check continuity of control
circuit (ECM to injectors). Refer to WIRING DIA-
GRAM for circuit details.
Fuel Injector Access
Remove air box cover and intercooler grill. tmr2017-011-008
Unscrew the TCV.
12 219100971-015
3. Disconnect the battery, refer to CHARGING

SYSTEM subsection.
WARNING
When removing or disconnecting the fuel in-
jectors, always disconnect the battery.
4. Remove parts required for access to the fuel

rail and fuel injectors, refer to FUEL INJECTOR
ACCESS.
5. Disconnect the fuel injector electrical connec-
tmr2017-030-015 tors.
Remove intercooler shroud. 6. Disconnect the fuel pressure hose from the fuel
rail.
REQUIRED TOOL
FUEL HOSE DISCONNECT
TOOL (P/N 529 036 037)
tmr2017-011-009
lmr2006-008-010
NOTE: Wrap a rag around the hose end to catch

any fuel leakage.
7. Remove the fuel rail mounting screws.
tmr2017-030-004_a
1. Fuel Injectors
2. Fuel Injector connectors
Removing the Fuel Injector

ware (BUDS2).
2. In BUDS2, go to:
– Functions page
– Vehicle or ECM button
– Functions tab
– Execute Fuel Pressure Relief.
219100971-015 13
FUEL INJECTOR INSTALLATION

O-RINGS New Lubricate with engine oil
3. Firmly push injector until it bottoms out.

4. Install fuel rail.
TIGHTENING TORQUE
9 N•m ± 1 N•m
Fuel rail retaining screw
5. Apply engine oil on O-rings of fuel pressure

hose fitting.
tmr2017-030-004_b
1. Injector connectors
2. Fuel rail mounting screws
8. Pull on fuel rail to remove the fuel rail and injec-

tors from the engine.
9. Remove the fuel injector retaining clips from
the fuel rail.
mmr2009-121-022_a
FUEL PRESSURE HOSE FITTING

1. Apply oil on O-rings
6. Connect fuel pressure hose to fuel rail.

IMPORTANT: Push fuel hose fitting on fuel rail un-
til you hear a "click". Try pulling on fuel hose fitting
to ensure it is properly locked.
mmr2009-120-010_a
Pressurize the fuel system and check for fuel
TYPICAL - FUEL RAIL ASSEMBLY
1. Fuel rail
leaks. Refer to FUEL SYSTEM PRESSURIZATION
2. Fuel injector retaining clip in FUEL TANK AND FUEL PUMP subsection.
3. Injector
4. Injector O-rings
WARNING
10. Pull the fuel injector(s) out of the fuel rail. Failure to pressurize the fuel system and
checking for fuel leaks may result in severe
Installing the Fuel Injector injury or a life threatening situation should a
The installation is the reverse of the removal pro- leak occur.
cedure. However, pay attention to the following
details. 7. Reinstall all remaining removed parts.
NOTICE If installing the removed injector(s),
ensure injector O-rings are in good condition.
Replace O-rings as required.
1. Apply a thin film of engine oil to O-rings to ease
insertion in rail.
2. Install fuel injector with your hand. Do not use
any tool.
14 219100971-015
THROTTLE BODY (ETC ECM ENGINE THROTTLE BODY

(ELECTRONIC THROTTLE Throttle actuator: Off.
CONTROL)) Throttle plate: Rest position,
OFF Stopped maintained opened at
Throttle Body (ETC) Description approximately 8° (1). This
is also the limp home position.
Throttle actuator: On.
Throttle plate: Moves
from the rest position to
approximately 15°. It then
moves back to the rest
position. This is the diagnostic
ON Not started mode where the rest position,
actuator opening force to
overcome the return springs
and the motor return rate are
monitored. If any of these
parameters are out of range, a
fault code is initiated.
tmr2017-030-001_a Throttle actuator: On.
1. Throttle body Throttle plate: Execute
2. Throttle plate Not started. check for ice on throttle plate.
3. TPS (Throttle Position Sensor) (inside)
4. ETA (Electric Throttle Actuator) (electric motor inside) ON Very cold If throttle plate does not
environment reach the fully closed position,
Electric Throttle Actuator (ETA) throttle plate is moving until
closed position can be reached.
The electric throttle actuator (ETA) is a DC mo-
tor on the throttle body that regulates the throttle Throttle actuator: On.
plate via a drive gear. It receives its control signal Throttle plate: Moves from the
Started. rest position to idle position
from the ECM. Pulse width modulation (PWM) is
Normal (approximately 1-3°) according
used to control the motor. ON
operation to ECM injection and ignition
at idle maps. Throttle plate is opened
Throttle Plate Operating Positions and closed as necessary to
Two torsional springs are connected to the throttle control the idle speed.
plate. A main spring and another one in a plunger Started.
mechanism. Throttle actuator: On.
Normal
Throttle plate: Opens and
When there is no power to the throttle actuator ON operation
closes according to ECM
(ETA), the plunger mechanism maintains the throt- at various
torque management priorities.
tle plate at a rest position. This also serves as the RPM
limp home position. (1) Degree values are given from the fully closed
When the throttle plate is opened by the ETA as position.
commanded by the ECM, it acts against the main
spring. If the ETA failed, the return spring would Throttle Body (ETC) Faults and Effects
bring the throttle plate back to the limp home po- NOTE: Among other things, a weak or broken
sition. spring and a sticky throttle plate are validated by
the throttle body diagnostic mode.
219100971-015 15
FAULT EFFECT
Limp home mode. Engine
Partial speed limited to idle.
failure of ECM will use the
TAS sensor remaining TAS sensor.
(one Fault code set and beeper
internal activated to emit warning signals.
sensor Check engine light is turned ON.
only) Driveability could be reset by releasing
and reapplying the throttle.
Complete
failure of
speed limited to 2500 RPM. tmr2017-030-006
TAS sensor
Fault code set and beeper
(both Disconnect electrical connectors.
activated to emit warning signals.
internal
Check engine light is turned ON.
sensors)
speed limited to 2500 RPM.
Any
Engine speed can still be increased up
throttle
to 3200 RPM using the throttle lever.
body
Fault code set and beeper
failure
activated to emit warning signals.
Check engine light is turned ON.
NOTE: Refer to DIAGNOSTIC AND FAULT

CODES and INTELLIGENT THROTTLE CON-
TROL (iTC) subsections for more informations.
tmr2017-030-005
Throttle Body (ETC) Access
Remove the CVT duct. Loosen clamp.
tmr2017-030-004 tmr2017-030-007
Disconnect intercooler hose. Lubricating the Throttle Body (ETC)

No lubrication is required.
Testing the Electric Throttle Actuator

(ETA)
Electric Throttle Actuator (ETA) Test with
BUDS2
ware (BUDS2).
2. Install key on D.E.S.S. post.
16 219100971-015
3. Press the START/STOP button without holding The throttle plate should cycle quickly from the
the brakes to wake up the ECM. rest position to a partially open position (approx-
4. In BUDS2, go to: imately 15°), then back to the rest position.
– Measurements page 5. Install the tether cord on the D.E.S.S. post.
– ECM button The throttle plate should cycle again.
– Presets and ECM - BASIC tabs 6. As you observe the throttle plate, have some-
– Throttle Opening. one gradually and evenly pull in the throttle
5. Slowly depress the throttle to WOT. The ETA lever, then release it in the same way.
should go from almost 10% to 100%. The throttle plate should open then close accord-
If result is out of specification, carry out a THROT- ing to throttle lever position however, the move-
TLE POSITION SENSOR INITIALIZATION. Refer ment of the throttle plate may not be linear with
to THROTTLE POSITION SENSOR (TPS) in this the displacement of the throttle lever.
subsection. If any test failed, proceed with TESTING THE
NOTE: The ETA is reset at the same time as the THROTTLE BODY (ETC) (STATIC).
TPS. Testing the Throttle Body (ETC) (Static)
After the reset, test ETA again.
If the result is still out of specification, check wire CAUTION First ensure the ECM is off. Do
continuity between ECM and throttle body before not move the throttle plate using your fingers.
assuming the ETA is at fault. Otherwise, should the START/STOP button be
pressed, the ECM would turn on and quickly
Inspecting the Throttle Body (ETC) cycle the throttle plate which could cause se-
rious finger injury.
1. Remove parts required to access throttle body,
refer to THROTTLE BODY (ETC) ACCESS. 1. Using a blunt tool, push in on the throttle plate
and ensure it opens smoothly within the throt-
2. Carry out the following:
tle body.
– Inspect throttle body for cleanliness.
– Ensure throttle plate opens fully and
smoothly.
– Check for corroded or damaged wiring or
damaged ETC connectors.
Testing the Throttle Body (ETC) (Dynamic)
1. Remove the parts required to access the
throttle body (ETC), refer to REMOVING THE
THROTTLE BODY (ETC).
2. Remove the air inlet hose from the throttle
body.
3. Observe the throttle plate with the engine
stopped.
The throttle plate should be in the rest position smr2009-030-016_b
(slightly opened). 1. Push here to open
NOTE: The throttle plate must open fully and re-

CAUTION Keep your fingers out of the turn freely to the rest position (slightly opened)
throttle plate area while the ECM turns on. The when released.
throttle actuator will cycle. This could cause
serious finger injuries as throttle plate quickly 2. Push throttle plate closed as indicated in follow-
moves. ing illustration. It must close completely and re-
turn freely to the rest position (slightly opened)
4. As you observe the throttle plate, have some- when released.
one press the START/STOP button to wake up
the ECM.
219100971-015 17
7. Reinstall all removed parts.
Removing the Throttle Body (ETC)
CAUTION Ensure the key is removed

from D.E.S.S. post and battery cables are dis-
connected so that nobody can activate the
electrical system, otherwise the ECM would
turn on and the throttle actuator (ETA) would
cycle. This could cause serious finger injury
as the throttle plate moves quickly.
1. Remove parts required to access throttle body,
refer to THROTTLE BODY (ETC) ACCESS.
smr2009-030-016_c
2. Loosen gear clamp and remove throttle body
1. Push here to close
from intake manifold.
If the throttle plate does not move smoothly or 3. Disconnect BPS and ETC connectors.
does not return freely to the rest position, the
problem is mechanical. Check for dirt accumu-
lation on throttle plate shaft. It may also be an
actuator or gear problem. Replace throttle body
as necessary.
If throttle plate operates normally, the problem is
electrical. Check electric throttle actuator (ETA)
wiring continuity, throttle position sensor (TPS)
and throttle accelerator sensor (TAS).
Cleaning the Throttle Body (ETC)

1. Remove throttle body from intake manifold.
Refer to REMOVING THE THROTTLE BODY
(ETC) further in this subsection. tmr2017-030-005_a
2. Check throttle body cleanliness using a flash-

light. Fully open throttle plate and verify: Installing the Throttle Body (ETC)
– Throttle body bore Installation of the throttle body is the reverse of
– Throttle plate edge. the removal procedure. However, pay attention
Look for: for the following details.
– Dirt 1. Perform the THROTTLE POSITION SENSOR
– Oily surfaces INITIALIZATION reset procedure. Refer to
THROTTLE POSITION SENSOR (TPS) in this
– Carbon and dirt deposits on throttle plate and
subsection.
the surrounding bore.
2. Install all remaining removed parts, refer to ap-
3. Clean as necessary. Use a throttle body cleaner plicable subsections.
such as GUNK INTAKE MEDIC or an equivalent
3. Start engine and ensure proper idle and throttle
NOTICE Only use an appropriate throttle control.
body cleaner that will not damage O-rings and
EFI sensors. THROTTLE POSITION SENSOR
4. To avoid getting dirt into engine, spray cleaner (TPS)
on a clean rag then rub rag against throttle plate
and bore. A toothbrush may also be used. TPS Description
5. Gently open throttle plate and hold fully open to The TPS is part of the throttle body (ETC).
clean all surfaces. The throttle position sensor (TPS) is a double po-
6. To remove residual dirt, spray cleaner on throt- tentiometer that sends signals to the ECM that
tle plate and throttle bore. are proportional to the throttle plate angle.
18 219100971-015
As a first troubleshooting step, always check for 2. Disconnect ECM connector A from the ECM
applicable fault codes using the BRP diagnostic and install it on the ECM adapter tool.
software (BUDS2). 3. Set multimeter to .
Throttle Position Sensor Initialization 4. Probe circuit as per following table while using
your hand to manually move throttle plate.
NOTE: The TPS initialization procedure must be
carried out whenever the throttle body (ETC) is re- FULLY CLOSED FULLY OPEN
placed, unless an ECM first initialization reset is ECM THROTTLE THROTTLE
carried out. ADAPTER PLATE (1) PLATE
This operation performs a reset of the TPS basic RESISTANCE ( )
values in the ECM. This reset is very important as PIN MIN. MAX. MIN. MAX.
the TPS values are part of the basic parameters
for all fuel mapping calculations and control of sev- A-A2 A-K4 875 1625 875 1625
eral settings such as for idle speed, LIMP HOME A-A2 A-K3 954 1934 228 585
mode and maximum RPM of the engine.
A-A2 A-F3 254 634 980 1983
NOTICE An improperly set TPS may lead to
A-K3 A-K4 228 585 954 1934
improper idle speed (too low or too high), poor
engine performance, poor engine starting and A-K3 A-F3 1385 2315 1385 2315
engine stop on deceleration, fault codes and A-K4 A-F3 980 1983 254 634
possible engine damage. Emission compli-
ance may also be affected.
(1)To obtain the fully closed position, it is necessary
to push against the throttle plate in the throttle body
1. Install key on D.E.S.S. post. with your hand and hold it in this position for the
measurement.
2. Press the START/STOP button to wake up the
ECM.
3. Ensure accelerator pedal is completely re-
leased.
ware (BUDS2).
5. In BUDS2, select
– Settings button
– ECM page tab
– Settings page
– Reset TPS. vmr2008-022-005_a
6. In the Reset TPS box, click on the Reset button.

If any resistance value is incorrect, check wire
A message will be displayed if the operation is continuity between ECM and throttle body before
successful. assuming the TPS is at fault. Refer to WIRING
If an error occurred or the TPS is not within the DIAGRAM subsection.
allowed range while resetting, the ECM will gen-
erate a fault code and will not accept the setting.
7. Start engine and make sure it operates normally
through its full engine RPM range.
8. Check for fault codes using BUDS2, If a fault
code related to the throttle actuator appears,
clear it, then carry out another Closed Throttle
Reset procedure. To clear faults, refer to DIAG-
Testing the TPS Resistance
1. Ensure the throttle body connector is properly
connected.
219100971-015 19
tmr2017-030-007_a
tmr2011-022-019_a
THROTTLE BODY CONNECTOR PIN-OUT 1. Locking tie

2. CPS connector
CRANKSHAFT POSITION 2. Probe CPS connector terminals as per following

SENSOR (CPS) table.
CPS READING
CPS TROUBLESHOOTING
PIN @ 20°C (68°F)
When troubleshooting a CPS fault, take into ac-
count that a CPS fault can be triggered by bent or 1 2 775 - 950
missing encoder wheel teeth.
Push START/STOP button and crank engine. If If resistance is not within specifications, replace
engine does not start within 15 seconds check the CPS.
for fault codes using the BRP diagnostic software If resistance tests good, reconnect the CPS con-
(BUDS2). nector.
1. Disconnect ECM-A connector from the ECM
CPS and CPS Connector Location and connect it to the ECM adapter.
Using a multimeter, recheck resistance as per ta-
ble.
ECM ADAPTER READING
PIN @ 20°C (68°F)
H1 K2 775 - 950
If resistance is as specified, test continuity of

wiring between ECM-A and CPS connectors.
Refer to WIRING DIAGRAM subsection.
If resistance value is not as specified, reconnect
ECM-A connector to the ECM and refer to TEST-
ING THE CPS OUTPUT VOLTAGE.
tmr2017-030-006_a
RH SIDE OF ENGINE
1. CPS location Testing the CPS Output Voltage
2. CPS connector location
1. Remove fuse F5.
Testing the CPS Resistance 2. Cut locking tie and disconnect the CPS connec-
tor.
1. Disconnect CPS connector.
20 219100971-015
tmr2017-030-007_a tmr2017-030-009_a
1. Locking tie
2. CPS connector 4. Remove CPS retaining screw and pull on CPS
to remove it.
3. Probe CPS connector terminals while cranking
engine as per following table.
CPS READING
PIN VOLTAGE
1 2 1 - 2 Vac min.
If voltage is out of specification, inspect

wiring/connectors. Replace CPS if wiring is good.
If voltage is within specification, the problem may
be related to the ECM.
4. Reconnect CPS connector and install all re-
moved parts.
tmr2017-030-010_a
Replacing the CPS
1. Remove parts required to access the CPS. 5. Install new CPS.
2. Take note of factory CPS wire harness routing TIGHTENING TORQUE
for reinstallation. Apply engine oil on
O-ring
3. Cut harness locking ties and disconnect CPS O-ring
connector. 9 N•m ± 1 N•m
CPS retaining screw
6. Route and secure CPS harness using harness

clamp and locking ties as noted prior to re-
moval.
tmr2017-030-008_a
219100971-015 21
CAMSHAFT POSITION SENSOR

(CAPS)
CAPS Location
smr2014-029-032_a
TYPICAL
1. CAPS
2. CAPS connector
If battery voltage is read, proceed with TESTING

tmr2017-019-001_c
THE CAPS (DYNAMIC) further in this subsection.
If battery voltage is not read, probe circuit as per
Testing the CAPS Voltage (Harness following table.
Side) CAPS BATTERY READING
1. Remove the parts required to access the CAPS.
PIN TERMINAL VOLTAGE
2. Disconnect CAPS connector.
Battery
3 Battery Voltage
Ground
tmr2017-019-001_a
3. Install key on D.E.S.S. post. smr2014-029-032_b
TYPICAL
4. Press the START/STOP button to wake up the
ECM without holding the brakes. If voltage is read to battery ground, check conti-
5. Probe harness connector terminals as per fol- nuity of ground circuit between CAPS pin 1 and
lowing table. ECM-A connector pin 4D. Repair or replace wiring
and connectors.
CAPS READING
If voltage is not read to battery ground, carry out
PIN VOLTAGE TESTING THE CONTINUITY OF CAPS POWER
3 1 Battery Voltage CIRCUIT.
Testing the Continuity of CAPS Power
Circuit
1. Remove the F5 fuse.
2. Use the multimeter and select .
22 219100971-015
3. Read resistance of the CAPS circuit as per fol-

lowing table.
CAPS FUSE BOX READING
PIN TERMINAL
3 B4 Close to 0
If continuity is good, wiring and connectors are

functional.
If a high resistance or an open circuit is measured,
refer to WIRING DIAGRAM and check the follow-
ing:
– Continuity from CAPS connector pin 3 to HIC
connector pin D.
– Continuity from HIC connector pin D to fuse box
contact B4.
smr2007-021-010_a
Pay attention to connector pin contact and junc- TYPICAL
tion JT-1 (VT/BU).
Repair or replace wiring and connectors as re- CAPS
CAPS READING
CONDITION
quired.
4. Reinstall all removed parts. PIN SENSOR END VOLTAGE
Metallic Object
Testing the CAPS (Dynamic) 3 2 Battery Voltage
on Sensor
1. Remove the parts required to access the CAPS.
2. Remove CAPS sensor from engine.
3. Back-probe connector with automotive back
probe pin.
NOTICE Do not use sharp end probes. They
could damage the connector seal.
4. Briefly press the START/STOP button to wake
up the ECM.
5. Install the tether cord cap on the D.E.S.S. post.
6. Read voltage as per following tables.
CAPS
CAPS READING
CONDITION
PIN SENSOR END VOLTAGE
3 2 Free Close to 0 Vdc smr2007-021-009_c
TYPICAL
1. Metallic object
If voltage is as specified, repair or replace wiring

and connectors between sensor and ECM.
If wiring is good, check ECM. Refer to ENGINE
CONTROL MODULE (ECM).
If battery voltage is not measured as specified, try
a new CAPS.
Replacing the CAPS

1. Disconnect CAPS connector.
219100971-015 23
MAPTS Pressure Function

Before the engine is started, when power is ap-
plied to the system, the sensor measures the
ambient air atmospheric pressure. The ambient
pressure is, at that moment, stored in the ECM.
Thereafter, once the engine is started, it mea-
sures the air pressure in the intake manifold at
operating RPMs.
The sensor must be correctly installed on the in-
take manifold. Otherwise, the MAPTS could gen-
erate a fault code for an unexpected sensor range
at idle when it reads the atmospheric pressure. If
tmr2017-019-001_a this is the case, remove sensor and check for oil or
dirt on its end and if problem persists, check throt-
2. Unscrew the CAPS retaining screw. tle plate condition/position and the wiring harness.
3. Pull CAPS from engine. Perform the following tests.
4. Install the new CAPS. Testing the MAPTS (Pressure Function)
NOTICE Be sure to install new O-ring on the 1. Connect vehicle to the .BRP diagnostic soft-
new CAPS. ware (BUDS2)
SERVICE PRODUCT
–
CAPS O-RING ENGINE OIL – Measurements page
DIELECTRIC GREASE – ECM button
CAPS CONNECTOR
(P/N 293 550 004) – Custom tab
– Manifold Pressure With Altitude Correc-
TIGHTENING TORQUE tion.
9 N•m ± 1 N•m 3. Look for and take note of the MAPTS pressure
CAPS Retaining Screw
(80 lbf•in ± 9 lbf•in) reading while the engine is stopped.
4. Perform the same test with a new MAPTS and
MANIFOLD ABSOLUTE compare both readings.
PRESSURE AND TEMPERATURE Values have to be within ± 3.4 kPa (.5 PSI).
SENSOR (MAPTS) NOTE: 1 kPa = 10 hPa.
NOTE: This sensor is a multifunction device. It MAPTS PRESSURE FUNCTION QUICK TEST
measures manifold absolute pressure and intake
temperature for air flow calculations. RESULT SERVICE ACTION
Circuit
MAPTS Location Continuity MAPTS
Repair or
The MAPTS is located on the intake plenum. NO Test of Input
replace
READING MAPTS Voltage
wiring
Pressure Test
Function
VALUE IS
OUT OF Replace MAPTS
RANGE
Testing the MAPTS Input Voltage

1. Remove electrical connector from MAPTS.
tmr2017-030-009
24 219100971-015

– Measurement page
– ECM button
– Custom tab..
3. Look for Intake Temperature reading while the
engine is stopped.
4. Perform the same test with a new MAPTS and
compare both readings.
If the engine's MAPTS temperature reading is sig-
nificantly different than the new MAPTS, replace
tmr2017-030-909_a it.
1. MAPTS NOTE: Both sensors must feel same ambient air
2. MAPTS connector to remove
temperature.
2. Briefly push START/STOP button. If there is no reading, carry out TESTING THE
3. Set multimeter to Vdc, measure for MAPTS in- MAPTS RESISTANCE (TEMPERATURE FUNC-
put voltage as per following table. TION).
MAPTS READING Testing the MAPTS Resistance (Temperature
Function)
PIN VOLTAGE
1. Disconnect the MAPTS connector.
1 3 5 Vdc
2. Test MAPTS resistance at the sensor as per fol-
If voltage test is good, replace the MAPTS. lowing tables.
If voltage test is not good, carry out TESTING MAPTS READING
THE MAPTS CIRCUIT CONTINUITY (PRESSURE PIN RESISTANCE
FUNCTION).
Refer to MAPTS
Testing the MAPTS Circuit Continuity 1 2
TEMPERATURE SENSOR TABLE
(Pressure Function)
1. Disconnect the ECM “A” connector. MAPTS TEMPERATURE SENSOR TABLE
2. Install ECM-A connector on ECM adapter tool. TEMPERATURE
3. Check continuity of the following circuits. °C °F MAPTS
ECM - 40 - 40 40528 to 56935
MAPTS READING
ADAPTER
- 10 - 14 8103 to 10919
PIN
20 68 2193 to 2863
B4 3
80 176 294 to 368
G4 4 Close to 0
120 248 98 to 122
H2 1
If resistance is not within specification, replace
If resistance is not within specification, repair or the MAPTS.
replace the wiring harness between ECM connec- If resistance tests good, reconnect the MAPTS
tor and the MAPTS. and proceed with the following steps.
MAPTS Temperature Function 3. Install ECM-A connector on the ECM adapter
tool.
The MAPTS also monitors the temperature of the
air in the intake manifold. 4. Recheck resistance value as per following ta-
ble.
Quick Testing the MAPTS (Temperature
Function)
ware (BUDS2).
219100971-015 25
ECM TIGHTENING TORQUE

READING
ADAPTER
4.5 N•m ± 0.5 N•m
MAPTS retaining screw
PIN RESISTANCE (40 lbf•in ± 4 lbf•in)
Refer to MAPTS TEMPERATURE
H2 H3
SENSOR TABLE COOLANT TEMPERATURE
MAPTS TEMPERATURE SENSOR TEST RESULTS
SENSOR (CTS)
RESULT SERVICE ACTION Overheat Warning
Circuit The CTS will cause the engine overheat warning
Continuity MAPTS to come on when the coolant temperature is
Repair or above 110°C (230°F).
NO Test of Input
replace
READING MAPTS Voltage
wiring CTS Location
Temperature Test
Function The CTS is located on the RH side of the engine,
INCORRECT between the water pump and oil cooler.
Check condition of connector
RESISTANCE
pins, replace MAPTS
VALUE
CORRECT
RESISTANCE Try a new ECM
VALUE
Testing the MAPTS Circuit Continuity

(Temperature Function)
ECM
MAPTS READING
ADAPTER
PIN
H2 1
Close to 0
H3 2 tmr2017-030-011_a
Repair or replace wiring as required. Testing the CTS using BUDS2

1. Connect the vehicle to BUDS2. Refer to COM-
Replacing the MAPTS
MUNICATION TOOLS subsection.
1. Disconnect MAPTS connector and remove the
2. Select the following:
MAPTS from the intake manifold.
– Measurements page tab
– ECM page.
3. Look for the engine temperature indication.
The engine temperature gauge in BUDS2 should
provide an indication of the actual engine coolant
temperature. Otherwise, perform TESTING THE
CTS RESISTANCE.
Testing the CTS Resistance
1. Disconnect the CTS connector.
2. Test the resistance of the sensor as per follow-
ing tables.
tmr2017-030-909_a
1. MAPTS
2. MAPTS connector
2. Install new MAPTS as per following table.
26 219100971-015
CTS READING TIGHTENING TORQUE

PIN Refer to CTS 16 N•m ± 2 N•m
CTS
TEMPERATURE SENSOR TABLE (142 lbf•in ± 18 lbf•in)
1 2
6. Reinstall remaining removed parts.
CTS TEMPERATURE SENSOR TABLE
TEMPERATURE NOTE: Ensure to reinstall wiring harness as noted
prior to removal.
°C °F LOW HIGH
7. Refill and bleed the cooling system, refer to
- 40 - 40 38400 52600
PERIODIC MAINTENANCE PROCEDURES
- 10 14 8200 10,600 subsection.
0 32 5900 6900
20 68 2200 2800 BOOST PRESSURE SENSOR
80 176 295 350 (BPS)
120 248 105 120 The BPS is a piezoresistive absolute pressure
sensor. Refer to TURBO CHARGER AND INTER-
NOTE: To test sensor at various temperatures, re-
COOLER subsection for more details.
move sensor and use a heat gun, ice and a ther-
mometer.
If resistance is out of specification, replace the
CTS.
If resistance test is good, proceed with the follow-
ing steps.
3. Reconnect the CTS connector.
4. Install ECM-A connector on adapter tool.
5. Recheck resistance from the ECM connector as
per following table.
ECM
READING
ADAPTER
PIN Refer to CTS tmr2017-030-005_b
TEMPERATURE SENSOR TABLE BPS

A1 J2
BPS Location
If resistance value is correct, refer to REPLACING
THE CTS. The BPS is located on the air hose between the
ETA and the intercooler.
If resistance value is incorrect, repair the connec-
tors or replace the wiring harness between ECM
connector and the CTS.
Replacing the CTS

1. Drain coolant, refer to PERIODIC MAINTE-
2. Cut locking ties of wiring harnesses and move
wiring aside for access.
NOTE: Take note of wiring and locking tie position
before removal.
3. Disconnect CTS connector.
tmr2017-030-011
4. Remove CTS from engine.
5. Install new CTS and torque as specified. BPS Troubleshooting
BPS pin 3 to ECMA - G3 is the signal wire.
219100971-015 27
Replacing the BPS
BA
1 +5v
ECMA - B4
2 -
ECMA - F2
3 21
3 ECMA - G3
tmr2015-031-011_a
The BPS is powered at key on.

Testing the BPS Voltage
1. Disconnect connector from BPS. tmr2017-030-005_b
2. Turn ignition key on. TIGHTENING TORQUE

3. Read voltage as per following table. 6 N•m ± 0.7 N•m
BPS retaining screw
BPS CONNECTOR VOLTAGE (53 lbf•in ± 6 lbf•in)
Terminal 1 to battery ground Approx. 5 V

Terminal 2 to battery ground Approx. 0 V
TURBO CONTROL VALVE (TCV)
Terminal 3 to battery ground Approx. 0 V The TCV is a pulse width modulated solenoid.
Refer to TURBO CHARGER AND INTERCOOLER
If voltage measured is as specified, replace the subsection for more details.
BPS.
If voltage measured is not as specified, refer to
TESTING THE CONTINUITY OF BPS WIRING
HARNESS.
Testing the Continuity of BPS Wiring Harness
1. Disconnect ECM connector "A" from the ECM
and connect it to the ECM adapter tool.
2. Test for circuit continuity as per following table.
BPS ECM
RESISTANCE
CONNECTOR CONNECTOR
Pin 1 B4
Close to 0
Pin 2 F2 tmr2017-030-012_a
continuity TCV
Pin 3 G3
TCV Access
3. If wiring harness is good, check ECM. Refer
The TCV is located above the turbocharger's com-
to ENGINE CONTROL MODULE (ECM) in this
pressor.
subsection.
Remove the bulkhead service cover.
4. If a high resistance or an open circuit is mea-
sured, repair or replace wiring and connectors
between the ECM and the BPS.
28 219100971-015
tmr2015-031-007_a
Ensure proper hose routing.
tmr2017-030-912
TCV Troubleshooting
3
BA
2 1 1 -
ECMA - M3
2 +12v
2 1
tmr2017-030-012
TIGHTENING TORQUE
tmr2015-031-012_a
5 N•m ± 0.5 N•m
TCV retaining screws
Replace TCV if it will not maintain pressure (leak- (44 lbf•in ± 4 lbf•in)
age) or if flow is restricted.
Leakage KNOCK SENSOR (KS)
Plug port no. 3. This engine is equipped with one knock sensor
Apply 80 kPa ± 0.5 kPa (11.6 PSI ± .07 PSI) of (KS) that measures the amount of noise generated
pressure to port no. 2. by the engine.
The TCV should maintain pressure for a minimum If an abnormally high amount of noise is mea-
of 10 seconds. sured, the ECM perceives this as a KNOCK
condition and adjusts ignition timing by retarding
Flow it to correct the situation.
Apply 12v to pin 2 and ground pin 1.
Air should flow freely from port no. 2 to ports no. 1
and no. 3.
TCV Specifications
SPECIFICATION
TCV resistance 23 ± 2
Replacing the TCV

Replace all Oetiker clamps.
219100971-015 29
Knock Sensor Location
tmr2017-030-013
Knock Sensor Troubleshooting

tmr2017-034-001_b
Always use the BRP diagnostic software (BUDS2)
ENGINE - EXHAUST SIDE to check for a knock sensor related fault code and
carry out service actions.
Knock Sensor and Connector Location
Knock sensor problems may be related to, but not
Remove the bulkhead service cover to have ac- limited to any of the following items:
cess to the knock sensor.
– Loose or improperly torqued knock sensor
– Dirty or corroded mounting surface
– Cracked knock sensor from over torquing
– Bad wiring and connections
– An induced knock (or vibration) due to a loose
part external to the engine.
Testing the Knock Sensor (KS)

Testing KS Operation (Dynamic Test)
1. Using BUDS2 to check for a knock sensor fault.
If an occurred fault is present, reset the fault.
tmr2017-030-912
2. Disconnect vehicle from BUDS2 and make ve-
hicle ready for a test ride.
3. During test ride, perform several accelerations
under load and ensure engine RPM exceeds
4000 RPM.
4. After test ride, reconnect vehicle to BUDS2 and
look for a knock sensor fault code.
If no fault code occurs, the knock sensor is good.
If a fault occurs, do the following:
– Refer to KNOCK SENSOR TROUBLESHOOT-
ING and check for any of the problems listed.
Repair as required.
– Carry out a knock sensor resistance test.
tmr2017-030-014
CVT DUCT REMOVED FOR CLARITY Testing the KS Resistance at the ECM
The KS connector is located under the throttle 1. Disconnect ECM-A connector and install it on
body, behind the CVT ducts on the left side. the ECM adapter tool.
2. Set multimeter to " ", measure the knock sen-
sor circuit resistance as per following table.
30 219100971-015
ECM ADAPTER MEASUREMENT 5. Remove knock sensor mounting screw.

RESISTANCE 6. Clean knock sensor contact surface on cylinder.
SENSOR PINS Also clean threaded hole.
@ 20°C (68°F)
KS C3 G2 5 M 7. Install new knock sensor and tighten as speci-
fied.
TIGHTENING TORQUE
23 N•m ± 3 N•m
Knock sensor screw +
LOCTITE 243 (BLUE)
(P/N 293 800 060)
NOTICE Improper torque may prevent sen-

sor from functioning properly and lead to
severe damage of internal engine compo-
vmr2008-022-005_a nents.
If knock sensor circuit resistance is as specified, 8. Ensure knock sensor connector is clean and
wiring harness and sensor are good. corrosion free before connecting it.
If resistance measured at ECM connector is not 9. Install new locking ties as per factory specifica-
close to specification, refer to TESTING THE KS tion.
RESISTANCE AT THE COMPONENT CONNEC-
TOR.
Testing the KS Resistance at the Component
Connector
1. Remove the required parts to access the knock
sensor connector.
2. Disconnect the knock sensor connector.
3. Measure the resistance between both termi-
nals on the knock sensor and compare the mea-
surement with the preceding table.
If resistance is not as specified, replace knock
sensor.
tmr2017-030-014_a
If resistance is good at the knock sensor, carry
LOCKING TIES
out a continuity check of the wiring between the
knock sensor connector and ECM connector "A". 10. Reinstall all remaining removed parts.
Refer to applicable WIRING DIAGRAM for details.
11. Install harness clamp and tighten to specifica-
NOTE: Although the knock sensor resistance is tion.
as specified, it may still be at fault as it may not
be producing a signal within its design specifica- TIGHTENING TORQUE
tion. 11 N•m to 1 N•m
Harness clamp screw
Repair or replace wiring and connectors between (97 lbf•in to 9 lbf•in)
the ECM and knock sensor.
Replacing the KS
HEATED OXYGEN SENSOR
(HO2S)
1. Remove rear CVT duct.
2. Disconnect KS sensor connector. Oxygen Sensor Location
3. Cut locking ties and remove clamp securing This vehicle is equipped with 1 heated oxygen
wire harness. sensors (HO2S): located on the exhaust pipe, near
the turbo.
4. Remove the bulkhead service cover
219100971-015 31
OXYGEN SENSOR VOLTAGE IN BUDS2

VOLTAGE READING CONDITION
Normal oxygen sensor
Varies 0.1 to 0.8 Volts
operation in closed loop
Oxygen sensor circuit
Constant 0.45 Volts
open
Indicates fuel
mixture too lean,
possible oxygen
Constant low voltage sensor fault,
tmr2017-030-017_a possible fuel
RIGHT SHOCK ABSORBER REMOVED FOR CLARITY system fault,
1. Oxygen sensor possible air leak
2. Connector
Indicates fuel
Oxygen Sensor and Connector Access mixture too rich,
Constant high voltage
possible fuel system
The oxygen sensor and its connector are accessi- fault
ble behind the right rear shock absorber.
Oxygen Sensor General Precautions Testing the Oxygen Sensor

Take the following precautions to avoid sensor Testing for Oxygen Sensor Input Voltage
malfunction: NOTE: This test validates the heater element cir-
– Do not use any product on sensor probe. cuit.
– Do not expose sensor to water, oil, windshield 1. Ensure main power relay (R2) is installed and
cleaner, anticorrosion oil, grease, terminal the F5 fuse is not burnt.
cleaner, etc.
2. Disconnect the oxygen sensor connector.
– Do not drop or use an oxygen sensor that has
been dropped. 3. Install key on D.E.S.S. post and press the
– Do not use any compound on sensor threads START/STOP button.
unless labeled as compatible with oxygen sen- 4. Using a multimeter set to Vdc, read the input
sor. voltage provided to the sensor heater.
– Do not use impact wrench or conventional OXYGEN SENSOR
socket type wrench to install sensor. CONNECTOR
– Do not allow sensor or wire to touch exhaust (HARNESS SIDE) MEASUREMENT
system or any other hot component. PIN
– Do not route sensor wires to create tension in
the wires. This could cause faults or sensor C Battery ground Battery voltage
malfunction.
If Input voltage is good, refer to TESTING THE RE-
Oxygen Sensor Troubleshooting SISTANCE OF THE OXYGEN SENSOR HEATER
and TESTING FOR OXYGEN SENSOR CIRCUIT
Always use the BRP diagnostic software (BUDS2) CONTINUITY.
to check for fault codes. Carry out service actions.
If input voltage is not good, test the continuity of
Also check oxygen sensor voltage and refer to fol- the power circuit from fuse F18 in fuse box 1. Re-
lowing table. fer to the applicable WIRING DIAGRAM for de-
In BUDS2, go to: tails.
– Measurement page If input voltage wire continuity is at fault, repair or
– ECM button replace wiring or connector.
– ECM - Fuel Trim tab.
Testing the Resistance of the Oxygen Sensor
Heater
Test the resistance value of the oxygen sensor be-
tween the sensor pins as follows.
32 219100971-015
OXYGEN RESISTANCE If the same oxygen sensor is installed, apply anti-

SENSOR PIN @ 20°C (68°F) seize on its first two threads. If not available, al-
ways use a product that is oxygen sensor safe.
Approximately
C D
7 - 11 SERVICE PRODUCT
If reading is not within specification, replace the LOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070)
oxygen sensor.
Testing for Oxygen Sensor Circuit Continuity
NOTE: This test validates the heater element cir-
cuit and the sensor circuits.
1. Remove main power relay (R2) in fuse box
1. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
2. Disconnect ECM-B connector and install it on
the ECM adapter tool.
rmr2008-048-003_a
3. Using a multimeter set to " ", test for continuity
TYPICAL
between the oxygen sensor harness connector 1. Apply antiseize lubricant first two threads
and the ECM adaptor as per following tables. 2. Must be free of any product
OXYGEN SENSOR CIRCUIT CONTINUITY TEST NOTICE Do not apply any antiseize lubricant
ECM
to the sensor probe as it could affect its opera-
OXYGEN RESISTANCE tion.
CONNECTOR
SENSOR PIN @ 20°C (68°F)
“B” 5. Screw sensor in exhaust pipe.
A J1
TIGHTENING TORQUE
B D2 Close to 0 50 N•m ± 10 N•m
D L2 (37 lbf•ft ± 7 lbf•ft)
+
Oxygen sensor LOCTITE 767
If a resistance value is NOT as specified, repair or (ANTISEIZE
replace the wiring and connectors. LUBRICANT)
(P/N 293 800 070)
Replacing the Oxygen Sensor
1. Remove main power relay (R2) in fuse box 6. Connect the electrical connector.
1. Refer to POWER DISTRIBUTION AND 7. Reinstall the main relay (R2).
GROUNDS subsection.
CAUTION Exhaust system and oxygen

sensor may be hot. To avoid possible injury,
allow exhaust system components time to
cool before proceeding.
2. Disconnect oxygen sensor connector.
3. Cut locking tie securing oxygen sensor harness.
4. Unscrew oxygen sensor from exhaust pipe.
NOTICE Handle oxygen sensor with clean
hands. Oxygen sensor probe must remain free
of oil, grease, antiseize lubricant and any other
foreign matter that could affect its operation.
If a new oxygen sensor is installed, its threads are
already coated with an antiseize product. Sensor
is ready for installation.
219100971-015 33
Subsection XX (FUEL TANK AND FUEL PUMP)
FUEL TANK AND FUEL PUMP

SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 2
FUEL HOSE ADAPTER.................................................................. 529 036 396 ............................................. 5
FUEL PUMP MODULE SOCKET................................................... 529 036 125 ..................................... 11–12
OETIKER PLIER............................................................................. 295 000 070 ............................................. 8
PRESSURE GAUGE....................................................................... 529 036 395 ............................................. 5
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ....................................... 4, 13
NEW
60 ± 5 N•m
(44 ± 4 lbf•ft)
NEW
NEW
NEW
NEW
22 ± 2 N•m
(16 ± 1 lbf•ft)
22 ± 2 N•m
NEW = Component must be replaced when removed. (16 ± 1 lbf•ft)
tmr2017-031-200_a
219100971-016 1
GENERAL Air can enter and exit the fuel tank at all times
through the fuel tank vent valve. This prevents
The following tool is required to test most of the negative pressure within the fuel tank which could
electrical parts. cause fuel starvation.
REQUIRED TOOL The vent valve also prevents fuel from flowing out
through the inlet of the vent system should the
vehicle be overturned.
ECM ADAPTER TOOL
(P/N 529 036 166) Fuel Tank Vent Breather Filter
The air inlet hose of the vent system is equipped
with an in-line breather filter that prevents entry of
particles such as dust or small insects.
(P/N 529 035 868)
WARNING
Fuel is flammable and explosive under cer-
tain conditions. Ensure work area is well ven- mmr2017-031-012_a
tilated. Do not smoke or allow open flames or
sparks in the vicinity. The arrow points towards the vent valve.
WARNING Fuel Pump Module

Always disconnect battery prior to working
on the fuel system.
WARNING
Do not allow fuel to spill on hot engine parts
and/or on electrical connectors.
When the repair is completed, ensure that all

hoses are connected and secured. Perform the
FUEL PRESSURE TEST and the FUEL TANK LEAK
TEST as explained in this subsection.
Fuel lines remain under pressure at all times. mmr2017-031-013_a
Proceed with care when removing/installing high
pressure test equipment. The fuel pump module is inserted in the fuel tank.
Use the appropriate diagnostic software or dis- It provides fuel delivery for the EFI system and en-
connect the fuel pump electrical connector to compasses the following components.
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 shop rag and carefully disconnect them
to minimize spilling.
SYSTEM DESCRIPTION
Fuel Tank Vent System
The fuel tank is equipped with a vent system that
ensures the fuel tank remains at ambient pres-
sure.
2 219100971-016
An electric float type fuel level sensor is mounted

on the side of the fuel pump reservoir. As the float
moves with changing fuel levels, it varies in re-
sistance. This signal is representative of the fuel
level.
The fuel level sensor resistance is at its lowest
value when the fuel tank is full, and at its highest
value when the tank is empty.
Refer to the FUEL LEVEL SENSOR in this subsec-
tion for fuel level sensor testing procedures.
mmr2017-031-016_a
Fuel Filters
FUEL PUMP MODULE COMPONENTS
1. Upper outlet filter
2. Fuel pressure regulator
3. Float type fuel level sensor
4. Fuel pump
5. Lower inlet filter
Fuel Pump Operation

When the pump is in operation, it draws fuel into
the reservoir through a lower inlet filter and a disk
type valve.
The pressurized fuel is pushed through an upper
outlet filter to the fuel rail.
Excess fuel pressure generated by the pump is
mmr2017-031-018_a
routed from the upper outlet filter back to the
FUEL FILTERS
pump canister reservoir by a pressure regulator 1. Upper outlet filter
mounted on the pump reservoir cover. 2. Lower inlet filter
When the START button is pressed, the electrical The system comprises two levels of filtration.
system is powered. The fuel pump will come on
A lower inlet filter (prefilter) attached to the bot-
momentarily to pressurize the fuel rail in prepara-
tom of the pump, and a upper outlet filter that is
tion for the engine start.
integral to the fuel pump module.
The ECM supplies the ground (power control sig-
nal) to turn on the fuel pump motor. Fuel Pump Pressure Regulator
The pressure regulator will ensure appropriate
fuel pressure is supplied to the injectors.
When the ECM receives a signal to shut down the
engine it removes the fuel pump ground signal.
Fuel Level Indication
mmr2017-031-019
The fuel pressure regulator is integral to the fuel

pump module. The pressure regulator maintains
proper fuel pressure for the EFI system.
mmr2017-031-017
219100971-016 3
INSPECTION If pressure drops, locate fuel leak(s) and repair or

replace leaking component(s).
FUEL TANK LEAK TEST NOTE: In case of fuel tank leak, do not attempt
repair. Fuel tank must be replaced.
WARNING
To locate a leak, check for a fuel smell or leaking
Always carry out a fuel tank leak test when- fuel.
ever the fuel tank shows signs of wear or
damage which may cause a leak, or when the To ease locating leak(s), spray soapy water on all
fuel pump has been removed or replaced, hose connections and components; bubbles will
or if you suspect a leak. If the fuel tank is indicate the leak location(s).
damaged, the fuel tank should be replaced
even if no leak is present. Do not attempt to FUEL PUMP PRESSURE TEST
repair the fuel tank.
The pressure test will show the available pressure
at the fuel pump outlet. It validates the pressure
1. Refill fuel tank and ensure fuel tank cap is in regulator, the fuel pump and tests for leaks in the
good condition and properly installed. system.
2. Remove the right side dashboard NOTE: Refer to the FUEL SYSTEM DIAGNOSTIC
FLOW CHART to help diagnose a fuel system re-
lated problem.
1. Ensure there are no leaks from hoses and fit-
tings. Repair any leak.
2. Ensure the fuel level in the tank is sufficient.
3. Before proceeding with the pressure test en-
sure the battery is fully charged. Battery volt-
age must be over 12 volts.
ware (BUDS2).
5. In BUDS2, go to:
tmr2017-031-001 – Functions page
3. Remove the vent hose from the fuel tank vent – Vehicle button
valve. – Functions tab
4. Using the VACUUM/PRESSURE PUMP (P/N 529 – Execute Fuel Pressure Relief.
021 800) and a short piece of hose, pressurize 6. Remove the right side dashboard.
the fuel tank through the vent valve.
tmr2017-031-010 tmr2017-031-001
TIME WITHOUT 7. Remove the connector cover

PRESSURE
PRESSURE DROP
14 kPa (2 PSI) 3 minutes
4 219100971-016
A rapid pressure drop after the engine is stopped

indicates leakage either from a fuel hose, fuel rail,
or from the fuel pump check valve.
– Check fuel hoses, fuel rail and fittings for leaks.
If not leaking, replace 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 leaking, re-
place fuel pump.
tmr2017-031-002
8. Carefully disconnect the fuel pump outlet hose

by pressing on the release tab of the quick dis-
connect fitting.
9. Install the fuel pressure gauge and fuel hose
adapter between the disconnected injector fit-
ting and fuel pump (in-line installation).
REQUIRED TOOLS
PRESSURE GAUGE
(P/N 529 036 395)
FUEL HOSE ADAPTER

(P/N 529 036 396)
10. Using BUDS2, reactivate fuel pump by select-

ing Activate Fuel Pump.
FUEL PRESSURE
ENGINE PRESSURE
450 kPa ± 14 kPa
Turbo with Intercooler
(65.27 PSI ± 2.03 PSI)
400 kPa ± 14 kPa
All Other
(58.02 PSI ± 2.03 PSI)
NOTE: Valid at 12 V ± 0.1 V.

11. Start engine and observe fuel pressure.
12. Stop engine.
13. In BUDS2, do a fuel pressure relief.
14. Remove tool and connect hose on fuel rail.
Test Conclusion
The fuel pressure should be within specification in
static or dynamic tests.
219100971-016 5
TROUBLESHOOTING
FUEL SYSTEM DIAGNOSTIC FLOW CHART
Fuel pump does not run Activate electric system to enable fuel pump Fuel pump runs
for 2 sec. then stops
Check fuse. Install fuel pressure gauge

Check fuel pump operation. on fuel pressure line
Repair or replace if necessary.
Activate electric system to enable fuel pump Replace fuel

pump module
Fuel pump runs
Repair or Fuel pressure less Fuel pressure within Fuel pressure more
replace than specifications specifications than specifications
Fails
Check fuel line/
rail for leaks
Fails OK Crank or start

Perform fuel pump test engine
OK
Fast Fuel pressure less Fuel pressure more Fuel pressure within
pressure drop than specifications than specifications specifications
No
Yes
Check
OK fuel line/
Verify fuel
pump check rail for leaks Repair or
valve Fails
replace FUEL SYSTEM OK
Fails OK
Fails
OK
Check fuel Perform fuel Replace fuel
injector pump test pump module Retest
OK
lmr2010-023-004_aen
6 219100971-016
PROCEDURES
FUEL HOSE AND OETIKER
CLAMPS
1
Replacing Fuel Hose
When replacing fuel hoses, be sure to use hoses
and clamps as available from BRP parts depart-
ment. This will ensure continued proper and safe
operation. 1
WARNING
Use of fuel lines other than those recom- tmr2017-031-301_a
mended by BRP may compromise fuel sys- 1. Location marks on fuel hose
tem integrity.
Engine Area (Hose Support - From Fuel Tank):
WARNING – Secure the corrugated hose over the fuel hose
with a locking tie. Tight just enough to avoid
Whenever removing a hose in the fuel sys- corrugated hose movements.
tem, always use new Oetiker clamps at as-
sembly. Then validate fuel system tightness – Secure fuel hose and the corrugated hose to
by performing a fuel pressure test. support with another locking tie.
.
When reinstalling fuel hoses, pay attention to the
following important points.
Fuel Tank Area:
– Make sure corrugated hose installed over the
front fuel hose is retained by at least 2 locking
ties.
– Locking ties must be installed at each end of
the corrugated hose and must be tight just
enough to avoid hose from moving.
1
2
tmr2017-031-302_a
1. Locking tie securing corrugated hose over fuel hose

1 2. Locking tie securing fuel hose on support
Engine Area (Hose Support - Toward Engine):

1 – Secure the corrugated hose over the fuel hose
with a locking tie. Tight just enough to avoid
corrugated hose movements.
– Attach fuel hose and thermostat inlet hose to-
gether.
tmr2017-031-300_a
1. Locking tie position
Along the Console:

– Install the locking ties between location marks
indicated on the fuel hose.
219100971-016 7
F01B04A 1
1. Securing clamp
tmr2017-031-303_a
1. Fuel hose
2. Thermostat inlet hose
– To retain the fuel hose on the rear portion of the
support, install a locking tie between location
marks indicated on the fuel hose.
1. Securing clamp in limited access
FUEL TANK
Draining the Fuel Tank
Remove fuel tank cap and siphon gas into an ap-
1 proved fuel container.
tmr2017-031-304_a
Removing the Fuel Tank
1. Location marks on fuel hose
1. Drain fuel tank. Refer to DRAINING THE FUEL
Replacing Oetiker Clamp TANK above in this subsection.
To secure or cut Oetiker clamps on fuel lines, use 2. Connect the vehicle to the BRP diagnostic soft-
OETIKER PLIER (P/N 295 000 070). ware (BUDS2).
3. In BUDS2, go to:
– Functions page
– Vehicle button
– Functions tab
4. Disconnect battery, refer to CHARGING SYS-
TEM subsection.
5. Remove right dashboard.
1. Cutting clamp
8 219100971-016
tmr2017-031-001 tmr2017-031-008
6. Remove connector cover. 9. Disconnect the fuel pump connector.

10. Remove the vent hose from the fuel tank
valve.
11. Disconnect the high pressure fuel hose.
tmr2017-031-002
7. Remove lower dashboard.
tmr2017-031-004_a
1. Fuel pump connector

2. Vent hose
3. High pressure fuel hose
12. Loosen both fuel filler neck clamps.
tmr2017-031-003
8. Remove glove box.
tmr2017-031-005
13. Remove fuel tank retaining straps.
219100971-016 9
If fuel pump does operate as in previous steps,

carry out the following:
– Check fuel pump fuse. Refer to WIRING DIA-
GRAM
– Check in BUDS2 for applicable fault codes. Re-
fer to COMMUNICATION TOOLS subsection.
– Carry out a fuel pump input voltage test.
Testing Fuel Pump Input Voltage

Turn ignition key ON.
tmr2017-031-006
SIDE PANEL REMOVED FOR CLARITY PURPOSE 5-FP-C

12 V
14. Pull fuel tank out of vehicle. 5-FP-D
Signal
Inspecting the Fuel Tank 5-FP-B
Inspect fuel tank for any damages or cracks which 12 V

may result in fuel leaks. 5-FP-A
Inspect tank and protector attachment points for

damages.
Inspect protector for damages.
tmr2017-031-001_a
If cracks, gouges or other damages which may
lead to a fuel leak, or damages to attachment FUEL PUMP INPUT VOLTAGE TEST
points that could prevent the tank from being VOLTAGE
secure are found, replace fuel tank. FUEL PUMP CONNECTOR
READING
Installing the Fuel Tank Pin A Pin B Battery voltage
The installation is the reverse of the removal pro- If battery voltage is read, carry out a fuel pump
cedure. However, pay attention to the following. resistance test.
NOTE: Inspect fuel tank retaining straps for dam-
If battery voltage is not read, test fuel pump
age, deformation or cracks. Replace as needed.
power input as follows.
Be sure to properly connect and route:
– Fuel tank vent tube FUEL PUMP POWER WIRE TEST
– Fuel pump pressure hose VOLTAGE
– Electrical connector. TEST PROBES
READING
Refill fuel tank and ensure there are no leaks by Fuel pump
performing a FUEL TANK LEAK TEST and a FUEL connector Battery ground Battery voltage
PRESSURE TEST as described in this subsection. Pin B
FUEL PUMP If battery voltage is now read, check fuel pump

ground circuit between fuel pump connector FP-A
Fuel Pump Pressure Test and ECM connector B-M1.
Refer to INSPECTION in this subsection. If battery voltage is still not read, check fuel pump:
– Fuse (F5)
Fuel Pump Quick Test – Power circuit
1. Turn ignition key to ON. – Wiring and connectors.
2. Listen for fuel pump operation.
3. Fuel pump should come ON for a few seconds, Testing Fuel Pump Resistance
then stop. 1. Remove the fuel pump fuse.
10 219100971-016
2. Remove connector B from the ECM and con-

nect it to the ECM adapter tool.
3. Set multimeter to .
4. Measure fuel pump resistance as follows.
FUEL PUMP RESISTANCE TEST
(AT ECM AND FUSE)
RESISTANCE
TEST PROBES
@ 20°C (68°F)
Fuse box1 Approximately
ECM B-M1
contact B4 2
tmr2017-031-002
If resistance test failed, disconnect fuel pump

connector and measure resistance at fuel pump 6. Disconnect fuel pump electric connector.
connector. 7. Disconnect high pressure fuel hose.
FUEL PUMP RESISTANCE TEST
(AT FUEL PUMP CONNECTOR)
Pins A and B Approximately 2
If test failed at pump connector, replace fuel

pump.
If test succeeded at pump connector, check
wiring and connectors from fuse box to ECM
connector. Repair or replace as necessary.
Removing the Fuel Pump

tmr2017-031-004_a
ware (BUDS2). 1. Fuel pump connector
2. In BUDS2, go to: 2. Vent hose
3. High pressure fuel hose
– Functions page
– Vehicle button 8. Remove fuel pump locking ring.
– Functions tab REQUIRED TOOL
FUEL PUMP MODULE
3. Disconnect battery, refer to CHARGING SYS- SOCKET (P/N 529 036 125)
TEM subsection.
4. Remove right dashboard. WARNING
Fuel vapors are flammable and explosive un-
der certain conditions. Use only non-spark-
ing tools.
9. Carefully pull out fuel pump.

NOTICE While pulling out the fuel pump, pay
attention to fuel sensor float arm. Float arm
can get stuck and bend reducing fuel sensor ac-
curacy.
10. Discard gasket ring.
tmr2017-031-001 Installing the Fuel Pump

5. Remove connector cover. For installation, reverse the removal procedure.
219100971-016 11
NOTICE Manipulate fuel pump with care. 10. Refill fuel tank and ensure there are no leaks
by performing a FUEL TANK LEAK TEST and
1. Wipe off any fuel residue in the sealing area. a FUEL PRESSURE TEST as described in this
2. Install a NEW gasket ring. subsection.
3. Place gasket so that it is located between pump 11. Check fuel level sensor operation.
and tank mounting surface. Make sure gasket
is sitting properly in place on the fuel tank with- FUEL FILTER
out any folds or wrinkles, then lower the pump
in place. Removing the Fuel Filter
4. Pay attention to pump orientation as in follow- NOTE: The lower fuel filter on the fuel pump mod-
ing illustration. ule does not require replacement under normal
operating conditions. Replace only if permanently
clogged or damaged.
Remove fuel pump. Refer to FUEL PUMP in this
subsection.
NOTE: The upper filter and fuel pump reservoir on
the fuel pump module contain fuel which will drain
out when fuel pump module is not in an upright
position.
Turn fuel pump upside down.
Using a small flat screwdriver, pry up the filter
locking tabs.
tmr2017-031-007
NOTE: Make sure arrow on fuel pump points to-

ward the line on fuel tank.
5. Insert fuel pump locking ring over the fuel pres-
sure hose and electrical wiring connector.
6. While firmly holding pump down against tank,
engage fuel pump locking ring on fuel tank
flange.
7. Turn locking ring until it is fully engaged.
NOTE: Make sure the pump body has not rotated
during nut torquing procedure.
smr2008-022-013_a
WARNING 1. Fuel filter locking tab (x2)

2. Filter locking pin (x2)
Fuel vapors are flammable and explosive un-
der certain conditions. Ensure pump locking Pull filter off fuel pump reservoir housing.
ring is fully engaged.
Installing the Fuel Filter
8. Tighten locking ring to the proper torque. Align new filter with pump reservoir housing.
REQUIRED TOOL Press new filter on by hand. Ensure it is fully
seated and locked onto the pump reservoir hous-
FUEL PUMP MODULE ing.
SOCKET (P/N 529 036 125)
Reinstall fuel pump as per procedure in this sub-
TIGHTENING TORQUE section.
60 N•m ± 5 N•m
Carry out a FUEL SYSTEM HIGH PRESSURE
Fuel pump locking ring LEAK TEST as described in this subsection.
9. Reconnect battery.
12 219100971-016
FUEL LEVEL SENSOR If readings are as specified, carry out an input volt-
age test. Refer to TESTING FUEL LEVEL SEN-
The fuel level sensor is a float actuated variable SOR INPUT VOLTAGE.
resistance type that is part of the fuel pump.
Testing Fuel Level Sensor Input
Voltage
Turn ignition key ON.
FUEL LEVEL SENSOR INPUT VOLTAGE TEST
FUEL PUMP
BATTERY VOLTAGE
CONNECTOR
Negative
Pin C Battery voltage
terminal
If battery voltage is not read, test wiring continuity

tmr2017-031-700_a between sensor and multifunction gauge.
1. Fuel level sensor If wiring continuity is good, replace multifunction
gauge.
Testing Fuel Level Sensor Resistance
If continuity is not obtained, repair or replace
Remove and disconnect multifunction gauge, re- wiring.
fer to the GAUGE subsection
FUEL LEVEL SENSOR RESISTANCE TEST Replacing the Fuel Level Sensor
GAUGE RESISTANCE
Replace fuel pump. See fuel pump removal and
FUEL LEVEL installation procedures in this subsection.
CONNECTOR @ 20°C (68°F)
Full 5 ±2
Pins 4 and 21 FUEL TANK VENT VALVE
Empty 90 ±3
Testing the Fuel Tank Vent Valve
Test for Normal Operation
1. Disconnect vent hose from fuel tank vent valve.
2. Connect a vacuum/pressure pump and a short
piece of hose to the fuel tank vent valve.
REQUIRED TOOL
VACUUM/PRESSURE
PUMP (P/N 529 021 800)
3. Remove fuel tank cap.

4. Set vacuum/pressure pump to PRESSURE and
activate pump. The gauge on the pump should
not change in reading; air should flow through
the vent valve and fuel tank freely.
vmr2006-020-052_c
If readings are out of specification, repeat test

at fuel pump connector. If resistance test at fuel
pump connector is not good, replace fuel level
sensor.
219100971-016 13
tmr2017-031-009_a
1. Air flows freely in through vent valve

2. Air flows out of fuel tank
5. Set vacuum/pressure pump to VACUUM and

activate pump. The gauge should not change
in reading; air should flow through the vent
valve and fuel tank freely.
tmr2017-031-009_b
1. Air is drawn out freely through vent valve

2. Air flows in fuel tank
Testing for Rollover Protection

1. Remove the fuel tank, refer to REMOVING THE
FUEL TANK in this subsection.
2. Turn the tank upside down.
3. Set vacuum/pressure pump to VACUUM and
activate pump. The vacuum gauge reading
should increase; air should not flow through
the valve.
The fuel tank vent valve is defective if air flows
freely through the valve when upside down and
the vacuum indication does not increase on the
pump gauge.
If the valve is defective, replace the fuel tank.
14 219100971-016
Subsection XX (EVAPORATIVE EMISSION CONTROL SYSTEM (EVAP))
EVAPORATIVE EMISSION CONTROL

SYSTEM (EVAP)
SERVICE TOOLS
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ........................................... 6

SNAP-ON SMOKE MACHINE ....................................................... EELD100 ........................................... 5
GENERAL
The evaporative emission control system (EVAP)
is designed to prevent fuel vapors from escaping
into the atmosphere.
When vehicle is at rest, fuel vapors accumulate in
the canister.
When engine is running in predetermined condi-
tions, the ECM controls the purge valve, allowing
the engine aspirate the fuel vapors through the in-
take manifold in order to burn them.
Fresh air is drawn at the other end of the canister
through a pre-filter.
NOTE: The illustrations in this document are from
a typical system and may not represent the exact
parts layout of the vehicle to be serviced.
219100914-001 1
TYPICAL PARTS IDENTIFICATION
219100914-001-100_a
CANISTER AREA
1. Canister purge hose (to canister port P)
2. Fuel tank vent hose (to canister port T)
3. Canister vent pre-filter
4. Canister vent hose inlet (To chassis)
5. Fuel tank vent hose (to fuel tank - rollover valve)
6. Canister purge hose (to intake manifold)
7. Purge valve wiring harness
8. Purge valve
9. Filter
10. Canister vent hose (to canister port A)
11. Canister
12. Check valve
2 219100914-001
219100914-001-101_a
FUEL TANK AREA

1. Fuel tank vent hose (to canister port T)
2. Y fitting
3. Check valve
4. Y fitting
5. Rollover valve
6. Fuel hose (to fuel injectors)
7. Pressure relief valve
219100914-001 3
SYSTEM SCHEMATIC
3
6 5
S
4 2
7
A P T
1
8
10
9
11
12
219100914-001-200
1. Fuel tank
2. Rollover valve
3. Pressure relief valve
4. Check valve
5. Filter
6. Purge valve
7. Check valve
8. Flow reducer (if equipped)
9. Engine intake manifold
10. Canister
11. Vent pre-filter
12. Vent hose
S: Solenoid
A: Vent port (to ambient air)
P: Purge port (to purge valve)
T: Vapor inlet port (to fuel tank)
4 219100914-001
MAINTENANCE
REPLACING THE CANISTER
VENT PRE-FILTER
To replace the pre-filter:
1. Remove the hose clamps.
219100914-001-006_a
2. Install the SNAP-ON SMOKE MACHINE

(P/N EELD100) or equivalent on the hose previ-
ously disconnected.
219100914-001-001_a
1. Clamps
2. Pre-filter
3. Install the pre-filter assembly with new Oetiker

clamps.
NOTE: Install the filter in the direction indicated
by the arrow in the illustration.
219100914-001-006_b
INSPECTION 1. Connect here
INSPECTING THE EVAP 3. Pinch the canister vent hose.

COMPONENTS
Check parts and hoses for:
– Proper rooting (ensure there is no kinks)
– Cracks or other damage
– Loose connections
– Clamps condition
TESTING THE FUEL SYSTEM

FOR LEAKS
1. Disconnect the fuel tank vent hose from the
rollover valve.
219100914-001-003_a
1. Pinch here
4. Pressurize the fuel system as per the following

specifications.
219100914-001 5
FUEL SYSTEM LEAK TEST The air must not pass through the purge valve. If
passes, replace the purge valve.
TIME WITHOUT
PRESSURE
PRESSURE DROP EVAP PURGE VALVE VACUUM
21 kPa (3 PSI) 30 seconds 20 kPa (3 PSI) for 10 seconds
If pressure drops, locate leak(s) and repair. If the valve cannot stand the vacuum applied for
If pressure does not drop, carry out a FUEL TANK 10 seconds, replace valve.
LEAK TEST. Refer to FUEL TANK AND FUEL If the valve stands the vacuum for 10 seconds,
PUMP subsection. continue as follows.
5. Reinstall purge hose with a new Oetiker clamp. 5. In BUDS2, select:
– Functions page
PROCEDURES – ECM button
– IO Controls tab
TESTING THE PURGE SOLENOID – Activate Purge valve.
VALVE 6. Follow the instructions on the screen to acti-
Before carrying out the following tests: vate the purge valve.
– Connect vehicle to the BRP diagnostic software You should feel it "clicking" and air should flow
(BUDS2) and check for purge valve related fault through the valve.
code(s). If the purge valve "clicks" but air does not flow,
– Make sure the fuse protecting the purge valve replace the purge valve.
is good. Refer to the appropriate WIRING DIA- If the purge valve doesn't not "click" and air
GRAM. doesn't flow, carry out: TESTING THE PURGE
VALVE SOLENOID.
Testing the Purge Valve Operation
1. Disconnect the purge hose on the intake mani- Testing the Purge Valve Solenoid
fold side. 1. Disconnect the purge valve connector.
2. Install the VACUUM/PRESSURE PUMP (P/N 529
021 800) on the purge hose.
219100914-001-004_a
2. Measure the resistance in the valve solenoid as

per following table.
219100914-001-005_a
PURGE VALVE SOLENOID TEST
1. Purge valve
2. Connect here RESISTANCE
10 to 20
@ 20°C (68°F)
3. Set vacuum/pressure pump to vacuum func-
tion. If the resistance is out of specification, replace the
4. Activate vacuum/pressure pump lever until vac- purge valve.
uum reaches the specification. If resistance is good, carry out TESTING PURGE
VALVE SUPPLY VOLTAGE.
6 219100914-001
Testing Purge Valve Supply Voltage

1. Disconnect the purge valve connector.
219100914-001-004_a
2. Activate the vehicle electrical system.

3. Refer to the appropriate WIRING DIAGRAM
and identify the positive (voltage supply) wire
of the purge valve harness.
4. Set multimeter to Vdc and test circuit voltage
as per following table.
VOLTAGE
TEST PROBES
(APPROXIMATE)
Purge solenoid
Chassis
voltage supply 12 to 14 Vdc
ground
pin
If voltage is not as specified, verify power sup-

ply wiring continuity. Refer to the appropriate
WIRING DIAGRAM for test points.
If voltage is good, verify wiring continuity in the
control circuit. Refer to the appropriate WIRING
DIAGRAM for test points.
REPLACING PARTS
For proper hose and parts connection, refer to
TYPICAL PARTS IDENTIFICATION and SYSTEM
SCHEMATIC.
Secure hoses with new Oetiker clamps.
Carry out TESTING THE FUEL SYSTEM FOR
LEAKS after any repair.
219100914-001 7
Subsection XX (POWER DISTRIBUTION AND GROUNDS)
POWER DISTRIBUTION AND GROUNDS

GENERAL Relays
Power distribution is shown in red on the color Relays and numbers are listed on the fuse box
wiring diagram. Refer to KNOWLEDGE CENTER. cover, in the TECHNICAL SPECIFICATIONS sub-
section and on the WIRING DIAGRAM.
OVERVIEW RELAY IDENTIFICATION
The battery is the primary source of power for the R3 Accessories
electrical system, it is recharged by the magneto. Relays
R8 Brake lights
Some components are permanently connected to
the battery (unswitched) while some require a re-
lay or switch to be closed (switched). Refer to the FUSE BOX 2
color WIRING DIAGRAM on KNOWLEDGE CEN- Fuse Box Location
TER.
The fuse box 2 is located behind the driver's seat.
At high RPM if the magneto power is greater
than the loads, the rectifier/regulator will regulate
power as necessary.
The system uses an external voltage regula-
tor/rectifier.
FUSE BOX 1
Fuse Box Location
219100971-017-001_a
Fuse Identification
Fuses and numbers are listed on the fuse box
cover, in the TECHNICAL SPECIFICATIONS sub-
PF2 FUSE IDENTIFICATION
219100971-017-002_a F4 Gauge 10 A
Ignition coils
Fuse Identification F5
Fuel injectors
10 A
Fuses and numbers are listed on the fuse box
F6 Engine control module (ECM) 10 A
section and on the WIRING DIAGRAM. Fuse F8
Ignition switch
10 A
Clock
F9 Radiator fan 25 A
F7 4WD actuator 10 A
F17 Intercooler fan 20 A
F11 Headlamps 20 A
EVAP
F12 Connectors (DC1 and DC3) 20 A F18 10A
Oxygen Sensor
Fuse
F14 Accessories 30 A
F16 Tail lamps 10 A
F23 Smartlok 20 A
219100971-017 1
Subsection XX (POWER DISTRIBUTION AND GROUNDS)
Relays GROUND LOCATIONS

Relays and numbers are listed on the fuse box C ha ssis
RELAY IDENTIFICATION
R1 Cooling fan
Relays R2 Main
R10 Intercooler fan
FUSE BOX 3
Fuse F2 DPS 40 A
tmr2017-032-003
REAR RIGHT SIDE OF VEHICLE

FUSIBLE LINKS TIGHTENING TORQUE
There are fusible links protecting power distribu- 4.5 N•m ± 0.5 N•m
tion to fuse box 1 (PF1) and fuse box 2 (PF2). Chassis ground screw
The fusible links are near the starter solenoid.
E ng ine
tmr2017-032-005_a
Fusible link gauge (AWG) varies by current capac- tmr2017-032-004
ity. NEAR OIL FILTER
FUSIBLE LINK IDENTIFICATION TIGHTENING TORQUE

FL-1 Main 16 AWG 9 N•m ± 1 N•m
Fusible link Engine ground screw
FL-2 Accessories 16 AWG
2 219100971-017
Subsection XX (WIRING HARNESSES AND CONNECTORS)
WIRING HARNESSES AND

CONNECTORS
SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 8
ECM TERMINAL REMOVER 2.25................................................. 529 036 175 ........................................... 8
ECM TERMINAL REMOVER 3.36................................................. 529 036 174 ........................................... 8

GM TERMINAL EXTRACTOR........................................................ 12094430 ........................................... 6
SNAP-ON TERMINAL REMOVER TOOL ...................................... TT600-4 ........................................... 10
219100971-018-003_a
219100971-018 1
219100971-018-001_a
2 219100971-018
GENERAL
WIRING HARNESS AND SPLICE LOCATION
The wiring harnesses and splice location illustrations are typical. Several variants of the connector types,
such as different number of pin cavities, are used on the vehicle. The wiring harnesses and splice loca-
tion illustrations are stored in the back cover pocket.
For engine harness, consult applicable ENGINE MANAGEMENT SYSTEM (EMS) subsection.
ACRONYMS ACRONYM DESCRIPTION
ACRONYM DESCRIPTION STSW Stop Switch
BD Multifunction Switch TLR Taillamp Right

TLL Taillamp Left
CI Cluster
DB Diagnostic Connector
PROCEDURES
DIFF Reverse Switch
DIFF ECO/Sport Switch DEUTSCH CONNECTORS
DPS1 Dynamic Power Steering Deutsch Connector Application
DPS2 Dynamic Power Steering A variety of Deutsch connectors are used on var-
DPS3 Dynamic Power Steering ious systems:
– Engine connector
EVAP EVAP
– Magneto connector.
FP Fuel Pump
The following procedures may be used on each as
FT Cooling Fan they are similar in construction.
LHL Left Headlamp
Deutsch Connector Removal from its
HIBM Hi Beam Support
HIC Harness interconnect 1. Insert a small flat screwdriver between the sup-
Harness interconnect port and the Deutsch connector.
HIC5MR
Right 2. Pry the connector away from the support
Harness interconnect slightly while sliding it out in the direction
HIC5ML shown.
Left
MODE 2WD/4WD
HO2S Oxygen Sensor
OVR DPS Switch
PF1 Fuse Box 1
PF2 Fuse Box 2
RHL Right Headlamp
Voltage
RD1
regulator/rectifier
SB Seatbelt
SIG_L Signature Light Left
SIG_R Signature Light Right smr2009-045-009_a
TYPICAL - MALE CONNECTOR REMOVED FOR CLARITY

SS Starter Solenoid 1. Insert screwdriver here
219100971-018 3
smr2009-045-010_a
F18Z0NA 2 1
TYPICAL - MALE CONNECTOR REMOVED FOR CLARITY
1. Insert screwdriver here TYPICAL
1. Deutsch connector
2. Press release button
Deutsch Connector Disconnect
1. To disconnect a Deutsch connector, press the 1
release tab and twist a small flat screwdriver
between the male and female housing to dis-
engage and disconnect them.
F18Z0LA 2
TYPICAL
1. Flat screwdriver
2
Deutsch Connector Disassembly and
F18Z0MA 1
Reassembly
TYPICAL
1. Release tab
3 1
3
2
4
F00H1CA
TYPICAL - DEUTSCH CONNECTOR

1. Male connector
2. Female connector
3. Secondary lock
4. Sealing cap
4 219100971-018
NOTICE Do not apply dielectric grease on ter- 3. Pry the retaining tab away from the terminal
minal inside connector. while gently pulling the wire and terminal out
of the back of the connector.
Terminal Removal
To remove terminals from connector, proceed as 1
follows:
1. Using long nose pliers, pull out the secondary
plastic lock from between the terminals.
V01G0QA 1
FEMALE CONNECTOR
1. Retaining tab
Terminal Insertion
1. For insertion of a terminal, ensure the sec-
ondary plastic lock is removed.
V01G0OA 1
2. Insert terminal through the back of the connec-
tor in the appropriate position, and push it in as
FEMALE CONNECTOR far as it will go. You should feel or hear the ter-
1. Female lock
minal lock engage.
3. Pull back on the terminal wire to be sure the
retention fingers are holding the terminal.
4. After all required terminals have been inserted,
the lock must be installed.
1 1
V01G0PA 1
MALE CONNECTOR
1. Male lock
F04H6LA
NOTE: Before pin extraction, push wire forward

CONNECTOR PIN-OUT
to relieve pressure on retaining tab. 1. Terminal position identification numbers
2. Insert a 4.8 mm (.189 in) wide screwdriver
blade inside the front of the terminal cavity.
219100971-018 5
FURUKAWA CONNECTOR
Furukawa Connector Application
Voltage regulator/rectifier.
Terminal Removal
1. Remove the secondary lock (plastic insert).
smr2010-050-023_a
Step 3: Pull wire to extract pin
NOTICE Before installing terminals in the

connectors, ensure all terminals are properly
crimped on the wires. After installation of the
wire terminals in the connectors, ensure they
are properly locked by gently pushing on them
smr2010-050-021_a as if to extract them.
Step 1: Remove the secondary lock
2. Carefully insert the GM TERMINAL EXTRACTOR MOLEX CONNECTOR

(P/N 12094430) between the lock and the pin to Molex Connector Application
release the pin.
The Molex connector is used on the ECM.
There are 2 MOLEX connectors on the ECM.
The engine wiring harness connector is con-
nected to ECM connector "A". The vehicle wiring
smr2010-052-003 harness connector is connected to ECM connec-
GM TERMINAL EXTRACTOR (P/N 12094430) tor "B".
Each ECM connector has 48 pins.
smr2009-027-005
ECM CONNECTORS
smr2010-050-022_a
Do not apply any product to the pins in the ECM
Step 2: Insert GM extractor tool (P/N 12094430)
connector.
3. Gently pull on the wire to extract the pin out the
back of the connector. Connector Removal
1. To access the ECM, refer to ELECTRONIC
FUEL INJECTION subsection.
2. Press and hold the locking tab on the connector
to be disconnected.
6 219100971-018
smr2009-045-013_b
smr2009-045-011_a
CONNECTOR LOCKING CAM IN RELEASE POSITION
LOCKING TAB TO PRESS AND HOLD
2. Insert connector on ECM.
3. As you hold the locking tab, rotate the connec-
tor locking cam until it stops. 3. As you push the connector onto the ECM, ro-
tate the connector locking cam until it snaps
locked.
smr2009-045-012_a
CONNECTOR LOCKING CAM ROTATION TO RELEASE
4. Pull connector off ECM. smr2009-045-011_b
1. Locked here
4. Ensure the locking tab is fully out.
smr2009-045-013_a
Connector Installation
1. Fully open connector locking cam.
219100971-018 7
529036166
1. Disconnect the ECM connector to be probed,

and reconnect it on the ECM adapter.
smr2009-045-011_a
2. Probe wire terminals of the circuit to be tested
LOCKING TAB FULLY OUT directly in the adapter holes.
Connector Inspection
Before replacing an ECM, always check electrical
connections.
1. Ensure connector locking mechanism is func-
tioning properly.
2. Ensure all wire terminals (pins) are properly
locked in the connector.
3. Ensure they are very tight, make good contact
with the pins in the ECM.
4. Ensure the pins in the harness connector vmr2008-139-016_a
and the ECM connector are clean, shiny and TYPICAL

corrosion-free. 1. ECM connector
2. ECM adapter
5. Check wiring harness for signs of scoring.
NOTICE Never probe directly on the ECM
NOTE: A “defective ECM module” could possi- harness connector. This could change the
bly be repaired simply by disconnecting and recon- shape or enlarge the terminals and create in-
necting it. termittent or permanent contact problems.
NOTICE Do not apply any lubricant product
to the pins of the ECM connector. Connector Terminal Removal (Harness
Connector)
Connector Probing To remove a signal terminal from the ECM har-
The most recommended and safest method to ness connector, use the ECM TERMINAL RE-
probe the MOLEX (ECM) connector terminals is MOVER 2.25 (P/N 529 036 175).
to use the ECM ADAPTER TOOL (P/N 529 036 166). To remove a power terminal, use the ECM TERMI-
This tool will prevent deforming or enlarging of NAL REMOVER 3.36 (P/N 529 036 174).
the terminals, which would lead to bad ECM ter-
minal contact creating intermittent or permanent
problems.
8 219100971-018
529036175
1. Remove rear protector from connector.

2. Pull out the connector lock.
smr2009-045-027_a
NOTICE Before installing wire terminals in

the connector, 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.
PACKARD CONNECTORS
Packard Connector Application
Packard connectors are used to connect:
– Electrical harnesses
smr2009-045-025_a
– Gauges
3. Insert tool to unlock terminal. – VCM
– EFB
– Headlamps.
3-Pin Packard Connector
smr2009-045-026_a
1. Unlock here C B A
4. Gently pull on the wire to extract the terminal

out the back of the connector.
F04H45A
VIEW OF A 3-PIN PACKARD CONNECTOR

1. Identification letters
NOTE: This type of connector also comes in other

pin configurations.
219100971-018 9
To remove a terminal from a 3-pin Packard connec-

tor, use the SNAP-ON TERMINAL REMOVER TOOL
(P/N TT600-4).
F01B1JA
WARNING
Ensure all terminals are properly crimped on
wires and connectors are properly fastened.
PACKARD CONNECTOR
(MULTIFUNCTION GAUGE)
Firmly push down tab and hold to unlock connec-
tor while pulling it out. vmr2006-032-001_b
CONNECTOR PINOUT
Push on both tabs to remove retainer.
A33Z01A 2 1
TYPICAL
vmr2006-032-001_a 1. Retainer
2. Tab (one on each side)
Open housing by lifting 4 tabs.
A33Z02A 1
TYPICAL
1. Tabs (2 on each side)
10 219100971-018
Lift the top plastic lock of the female terminal to

be removed and hold in position. Lift the female
terminal to unlock from the housing and push out
of housing.
1 A32E2RA
INSTALLATION OF TERMINAL
Follow the instructions provided with the (P/N 529

035 730) to select the proper position of the tool.
529035730
2
NOTE: Different wires require different crimping
pliers settings.
A32E3XA
TYPICAL
1. Lift and hold plastic lock
2. Lift to unlock and push out
BATTERY AND STARTER CABLE 1

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.
2
A32E2SA
POSITIONING THE CRIMPING PLIERS

Step 1: Press
Step 2: Rotate
After positioning the crimping pliers, crimp the ter-

A minal already installed on wire.
A32E2QA
A. 10 mm (3/8 in)
NOTE: Make sure not to cut wire strands while

stripping the wire.
Install the appropriate terminal on the wire ac-
cording to the requirement. Refer to appropriate
PARTS CATALOG.
219100971-018 11
3. To repair a splice, we recommend the use of a

tin solder meeting the followings requirements
or an equivalent.
TIN SOLDER REQUIREMENTS
SN 60
PB 40
DIA 0.062
FLUX RA 2%
CASE 1: Wire Detached from Splice

WARNING
A32E2TA
Repairs described in this section should
CRIMPING OF WIRE never be performed on harness sections that
can be exposed to water.
1. Locate splice. Refer to splices location dia-

grams.
2. Remove wires from protector tube.
3. Locate the shrink tube protecting the defective
splice.
A32E2UA
PROPERLY CRIMPED WIRE
To verify, if the wire is properly crimped, apply

some pulling force on wire and the terminal at the
same time from both directions.
NOTICE Never weld the wire to the terminal.
Welding can change the property of the wire
and it can become brittle and break.
Install the protective heat shrink rubber tube on mmr2010-043-001_a
the terminal. Heat the heat shrink rubber tube us- 1. Shrink tube
ing the heat gun so that it grasps the wire and the
terminal. 4. Remove the shrink tube.
4.1 Using a blade, cut the shrink tube.
NOTICE Make sure that the protective heat
shrink rubber tube has been properly installed
and no part of wire is exposed.
SPLICES REPAIR PROCEDURE

This section gives the procedures in order to
quickly repair electrical harness splices.
1. Make sure to perform the usual tests described
in ELECTRICAL SYSTEM sections before inves- mmr2010-043-002
tigating the harness splices. NOTICE Be careful with the blade to

2. If an electrical issue can not be found with the avoid cutting wires insulation.
usual tests, locate the main harness splice that
is involved in the faulty circuit and repair it as 4.2 Slightly heat the shrink tube using a heat
described further in this section. gun.
12 219100971-018
CASE 2: Wire Broken from Splice

WARNING
never be performed on harness sections that

grams.
mmr2010-043-003 2. Remove wires from protector tube.
4.3 Remove the shrink tube with long nose pli- 3. Locate the shrink tube protecting the defective
ers. splice.
5. Locate detached wire from splice.
mmr2010-043-001_a
1. Shrink tube
4. Remove the shrink tube.

mbg2008-021-116_a
1. Detached wire
2. Splice
6. Twist detached wire around splice.
mmr2010-043-002
NOTICE Be careful with the blade to

avoid cutting wires insulation.
4.2 Slightly heat the shrink tube using a heat
gun.
mbg2008-021-117_a
1. Twisted wire
7. Perform a tin solder on twisted wire.

8. Apply electrical tape to cover splice.
NOTE: Make sure tape overlaps on wire insula-
tion, approximately 13 mm (1/2 in) each side.
9. Reinstall wires into protector tube.
mmr2010-043-003
219100971-018 13
4.3 Remove the shrink tube with long nose pli- 11. Reinstall wires into protector tube.
ers. NOTE: Always perform a solder on a bigger wire
5. Locate broken wire from splice. (lower gage).
mbg2008-021-118_a
1. Broken wire
2. Splice
6. Strip wire insulation at the end of broken wire.

7. Strip wire insulation below the splice.
mbg2008-021-119_a
1. Broken wire stripped

2. Splice wire stripped
8. Twist wire around stripped wire.
mbg2008-021-120_a
1. Twisted wire

14 219100971-018
Subsection XX (IGNITION COILS AND SPARK PLUGS)
IGNITION COILS AND SPARK PLUGS

SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 3
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 2–3
SERVICE PRODUCTS
HEAT-SINK PASTE P12.................................................................. 420 897 186 ............................................. 5
GENERAL Remove rear service cover.

WARNING
must be strictly adhered to.
tabs, elastic stop nuts, self-locking fasteners,

procedure must be reinstalled as per factory stan-
dards.
WARNING
tmr2017-034-001
Never check for engine ignition spark from
an open coil and/or spark plug as spark may Remove intercooler screws.
cause potential fuel vapors to ignite. Always
use an approved spark tester.
PROCEDURES
IGNITION COILS
Ignition Coil Access
Remove the following parts and fasteners.
tmr2017-034-007
tmr2017-034-009
tmr2017-034 1
tmr2017-034-702_a tmr2017-034-004_a
1. Intercooler assembly
2. Intercooler fan connector
Testing the Ignition Coil

1. Connect to BRP diagnostic software. Refer to
COMMUNICATION TOOLS subsection.
2. Select the Function and ECM tabs.
3. Energize the ignition coil to be tested.
You should hear the spark occurring. If in doubt,
use a sealed vapor proof spark tester or an induc-
tive spark tester as available from tool suppliers,
to prevent a spark from occurring.
tmr2017-034-703_a
If there is no ignition at one or more coils, carry out
Disconnect intercooler hose. TESTING THE IGNITION COIL INPUT VOLTAGE.
If spark is weak, try a new spark plug. If spark is
still weak, try a new ignition coil.
NOTE: The voltage required to produce a spark in
the combustion chamber is higher when the en-
gine is running.
Testing the Ignition Coil Input Voltage

Make sure fuse F5 and the relay are good before
testing.
1. Disconnect the applicable ignition coil connec-
tor.
2. Install key on the D.E.S.S. post.
tmr2017-034-006
3. Set multimeter to Vdc.
Lift intercooler assembly.
REQUIRED TOOL
Disconnect intercooler fan connector.
Set intercooler aside. FLUKE 115 MULTIMETER
(P/N 529 035 868)
4. Press the START/STOP button to activate the

ECM.
NOTE: Do not press the brake pedal.
5. Measure voltage.
2 tmr2017-034
TEST PROBES VOLTAGE Testing the Ignition Coil Control Circuit

Continuity
Ignition coil connector
Pin 1 (ignition coil no. 1) 1. Disconnect ECM connector "A". For connector
identification, refer to WIRING HARNESS AND
Ignition coil connector Battery Battery
Pin 1 (ignition coil no. 2) ground voltage
CONNECTOR subsection.
2. Connect ECM connector to ECM adapter tool.
Ignition coil connector
Pin 1 (ignition coil no. 3) REQUIRED TOOL
ECM ADAPTER TOOL

(P/N 529 036 166)
3. Disconnect ignition coil connector.

4. Test for continuity of circuit as per following ta-
ble.
IGNITION ECM
PIN RESISTANCE
COIL ADAPTER
Cylinder 1 A-M4
Close to 0
Cylinder 2 1 A-M2
(continuity)
tmr2017-034-002_a
Cylinder 3 A-M1
IGNITION COIL INPUT VOLTAGE TEST
If test succeeds, carry out a TESTING THE IGNI-

TION COIL RESISTANCE.
If test fails, carry out a TESTING THE IGNITION
COIL POWER CIRCUIT CONTINUITY.
Testing the Ignition Coil Power Circuit
Continuity
1. Set multimeter to .
REQUIRED TOOL

(P/N 529 035 868) tmr2017-034-002_b
IGNITION COIL CONTROL CIRCUIT TEST
2. Read resistance of the desired ignition coil cir- If test fails, repair the connector or replace the en-
cuit. gine wiring harness.
IGNITION FUSE Testing the Ignition Coil Resistance
PIN MEASUREMENT
COIL BOX
An ignition coil with a good resistance measure-
1 ment can still be faulty. Current leakage can occur
Terminal at high voltage levels which is not detectable with
2 2 Close to 0
B4
an ohmmeter. Replacing the ignition coil may be
3
necessary as a test.
If test fails at any ignition coil, test the following 1. Remove ignition coil. Refer to REMOVING THE
items separately and repair/replace wiring or ter- IGNITION COIL in this subsection.
minals from fuse box to the applicable ignition coil. 2. Perform a visual inspection of the ignition coils.
Refer to WIRING DIAGRAM for details. Check for corrosion, bent pins, loose or burnt
– Wiring from fuse box to engine connector contacts, and cracked or torn insulator.
– Wiring from engine connector to ignition coil.
tmr2017-034 3
3. Using a multimeter, test the resistance of pri-

mary winding.
smr2014-032-012_a
PRIMARY WINDING
tmr2017-019-002_a
RESISTANCE @ 1. Retaining screws
CIRCUIT TERMINAL
20°C (68°F) 2. Ground connectors
3. Ignition coil connectors
Primary
1 and 2 0.85 - 1.15 NOTICE Do not pry on ignition coil with a
winding
tool.
NOTICE The secondary winding on this type
4. Remove ignition coils with gaskets from spark
of ignition coil cannot be tested.
plug by rotating coil side to side as you pull up.
If test fails, replace ignition coil.
If test succeeds, carry out TESTING THE IGNI-
TION COIL CONTROL CIRCUIT CONTINUITY.
Removing the Ignition Coil
1. Unplug CAPS (camshaft position sensor).
tmr2017-019-003_a
1. Ignition coils
2. Gaskets
Installing the Ignition Coil

Install the ignition coil on the spark plug.
Align the retaining screw hole of the ignition coil
tmr2017-019-001_a
with the threaded hole on the valve cover.
2. Remove: Push the ignition coil all the way down until it rests
– Ignition coil retaining screws. on the valve cover.
– Ground connector. Install and tighten retaining screw.
3. Disconnect ignition coil connectors. TIGHTENING TORQUE
Ignition coil retaining 9 N•m ± 1 N•m
Connect ignition coil connectors.

Reinstall all removed or disconnected compo-
nents.
4 tmr2017-034
SPARK PLUGS The plug face of a fouled spark plug has either a
wet or dry black carbon deposit. Such coatings
Removing the Spark Plugs form a conductive connection between the center
1. Remove ignition coils. electrode and the ground electrode.
2. Using a spark plug socket, release the torque
applied to the spark plug.
Spark Plug Analysis
1 2
A00E0AA 1 2 3
TYPICAL
1. Overheated (light gray, white)
2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, gray, melted coating)
A00E0BA
The plug face reveals the condition of the engine,
1. Approved socket operating condition, method of driving and fuel
2. Improper socket
mixture. For this reason it is advisable to inspect
3. Clean the spark plug area with pressurized air. the spark plug at prescribed intervals, examining
the plug face (i.e. the part of the plug projecting
4. Unscrew spark plug. into the combustion chamber).
5. Use the ignition coil to take spark plug out of
spark plug hole. Installing the Spark Plug
Prior to installation make sure that contact sur-
faces of the cylinder head and spark plug are free
of grime.
1. Using a wire feeler gauge, set electrode gap as
specified in TECHNICAL SPECIFICATIONS.
2. Hand screw spark plug into cylinder head, then
tighten with a torque wrench and an appropri-
ate socket.
TIGHTENING TORQUE
HEAT-SINK PASTE P12
Service product
(P/N 420 897 186)
11 N•m ± 1 N•m
tmr2017-007-003_a Spark plug
1. Ignition coil
2. Spark plug
3. Install ignition coil.
Troubleshooting a Fouled Spark Plug
Fouling of the spark plug is indicated by irregular
running or misfiring of the engine, decreased
engine speed due to misfiring, reduced perfor-
mance, and increased fuel consumption.
Other possible causes are: use of an incorrect
or bad fuel, defective ignition system, incorrect
spark plug gap, loss of compression, or lubricating
oil entering the combustion chamber.
tmr2017-034 5
Subsection XX (IGNITION SYSTEM)
IGNITION SYSTEM
SERVICE TOOLS
D.E.S.S. POST REMOVER ............................................................ 529 035 943 ........................................... 3
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ........................................... 1
GENERAL
The following tool is required to test most of the
electrical parts.
REQUIRED TOOL

(P/N 529 035 868)
WARNING
Torque wrench tightening specifications tmr2017-019-001_b
must be strictly adhered to. IGNITION COILS

When a ground signal is provided by the ECM to
tabs, elastic stop nuts, self-locking fasteners,
an ignition coil primary winding, a high voltage is
induced in the coil secondary winding that is used
to produce a spark at the spark plug electrode.
procedure must be reinstalled as per factory stan- Cylinder 1 is located on the PTO side of the en-
dards. gine. Each cylinder is identified by a number on
cylinder block housing.
WARNING
Never check for engine ignition spark from
an open coil and/or spark plug as spark may
cause potential fuel vapors to ignite. Always
use an approved spark tester.
SYSTEM DESCRIPTION
The ignition system is a digital inductive type (IDI)
system.
Ignition system parameters such as ignition tim-
ing, spark duration, and firing order, as well as
many other engine related functions are con-
trolled by the engine management system (EMS) tmr2017-034-001_a
in order to meet engine operational requirements. CYLINDER BLOCK - EXHAUST SIDE

The EMS can detect many abnormalities includ-
ing a short circuit in the primary winding of the Ignition Timing
ignition coils as well as its associated circuits. Ignition timing is not adjustable.
Three direct ignition coils receive power from the The ECM is programmed with data (ignition map-
fuse F5. pings) that it uses to establish optimum ignition
timing under all engine operating conditions.
219100971-019 1
It receives signals from a variety of sensors that Testing Ignition System

it compares with the ignition mappings and uses Check for fault codes using BUDS2 software as a
it to control the ignition spark timing, duration and first troubleshooting step. Refer to DIAGNOSTIC
firing order. SYSTEM AND FAULT CODES subsection.
The firing of each spark plug is independent of the Ensure fuse F5 and relay are powered and in good
others. condition.
Engine RPM Limiter If a fuse is burnt, test for a short circuit or faulty
component on that fuse circuit before replacing
The ECM will limit the maximum engine speed by the fuse.
cutting off ignition spark and fuel at a predeter-
mined engine RPM. Check ignition spark, refer to TESTING THE IGNI-
TION COIL WITH BUDS2. in this subsection.
ENGINE SPEED LIMITER
8300 RPM
SETTING
DIAGNOSTIC GUIDELINES
Knock Sensor The following is provided to help in diagnosing the
probable cause of a problem. It is a guideline and
A knock sensor is mounted on the cylinder block
should not be assumed to list all possible causes.
below the exhaust manifold. It detects specific vi-
brations that would typically be generated by en- ENGINE WILL NOT STOP WHEN
gine detonation. REMOVING KEY FROM D.E.S.S. POST
If detonation occurs, the knock sensor detects
1. Defective D.E.S.S. post
it and the ECM goes into a specific operating
mode whereby it temporarily retards the ignition - Check D.E.S.S. post. Replace if necessary.
advance until detonation stops.
ENGINE WILL NOT START (ENGINE
The ECM is able to identify in which cylinder the TURNS OVER)
knocking occurs and modifies the ignition advance
on that cylinder only. 1. Fouled or defective spark plug
- Check spark plug condition. Replace if necessary.
Refer to the ELECTRONIC FUEL INJECTION
(EFI) subsection for testing and replacement pro- 2. Defective CPS
cedures. - Test CPS, refer to ELECTRONIC FUEL INJEC-
TION (EFI) subsection.
TROUBLESHOOTING 3. Defective trigger wheel
It is good practice to check for fault codes using - Check. Refer to MAGNETO AND STARTER sub-
the BUDS2 as a first troubleshooting step. Refer section.
to DIAGNOSTIC AND FAULT CODES subsection. 4. Defective ignition circuit
Refer to POWER DISTRIBUTION AND GROUNDS - Check fuses, ignition coils, wiring and connec-
for fuses and relay information. tors.
Always refer to the WIRING DIAGRAM when ENGINE HARD TO START
troubleshooting an electrical circuit.
1. Faulty, fouled or worn out spark plug
IGNITION SYSTEM TESTING - Check spark plug condition. Replace if necessary.
The ECM controls the ignition system. 2. Drowned engine

If a fault is detected by the ECM, the check engine - Check engine temperature value using B.U.D.S.2
measurements page. If the temperature read is
light will turn on. lower than the ambient temperature, CTS sen-
The ECM can detect a problem on the primary sor may be defective or have a bad connection.
winding or circuit of the ignition coils. Therefore, the ECM would erroneously set the
engine in cold start mode and it could flood the
The secondary winding of the ignition coils is not spark plugs.
monitored by the ECM.
Other sensors in relation with the ignition system
are also monitored by the ECM.
2 219100971-019
ENGINE MISFIRES, RUNS IRREGULARLY START/STOP BUTTON

1. Fouled, defective, worn spark plugs Start/stop Button Wire Identification
- Check spark plug condition. Replace if necessary.
FUNCTION PIN COLOR
2. Damaged trigger wheel/loose CPS
12 volt input from F8 1 BG/WH
- Check. Refer to MAGNETO AND STARTER sub-
section. 12 volt output to ECM-B
2 BK/YE
pin D1
3. Defective ignition circuit
- Check fuses, ignition coils, wiring and connec-
tors. Start/Stop Button Test with BUDS2
Connect to BUDS2 software. Refer to COMMU-
4. Poor engine grounds
NICATION TOOLS AND B.U.D.S. subsection.
- Check ground condition, refer to POWER DISTRI-
BUTION AND GROUNDS subsection. Select the Measurements and ECM tabs.
Press the vehicle's start button and look at the
ENGINE CONTINUALLY BACKFIRES Start Button LED.
1. Fouled, defective spark plugs It should turn on, indicating the start signal
- Check spark plug condition. Replace if necessary. reaches the ECM.
2. Damaged trigger wheel/defective or loose CPS If it does not turn on, check the start button and
- Check, refer to MAGNETO AND STARTER and wiring.
ELECTRONIC FUEL INJECTION (EFI) subsec-
tions. Start/Stop Button Resistance Test
Disconnect start/stop button connector.
ENGINE DETONATION OR PINGING
Using a multimeter, measure resistance as per the
1. Faulty or disconnected knock sensor following table.
- Check, refer to ELECTRONIC FUEL INJECTION
(EFI) subsection. START BUTTON
POSITION RESISTANCE
CONNECTOR PIN
ENGINE LACKS ACCELERATION OR Switch
POWER Infinite (OL)
released
1. Weak spark Switch 1 2
- Check spark plugs, coils, wiring and connections. depressed 0.6 max.
and held
PROCEDURES Replace start/stop button if defective.
D.E.S.S. POST
Testing Continuity of D.E.S.S. post
Refer to RADIO FREQUENCY DIGITALLY EN-
CODED SECURITY SYSTEM (RF D.E.S.S.)sub-
section.
Replacing the D.E.S.S. post

REQUIRED TOOL
D.E.S.S. POST
REMOVER (P/N 529
035 943)
219100971-019 3
Subsection XX (CHARGING SYSTEM)
CHARGING SYSTEM
EXTECH INDUCTIVE AMMETER .................................................. 380941 ............................................. 2
NAPA ULTRA PRO BATTERY LOAD TESTER ............................... 95260 ......................................... 2–4
GENERAL
SYSTEM DESCRIPTION
The purpose of the charging system is to keep
the battery at a full state of charge and to provide
the electrical system with the required electrical
power for normal vehicle operation.
Magneto
The magneto is the primary source of electrical rmr2010-027-004
energy. It transforms magnetic field into electric TYPICAL – VOLTAGE REGULATOR/RECTIFIER
current (AC).
The magneto has a 3 phase series stator. Battery
The battery supplies DC power to the electric
starter for cranking the engine. During engine
starting, it also supplies DC power to the entire
electrical system.
At low engine RPM operation and high current
load conditions, it supplements the magneto
output and helps to maintain a steady system
voltage.
INSPECTION
CHARGING SYSTEM OUTPUT
First ensure that battery is in good condition prior
to performing the following tests.
vmr2006-017-001
Testing the Output Voltage.
TYPICAL
Voltage Regulator/Rectifier ware (BUDS2).
The rectifier receives AC current from the mag- In BUDS2, go to:
neto and transforms it into direct current (DC). – Measurements page
The voltage regulator, included in the same unit, – ECM button
limits voltage to prevent any damage to electrical – Battery voltage (V)
components. 2. Start engine.
3. Increase engine RPM as specified in the follow-
ing table.
219100903-007 1
OUTPUT VOLTAGE TEST USING BUDS2 TEST CONDITIONS

ENGINE SPEED VOLTAGE (DC) Initial battery voltage‡ Above 12.5 Vdc
4000 RPM 14.8 ± .4 Vdc Engine OFF
3 times the amp-hour
If voltage is above specification, replace voltage Load
(AH) rating
regulator/rectifier.
Time 15 seconds
If voltage is below specification, check stator
output and wiring harness prior to concluding that ‡ Required for accurate testing
voltage regulator/rectifier is defective. Refer to
MAGNETO SYSTEM subsection. SPECIFICATION
Battery Above 9.6 Vdc
TROUBLESHOOTING
If battery voltage drops below specification during
It is good practice to check for fault codes using test, replace battery. Procede to LOAD TESTING
the BUDS2 software as a first troubleshoot- THE CHARGING SYSTEM.
ing step. Refer to DIAGNOSTIC SYSTEM AND
FAULT CODES subsection.
LOAD TESTING THE CHARGING
BATTERY REGULARLY DISCHARGED OR SYSTEM
WEAK
1. Loose or corroded battery cables connections.
+
- Tighten or repair battery cables connections. RD
RD1 -
+
2. Worn or defective battery.
- Charge and test battery.
3. Defective magneto stator.
- Test stator.
4. Defective regulator/rectifier. -
RD2
- Test system voltage.
vmr2015-134-001_a
5. Damaged magneto rotor or Woodruff key.
- Replace magneto rotor or Woodruff key. 1. Connect a battery load tester such as the NAPA
ULTRA PRO BATTERY LOAD TESTER (P/N 95260).
PROCEDURES 2. Start vehicle and read voltage on tester.
SPECIFICATION
VOLTAGE REGULATOR WIRE
IDENTIFICATION Voltage 12.5 - 15 Vdc
FUNCTION PIN COLOR If voltage is above specification, replace regulator

and continue the procedure.
12 Vdc output RD1-1 RD
3. Connect an ammeter such as EXTECH INDUC-
12 Vdc ground RD1-3 BK
TIVE AMMETER (P/N 380941) around RD1-1 wire.
12 Vac input RD2-1 YE
LOAD TESTING THE BATTERY

1. Connect a battery load tester such as the NAPA
2. Ensure proper test conditions.
2 219100903-007
tmr2017-035-001
tmr2015-036-002_a
DC CURRENT TEST WITH INDUCTIVE AMMETER

1. Output connector of voltage regulator Voltage Regulator Power Test
2. Ammeter clamped over RED wire
1. Check voltage at RD1-1.
TEST CONDITIONS +
RD
Battery voltage at idle‡ Above 12.6 Vdc RD1 -
+
Engine Increase to 4000 RPM
As required to decrease
Load
battery voltage to 12 Vdc
Time 15 seconds
-
‡ Required for accurate testing RD2
5. Read amperage on ammeter. vmr2015-134-003_a
MODEL SPECIFICATION TEST CONDITIONS

All models 50 ± 5 Amps RD1-1 Hot at all times
NOTE: With a fully charged battery and no electri- BACKPROBE PROBE SPECIFICATION
cal loads, specification is less than 10A. RD1-1 BAT2 (-) Battery voltage
If amperage or voltage is not within specification,
verify magneto and wires. Refer to MAGNETO 2. Connect a battery load tester such as the NAPA
AND STARTER subsection. ULTRA PRO BATTERY LOAD TESTER (P/N 95260).
– Replace voltage regulator if magneto test is 3. Start vehicle.
within specifications. 4. Ensure proper test conditions.
– Replace magneto if magneto test is not within
specifications. TEST CONDITIONS
Battery voltage at idle‡ Above 12.6 Vdc
VOLTAGE REGULATOR (RD) Engine Increase to 4000 RPM
Voltage Regulator Continuity Test As required to decrease
Load
Due to internal circuitry, there is no static test battery voltage to 12 Vdc
available. Time 15 seconds
Accessing the Voltage Regulator ‡ Required for accurate testing

The voltage regulator is located on the RH side,in 5. Measure voltage drop.
front of the engine.
219100903-007 3
+ +
RD RD
RD1 - RD1 -
+
- -
RD2 RD2
vmr2015-134-004_a vmr2015-134-006_a
BACKPROBE PROBE SPECIFICATION BACKPROBE PROBE SPECIFICATION

RD1-1 BAT1 (+) Under 0.2 Vdc RD1-3 BAT2 (-) Under 0.4 Vdc
If voltage drop is above specification, locate and If voltage drop is above specification, locate and
repair damaged connector/wire. repair damaged connector/wire.
Voltage Regulator Ground Test BATTERY

1. Check ground at RD1-3.
Battery Information
These vehicles are equipped with a VRLA battery
+ (Valve Regulated Lead Acid). It is a maintenance-
RD
RD1 - free type battery.
+
Refer to battery manufacturer's instructions for

proper filling, activation and routine charging pro-
cedures.
Accessing the Battery

-
RD2 The battery is located on the RH side, behind the
passenger seat.
vmr2015-134-005_a
TEST CONDITIONS
RD1-3 Permanent ground
BACKPROBE PROBE SPECIFICATION

RD1-3 BAT1 (+) Battery voltage
2. Connect a battery load tester such as the NAPA

3. Start vehicle.
tmr2017-035-002
TEST CONDITIONS
Battery voltage at idle‡ Above 12.6 Vdc Removing the Battery
Engine Increase to 4000 RPM 1. Disconnect BLACK (-) cable first, then the RED
As required to decrease (+) cable.
Load
battery voltage to 12 Vdc NOTICE Always respect this order for re-
Time 15 seconds moval; disconnect BLACK (-) cable first.
‡ Required for accurate testing 2. Remove battery holder retaining screws.
5. Measure voltage drop. 3. Remove battery holder.
4 219100903-007
4. Remove battery. NOTICE If battery becomes hot, stop charg-

ing and allow it to cool before continuing.
Cleaning the Battery
NOTE: Sealed VRLA batteries have an internal
Clean the battery rack, cables and battery posts safety valve. If battery pressure increases due to
using a solution of baking soda and water. overcharging, the valve opens to release excess
Remove corrosion (if so) from battery cable ter- pressure, preventing battery damage.
minals and battery posts using a firm wire brush. An automatic charger is a fast and convenient way
Rinse with clear water and dry well. for error-proof charging.
Inspecting the Battery Always follow the battery manufacturer's charg-
ing instructions.
Visually inspect battery casing for cracks or any
other damages. If casing is damaged, replace bat- When using a constant current charger, charge
tery and thoroughly clean battery support with a battery according to the chart below.
water and baking soda solution. Battery Voltage Below 12.8 V and Above 11.5
Inspect condition of battery posts, battery sup- V
port, holding strap and strap attachment points
STANDARD CHARGING
and wire terminal lugs. (RECOMMENDED)
Battery Storage BATTERY
TIME CHARGE
TYPE
It is not necessary to remove the battery during
vehicle storage but it is recommended for long YTX20L-BS 4 - 9 HOURS 2 A
term storage.
If the battery is left in the vehicle during storage or QUICK CHARGING
used infrequently, disconnect the BLACK (-) nega- BATTERY
TIME CHARGE
tive battery cable to eliminate battery current drain TYPE
from the electrical equipment. YTX20L-BS 50 MINUTES 10 A
Recharge the battery once a month with an ap-
proved battery charger as per manufacturer's rec- Installing the Battery
ommendations.
Clean battery, battery support and connections as NOTICE Always connect RED (+) cable first
required, refer to CLEANING THE BATTERY in this then BLACK (-) cable.
section. Installation is the reverse of removal procedure,
For other recommendations during storage, refer however pay attention to the following:
to battery manufacturers instructions. – Tighten battery holder retaining nut to specifica-
tion.
WARNING
TIGHTENING TORQUE
Ensure battery is stored in a safe place, out of
reach for children. Battery holder retaining 5 N•m ± 1 N•m
nut (44 lbf•in ± 9 lbf•in)
Activating a New Battery
Refer to the instructions provided with the battery.
Charging the Battery

WARNING
Always wear safety glasses and charge in a
well ventilated area. Never charge or boost a
battery while it is installed on vehicle. Do not
open the sealed cap during charging. Do not
place battery near open flame.
219100903-007 5
Subsection XX (STARTING SYSTEM)
STARTING SYSTEM
SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 1
GENERAL Check all connections, cables and wires. Tighten

any loose connections. Replace any chafed or cor-
REQUIRED TOOL roded wires/cables.
FLUKE 115 MULTIMETER DIAGNOSTIC GUIDELINES

(P/N 529 035 868)
FUSE 8 IN FUSE BOX 2 BURNS WHILE
ATTEMPTING TO CRANK ENGINE
1. Defective D2 Diode
ECM ADAPTER TOOL
(P/N 529 036 166) - Test diode, see procedure in this subsection.
2. Defective starter solenoid
- Test starter solenoid, see procedure in this sub-
section.
SYSTEM DESCRIPTION
3. Wiring short to ground
The starting system is composed of an electric
- Check wiring.
starter supplied in current by the battery through
a solenoid. ENGINE DOES NOT CRANK AND GAUGE
The starter solenoid receives a 12 volt input from DOES NOT TURN ON
the ignition switch and the ground signal is pro-
1. Burnt main fuse (F4) in fuse box 2
vided by the ECM when the following engine
cranking conditions are met. - Check fuse.
– Ignition switch ON. 2. Burnt fuse F8 in fuse box 2
– Transmission in Park or Neutral position and/or - Check fuse.
brake pedal held.
3. Defective or discharged battery
– Start button held.
- Test battery, refer to CHARGING SYSTEM sub-
NOTE: If the ignition switch is left ON for more section.
than 15 minutes, engine will not start unless igni-
4. Defective ignition switch or circuit
tion switch is turned OFF, then ON again.
- Check ignition switch, refer to IGNITION SYS-
TEM subsection.
TROUBLESHOOTING
ENGINE DOES NOT CRANK BUT GAUGE
It is good practice to check for fault codes using
TURNS ON
the BUDS2 software as a first troubleshooting
step. Refer to DIAGNOSTIC AND FAULT CODES 1. Defective brake switch
subsection. - Check brake switch, refer to BRAKES subsection.
NOTE: Clear any fault code after solving a prob- 2. Defective gearbox position sensor (GPBS)
lem.
- Check GPBS, refer to GEARBOX AND 4X4 COU-
Always refer to the WIRING DIAGRAM when PLING UNIT subsection.
troubleshooting an electrical circuit.
3. Defective START/STOP button or circuit
Refer to POWER DISTRIBUTION AND GROUNDS - Test START/STOP button, see procedure in this
for fuse and relay information. subsection.
219100971-020 1
4. Defective starter solenoid or circuit STARTER SOLENOID

- Test starter solenoid, see procedure in this sub-
section. Starter Solenoid Access
5. Defective starter motor The starter solenoid is located on the RH side, be-
hind the passenger seat.
- Check starter motor, refer to MAGNETO AND
STARTER subsection.
Starter Solenoid Wire Identification
PROCEDURES FUNCTION PIN
WIRE
COLOR
START/STOP BUTTON 12 volt input from
SS1 BK/YE
ignition switch
START/STOP Button Wire
Ground from ECM-B
Identification pin L4
SS2 OG/BN
FUNCTION PIN COLOR
12 volt input from fuse F8 1 BG/WH Testing the Starter Solenoid Operation
12 volt output to ECM-B
2 BK/YE
pin D1
+
Testing the START/STOP Button with -
BUDS2
ware (BUDS2).
Go to:
– Measurements page
– ECM button
– ECM Basic tab
The Start Switch value should turn on, indicat- vmr2015-135-001_a
ing the start signal reaches the ECM when the

START/STOP button is pressed. 1. Disconnect connector
If it does not turn on, check the START/STOP but-
ton and wiring.
START/STOP Button Resistance Test

Disconnect START/STOP button connector.
Using a multimeter, measure resistance as per the
following table.
START BUTTON
POSITION RESISTANCE
CONNECTOR PIN
Switch
Infinite (OL)
released
Switch 1 2
depressed 0.6 max.
and held
Replace START/STOP button if defective.
tmr2017-036-003
2 219100971-020
2. Activate the starter solenoid. STARTER SOLENOID INPUT VOLTAGE TEST

2.1 Apply 12Vdc to SS1 RESULT
2.2 Ground SS2. TEST PROBES (START BUTTON
RELEASED)
BK/YE wire Battery ground Battery voltage
Testing the Starter Solenoid Ground

Signal
1. Disconnect connector.
tmr2017-036-004_b
SS1 IS THE LEFT
If starter runs, carry out the TESTING THE

STARTER SOLENOID INPUT VOLTAGE.
If starter does not run, carry out the TESTING THE
STARTER SOLENOID WINDING RESISTANCE.
Testing the Starter Solenoid Input
Voltage
1. Disconnect connector.
tmr2017-036-003
2. Wake up the ECM by installing the D.E.S.S.

key on the D.E.S.S. post and pushing the
START/STOP button.
3. Measure voltage as per following table.
STARTER SOLENOID GROUND SIGNAL TEST
RESULT
TEST PROBES (START BUTTON
DEPRESSED)
Battery
OG/BN wire Battery voltage
positive post
Testing the Starter Solenoid Winding

Resistance
tmr2017-036-003 Disconnect terminals from solenoid.
With a multimeter, check primary winding resis-
2. Wake up the ECM by installing the D.E.S.S.
tance as follows.
key on the D.E.S.S. post and pushing the
START/STOP button.
3. Measure voltage as per following table.
219100971-020 3
If voltage is out of specification, replace solenoid.
D2 DIODE (STARTER SOLENOID)

Diode Location
The diode is located in the main harness, near
starter solenoid.
Testing the Diode

1. Make sure ignition is OFF.
2. Disconnect solenoid connector.
tmr2017-036-004_a
STARTER SOLENOID WINDING

RESISTANCE TEST
RESULT @ 20°C
TEST PROBES
(68°F)
Starter Starter
solenoid solenoid SS2 Approximately 5
SS1 pin pin
If measurement is out of specification, replace so-

lenoid.
Testing the Starter Solenoid Voltage

Drop
Wake up the ECM by installing the D.E.S.S. key on
the D.E.S.S. post and pushing the START/STOP
button.
Measure voltage as per following table while
cranking engine in drowned mode (to prevent tmr2017-036-003
engine starting).
NOTE: For drowned mode, refer to ENGINE 3. Disconnect ECM connector B.
MANAGEMENT subsection. 4. Connect the ECM adapter tool to the ECM con-
nector B.
STARTER SOLENOID VOLTAGE DROP TEST
5. Set multimeter to "diode check".
RESULT (WHILE
TEST PROBES
CRANKING)
Post coming Post going to
0.2 Vdc max.
from battery starter
tmr2017-036-005_a
4 219100971-020
vmr2006-020-005
6. Test diode as per following table.
SS2- SS1-
vmr2015-048-013_a
D2 DIODE TEST
MULTIMETER MULTIMETER
POSITIVE NEGATIVE RESULT
PROBE PROBE
ECM-B pin D1 ECM-B pin L4 Overload (open)

Approximately
ECM-B pin L4 ECM-B pin D1
0.5 volts
If diode fail any test, replace it.
219100971-020 5
Subsection XX (RADIO FREQUENCY DIGITALLY ENCODED SECU-
RITY SYSTEM (RF D.E.S.S.))
RADIO FREQUENCY DIGITALLY

ENCODED SECURITY SYSTEM (RF
D.E.S.S.)
GENERAL The D.E.S.S. key contains a magnet and a RFID
chip.
SYSTEM DESCRIPTION – The magnet closes the hall effect switch inside
the engine cut-off switch.
This system limits engine or vehicle speed.
– The RFID chip contains a unique digital code. It
At startup the D.E.S.S. module attempts to read is the equivalent of the tooth-pattern cut on a
the key and sends a signal to the ECM. The ECM conventional ignition key.
analyses the signal and determines if the key is:
D.E.S.S. keys are programmed in the ECM mem-
– Performance ory using BUDS2. The keys can also be erased in-
– Learning dividually.
SPEED/TORQUE LIMITED TO NOTE: If desired, a D.E.S.S. key can be used on
another vehicle equipped with the D.E.S.S. sys-
KEY LIMIT HOW
tem. It only needs to be programmed for that ve-
No D.E.S.S. hicle.
Performance Not applicable
imposed limit
Vehicle speed
By varying
RF D.E.S.S. MODULE / CUT-OFF
Learning1
limited to
70 km/h
throttle opening SWITCH / D.E.S.S. POST
(iTC)
(43 MPH)
DESS key not ECM will not
Engine will not
recognized / ground starter
start
Bad Key2 solenoid
1 Two different speeds can be set. Refer to D.E.S.S.
KEY PROGRAMMING in this subsection
2 BUDS2 will display an error when trying to read
key. Messages will scroll on gauge.
NOTE: Additional information on learning key

modes and how an operator can modify engine
torque and vehicle speed is available in the OP-
ERATOR'S GUIDE.
RF D.E.S.S. KEY mmr2016-028-002
The hall effect switch (cut off switch) must be

closed to start the engine.
The RF D.E.S.S. module emits an RF signal when
the vehicle is powered up that activates the chip
in the key, the module can then read the key.
The RF D.E.S.S. module does not determine the
type of key, it only reads the chip for the ECM.
mmr2016-028-001
219100903-009 1
TROUBLESHOOTING
When starting the engine with a D.E.S.S. key on the engine cut-off switch, the key is identified by the
ECM and D.E.S.S. signals will be issued according to the key recognition. See table.
D.E.S.S. SIGNAL
DISPLAYED DESCRIPTION COMMENT
BEEPER
MESSAGE
Welcome message,
2 shorts beeps Can-Am Working D.E.S.S. key.
good key
– Make sure no accessory or accessory wires
are near key or engine cut-off switch.
Short beeps CHECK – RPM limited to 2500. Vehicle cannot be
Unable to read key
repeating slowly KEY driven
– Check D.E.S.S. status in BUDS2
– No voltage at RFID connector pin D
– Use the proper key for this vehicle or have
Shorts beeps BAD Invalid key or key not the key programmed.
repeating rapidly KEY programmed – RPM limited to 2500, Vehicle can not be
driven.
PROCEDURES 7. Press the READ button (top right of the table).

8. Select key type
D.E.S.S. KEY 9. Press ADD button to register the key. The new
Programming D.E.S.S. Keys key should be displayed in the table. Repeat
steps 6 to 9 to add other keys.
1. Connect the vehicle to BRP diagnostic software
(BUDS2). Refer to COMMUNICATION TOOLS Erasing Keys
subsection. 1. Install the D.E.S.S. key on the engine cut-off
2. Briefly press START/STOP button to power the switch.
ECM.
3. Install a D.E.S.S. key on the engine cut-off
switch.
219100903-009-001
2. Click on Erase Key.

219100903-009-001
After approximately 10 seconds, a message will
appear.
4. Go to the key page. The key is now erased.
5. Ensure that anti-theft system is activated. If
not, activate it before trying to add a key. Erasing All Keys
6. Install new key on the D.E.S.S. post. 1. Click on Erase All Keys.
2 219100903-009
2. When done, program at least one new key to

the vehicle. Refer to ADDING A KEY in this sub-
section.
D.E.S.S. / ENGINE CUT-OFF

OPERATION
Normal Operation
BUDS2 can read and recognize key type.
Vehicle starts.
Refer to WIRING DIAGRAM.
SPECIFICATIONS
(DISCONNECTED
RFID CONNECTOR PIN RFID CONNECTOR)
ECM AWAKE (PUSH
START/STOP BUTTON)
A Ground thru ECM
B 3.3 Vdc
0 Vdc (data signal to
C
ECM)
D 12 Vdc
Key Not Recognized

The gauge scrolls the message: "Key not recog-
nized".
Possible causes:
– Wrong key
– Damaged RFID chip
– No signal at RFID-C to ECM
Bad Key
The gauge scrolls the message: "Bad key".
Possible causes:
– Key not programmed to vehicle
Condition can be duplicated by installing a key that
is not programmed to the vehicle.
Gauge and Vehicle Won't Stay Awake

The gauge powers off shortly after the start/stop
button is pressed.
Possible causes:
– No key on D.E.S.S. post.
– Magnet in key not closing hall effect switch in
D.E.S.S. post.
– No voltage at RFID-D connector
– No voltage at RFID-B connector
– No ground at RFID-A connector
Condition can be duplicated by unplugging the
RFID connector.
219100903-009 3
Subsection XX (LIGHTS)
LIGHTS
SERVICE PRODUCTS
GENERAL SERVICE PRODUCT
NOTICE It is recommended to always discon- DIELECTRIC GREASE (P/N 293 550 004)
nect the battery when replacing any electric
Pay attention to ground wires.
or electronic parts. Always disconnect battery
exactly in the specified order, BLACK (-) cable
first. PROCEDURES
TROUBLESHOOTING CONSOLE SWITCHES

Replacing the Switches
DIAGNOSTIC TIPS Disconnect electrical connector.
NOTE: It is a good practice to check for fault Release retaining clips, then push switch out of
codes using BUDS2 software as a first trou- the console.
bleshooting step. Refer to COMMUNICATION
TOOLS AND B.U.D.S. subsection.
IMPORTANT: When troubleshooting an electrical
system fault, check battery condition, cables and
connections first.
Circuit Testing
Check the related-circuit fuse condition with a
fuse tester or test lamp (a visual inspection could
lead to a wrong conclusion).
NOTE: If the ignition switch is left ON for more
than 30 minutes, the accessory relay will shut
down.
tmr2011-030-012_a
Inspecting the Electrical Connection 1. Retaining clips
When replacing an electric or electronic compo- For installation, reverse removal procedure.
nent, always check electrical connections. Make
sure they are tight, make good contact, and are Switches Illumination Wire
corrosion-free. Dirty, loose or corroded contacts Identification
are poor conductors and are often the source of a
system or component malfunction. FUNCTION PIN COLOR
Pay particular attention to ensure that pins are not 12 volt input from fuse F11 8 YE/BK
bent or pushed out of their connectors. Ground 7 BK/BL
Ensure all wire terminals are properly crimped on
wires, and connector housings are properly fas- NOTE: The illumination circuit of all console
tened. switches is supplied by the RD/BK wire.
Check for signs of moisture, corrosion or dull-
ness. Clean pins properly and coat them with
dielectric grease or other appropriate lubricant
when reassembling them, except if otherwise
specified such as for the ECM connectors.
219100971-021 1
Switches Illumination Circuit SWITCH

WIRE COLOR VOLTAGE
Protection POSITION
CONDITION CIRCUIT PROTECTION GN
LO beam/
(Low BK
Supplied by main relay Fuse 11 of fuse block 1 HI beam Battery
beam)
voltage
BU
HI beam BK
HEADLIGHTS (Hi beam)
Headlight Wire Identification
Replacing the Headlight
MAIN RELAY (R2)
Unplug connector from headlight.
FUNCTION PIN COLOR Remove the three screws.
12 volt input from battery D2 RD/GY
12 volt input from battery
D1 RD/GY
(Relay winding input)
12 volt output to headlights
low beam and low/high C1 RD/BG
beam switch (fuse F11)
Relay winding ground
C2 OR/BU
(from ECM-B H2)
HEADLIGHT LOW/HIGH BEAM SWITCH

FUNCTION PIN COLOR
12 volt output to low tmr2017-038-002
3 GN
beam headlights
Properly reinstall removed parts in the reverse or-
12 volt input from F11 der of their removal.
2 YE/BK
(low beam)
Validate headlight operation.
12 volt output to high
6 BU
beam headlights Headlamp Beam Aiming
12 volt input from F11 Make sure the vehicle is squared with the test sur-
5 YE/BK
(high beam) face (wall or screen).
SIGNATURE LIGHTS
FUNCTION PIN COLOR
12 volt input (from F11) A YE/BK
Ground C BK
Headlights Circuit Protection

Supplied by main
Fuse 11 of fuse block 1
relay (R2)
tmr2017-038-007_a
Testing the Headlight
Disconnect headlight connector. Select high beam.
Using a multimeter, measure the voltage on head- NOTE: Load vehicle as per normal use.
light connector as follows. Measure headlight center distance from the
ground. Scribe a line at this height on test sur-
face (wall or screen). Light beam center should
be 130 mm (5 in) below scribed line.
2 219100971-021
BRAKE LIGHT SWITCH

FUNCTION PIN COLOR
12 volt input from fuse F4 2 OG/GN
12 volt output to RH brake
1 WH/OR
light and R8 relay winding
Taillight/Brake Light Circuit Protection

LAMP CIRCUIT PROTECTION
Tail lamp and Brake lamp Fuse 16 of fuse block 1
tmr2017-038-005_a
1. Light beam center

A. 5 m (16 ft)
Replacing Taillight/Brake Light
B. 130 mm (5 in) Disconnect connector.
Beam Aiming Adjustment Remove the four screws.
Turn adjustment screws to adjust beam height
and side orientation as described below. Adjust
both headlight evenly.
tmr2017-038-003
tmr2017-039-002_a
1. Adjustment screws
TAILLIGHTS/BRAKE LIGHTS
Taillight/Brake Light Wire Identification
MAIN RELAY (R2)
FUNCTION PIN COLOR
12 volt input from battery D2 RD/GY
tmr2017-038-004
12 volt input from battery
D1 RD/GY
(Relay winding input) Installation is the reverse of the removal proce-
12 volt output to taillights dure.
C1 RD/BG
(fuse F16)
Relay winding ground
C2 OR/BU
(from ECM-B H2)
219100971-021 3
Subsection XX (GAUGE)
GAUGE
SERVICE PRODUCTS
GENERAL SERVICE PRODUCT
NOTICE It is recommended to always discon- DIELECTRIC GREASE (P/N 293 550 004)
nect the battery when replacing any electric
Pay attention to ground wires.
exactly in the specified order, BLACK (-) cable
first. PROCEDURES
TROUBLESHOOTING MULTIFUNCTION GAUGE

Multifunction Gauge Wire
DIAGNOSTIC TIPS Identification
NOTE: It is a good practice to check for fault FUNCTION PIN COLOR
codes using BUDS2 software as a first trou-
bleshooting step. Refer to COMMUNICATION 12 volt input from fuse F4 17 OG/GN
TOOLS AND B.U.D.S. subsection. 12 volt input from fuse F8 16 BG/WH
IMPORTANT: When troubleshooting an electrical Ground 20 BK
connections first. CAN LO 18 WH/BK
CAN HI 19 WH/BG
Circuit Testing
Fuel level gauge supply 4 BN/PK
fuse tester or test lamp (a visual inspection could Fuel level gauge ground 21 VT/PK
lead to a wrong conclusion). 2WD/4WD switch signal
7 BK/BG
NOTE: If the ignition switch is left ON for more (-)
than 30 minutes, the accessory relay will shut HI beam signal (+) 5 BU
down.
Electrical Connection Inspection Multifunction Gauge Circuit Protection

When replacing an electric or electronic compo- CONDITION CIRCUIT PROTECTION
nent, always check electrical connections. Make Supplied at all times Fuse 8 of fuse block
sure they are tight, make good contact, and are
corrosion-free. Dirty, loose or corroded contacts Fuse 4 of fuse block 1
Supplied by main relay
are poor conductors and are often the source of a (from main relay R2)
system or component malfunction.
Pay particular attention to ensure that pins are not Removing the Multifunction Gauge
bent or pushed out of their connectors. 1. Remove retaining screws at bottom of gauge.
wires, and connector housings are properly fas-
tened.
Check for signs of moisture, corrosion or dull-
ness. Clean pins properly and coat them with
dielectric grease or other appropriate lubricant
when reassembling them, except if otherwise
specified such as for the ECM connectors.
219100971-022 1
On ECM wake-up, the gauge will perform a self-

test. All indications should come ON and gauge
pointers will cycle once. You will have a few sec-
onds to ensure the indications (LEDs and LCDs)
are functioning correctly.
NOTE: This test only validates the gauge opera-
tion of the LEDs, LCDs in the gauge digital display
and the pointers. It does not test the actual circuit
functions related to each indication.
If the self test does not take place, test gauge in-
put power.
tmr2017-039-001
Gauge Setup
2. Disconnect gauge connector.
Changing Gauge Units of Measurement
Installing the Multifunction Gauge The gauges are factory preset to indicate in im-
The installation is the reverse of the removal pro- perial units and can be changed using the BUDS2
cedure. software.
Maintenance Soon Message ware (BUDS2).
Maintenance Soon Message Manual Reset In BUDS2, go to:
1. Select PARK. – Settings page
2. Turn ignition switch to ON. Do NOT start en- – Cluster button
gine. – Change Cluster Units button
NOTE: The steps 3 through 9 must be completed NOTE: Speedometer, odometer and trip meter
within 5 seconds. will have their units (kilometer or miles) changed
3. Press override button and HOLD. simultaneously.
4. Press and release brake pedal. Changing Language
5. Release override button. Connect the vehicle to the BRP diagnostic soft-
ware (BUDS2).
6. Press and release brake pedal.
In BUDS2, go to:
7. Press override button and HOLD.
– Settings page
8. Press and release brake pedal.
– Cluster button
9. Release override button. – Change Cluster Language button
10. Turn ignition switch to OFF.
NOTE: Do not turn ignition switch to ON before Displaying “P” Codes
the multifunction gauge turns off. 1. To activate P CODE mode, push and hold the
“M” button for 2 seconds.
Maintenance Soon Message Reset Using
BUDS2 2. As you hold the “M” button, quickly turn ON
and OFF the high beams a few times. The
gauge will enter P CODE mode.
ware (BUDS2). Refer to COMMUNICATION
TOOLS AND B.U.D.S. subsection. 3. While in P CODE mode, use the “M” or “S”
button to scroll over available failure codes.
In BUDS2, go to:
– Summary page 4. Push and hold the “M” button to exit P CODE
mode.
– Vehicle button
– Reset Service button A NO ACTIVE P CODE message is displayed if
there are no P CODES in memory.
Gauge Self Test Function
Gauge self test only runs if the gauge has been
off for more than 30 seconds.
2 219100971-022
Testing Gauge With BUDS2 2. Disconnect the gauge connector.

The GAUGE SELF TEST can be duplicated using 3. Set multimeter to Vdc.
BUDS2. 4. Measure voltage as per following table.
GAUGE CONNECTOR VOLTAGE
ware (BUDS2).
In BUDS2, go to: Pin 16 Battery voltage
– Functions page 5. If there is no voltage read, test input wire con-
– Cluster button tinuity. Refer to WIRING DIAGRAM for circuit
– Routines tab details.
– Execute Cluster WOW Test button
Testing Gauge Beeper
Testing Gauge Power (Main 12 Vdc) Connect the vehicle to the BRP diagnostic soft-
If the gauge does not come on when the engine ware (BUDS2).
is started, carry out the following test. In BUDS2, go to:
1. Remove multifunction gauge. – Functions page
2. Disconnect the gauge connector. – Cluster button
3. Set multimeter to Vdc. – Routines tab
4. Start engine. – Execute Cluster Buzzer Test button
5. Measure voltage with the chassis ground as per Testing Gauge Buttons with BUDS2
following table.
GAUGE CONNECTOR VOLTAGE ware (BUDS2).
Approximately 14.75 In BUDS2, go to:
Pin 17
Vdc – Measurements page
– Cluster button
6. If gauge main power input test was as speci-
– Custom tab
fied, test the gauge ground circuit.
Press the "M" and "S" buttons on the cluster.
7. If no voltage was read, test wiring continuity.
Refer to WIRING DIAGRAM for details. If the indicator light(s) come ON in BUDS2, the
gauge buttonsare functioning correctly.
Testing Gauge Ground If the indicator lights do not come ON, check
1. Set multimeter to selection. buttons and wiring continuity, refer to WIRING
2. Measure for continuity of gauge ground wire to DIAGRAM. If they are in good condition, replace
chassis ground as per following table. gauge.
GAUGE CONNECTOR RESISTANCE

Pin 20 Close to 0
If ground test failed, check vehicle ground. Refer

to POWER DISTRIBUTION AND GROUNDS sub-
section.
If gauge power input test and ground circuit con-
tinuity tests are good, replace gauge.
Testing Clock 12 Vdc Input
If the clock function in the gauge does not hold the

proper time of day when the engine is not running,
carry out the following test.
1. Remove multifunction gauge.
219100971-022 3
Subsection XX (ACCESSORIES)
ACCESSORIES
SERVICE PRODUCTS
DEOXIT LUBRICANT ..................................................................... 293 550 034 ........................................... 1
GENERAL SERVICE PRODUCTS
NOTICE It is recommended to always discon- DEOXIT LUBRICANT (P/N 293 550 034)
nect the battery when replacing any electric DIELECTRIC GREASE (P/N 293 550 004)
exactly in the specified order, BLACK (-) cable Pay attention to ground wires.
first.
PROCEDURES
TROUBLESHOOTING
CONSOLE SWITCHES
DIAGNOSTIC TIPS Replacing the Switches
NOTE: It is a good practice to check for fault Disconnect electrical connector.
codes using BUDS2 software as a first trou-
bleshooting step. Refer to COMMUNICATION Release retaining clips, then push switch out of
TOOLS AND B.U.D.S. subsection. the console.
IMPORTANT: When troubleshooting an electrical
connections first.
Testing Circuits
fuse tester or test lamp (a visual inspection could
lead to a wrong conclusion).
NOTE: If the ignition switch is left ON for more
than 30 minutes, the accessory relay will shut
down.
Inspecting Electrical Connections tmr2011-030-012_a
When replacing an electric or electronic compo- 1. Retaining clips

nent, always check electrical connections. Make
sure they are tight, make good contact, and are For installation, reverse removal procedure.
corrosion-free. Dirty, loose or corroded contacts
are poor conductors and are often the source of a Identifying Switches Illumination Wire
system or component malfunction. FUNCTION PIN COLOR
Pay particular attention to ensure that pins are not 12 volt input from fuse F12 8 RD/BK
bent or pushed out of their connectors.
Ground 7 BK
wires, and connector housings are properly fas- NOTE: The illumination circuit of all console
tened. switches is supplied by the RD/BK.
Check for signs of moisture, corrosion or dullness.
Clean pins properly with deoxit lubricant and coat
them with dielectric grease or other appropriate
lubricant when reassembling them, except if oth-
erwise specified such as for the ECM connectors.
219100971-023 1
Switches Illumination Circuit WINCH SWITCH

Protection
FUNCTION PIN COLOR
12 volt input from fuse 12 2 RD/BK
Supplied by main relay Fuse 12 of fuse block 1
12 volt output to relay
1 GN/BU
winding ("IN")
12 VOLT POWER OUTLET 12 volt output to relay
3 LT BU
winding ("OUT")
Removing and Installing 12 Volt Power
Outlet For detailed information refer to the WIRING DIA-
Refer to BODY and remove mid dashboard cover. GRAM.
Unplug the connector of the power outlet. WARNING
Unscrew the retaining nut. Before testing, make sure the winch is in
Reverse procedure for installation. FREESPOOL mode (Freespool clutch disen-
gaged).
Identifying 12 Volt Power Outlet Wire
FUNCTION PIN COLOR Winch Switch Circuit Protection
12 volt input from CONDITION CIRCUIT PROTECTION
2 RD/BR
fuse F12 Fuse 12 of fuse block
Supplied with
Ground (to ground accessories relay 1 (from accessories
1 BK activated relay R3)
terminal BN1)
12 Volt Power Outlet Circuit Protection Winch Motor Circuit Protection

CONDITION CIRCUIT PROTECTION Two circuit breakers (50 A) are used to protect the
winch motor in case of overheating.
Supplied with Fuse 12 of fuse block
accessories relay 1 (from accessories Removing the Winch
activated relay R3)
1. Disconnect, the battery BLACK (-) cable first,
then the RED (+) cable.
WINCH
WARNING
Winch Wire Identification Always respect this order for disassembly;
WINCH RELAY disconnect BLACK (-) cable first. Electrolyte
or fuel vapors can be present in engine com-
FUNCTION PIN COLOR
partment and a spark may ignite them and
12 volt input from battery possibly cause personal injuries.
RD RD
(winch power)
Ground BK BK 2. Remove the hook.
12 volt input from switch (1) IN LT BU 2.1 Remove and discard the cotter pin.
12 volt input from switch (2) OUT GN/BU 2.2 Remove the hook pin.
2.3 Remove the stopper.
Motor power (switches
RD (with
polarity depending on YL
Yellow tape)
rotation direction)
Motor power (switches
RD (with Blue
polarity depending on BU
tape)
rotation direction)
2 219100971-023
7. Remove winch.
Installing the Winch

Tighten winch retaining screws to specification.
TIGHTENING TORQUE
16 N•m ± 2 N•m
M8 x 30 Bolt
Skid plate retaining 2.5 N•m ± 0.5 N•m
219100903-011-001_a
1. Hook
2. Hook pin Connect wires the YELLOW wire at front and the
3. Cotter pin BLUE one at back.
4. Stopper
Install a NEW cotter pin on the hook pin.
3. Remove front skid plate.
219100903-011-002_a
4. Remove the four retaining screws from under-

neath the winch.
219100903-011-003_a
5. Disconnect both winch power cables.

NOTE: Note the position of the power cables for
reinstallation.
6. Pass the cable through the cable guide.
219100971-023 3
Subsection XX (WHEELS AND TIRES)
WHEELS AND TIRES

SERVICE PRODUCTS
PROCEDURES
TIRES
WARNING
Do not rotate tires. The front and rear tires
have a different size. Respect direction of ro-
tation when applicable.
Tire Pressure
WARNING tmr2011-033-002_a
TYPICAL
Tire pressure greatly affects vehicle handling 1. Direction of rotation
and stability. Insufficient pressure may cause
tire to deflate and rotate on wheel. Excessive Check for proper tire size
pressure may burst the tire. Always follow
Tire Mounting on Beadlock Wheels
recommended pressure.
Check pressure when tires are cold before us-

ing the vehicle. Tire pressure changes with tem-
perature and altitude. Recheck pressure if one of
these conditions has changed.
Refer to technical specifications for tire pressure
table.
Tire Inspection
Check tire for presence of slits, bulges, wear or
other damage. Replace if necessary.
Tire Replacement
Use an automotive tire changer to replace tires. tmr2013-091-006_a
TYPICAL
WARNING 1. Inner tire bead seat
2. Outer tire beadlock ring
– Replace tires only with the same type and
size as original tires. NOTE: Tires should be mounted, by an experi-
– For unidirectional tread pattern, ensure enced person, in accordance to good tire mount-
that the tires are installed in the correct ing practices using acceptable tire mounting
direction of rotation. equipment designed for the tire industry.
1. Mount the tire on wheel.
1.1 On the opposite side of beadlock, apply
the tire mounting lube on inner bead of tire
and wheel to ensure proper seating when
inflating.
1.2 Mount the inner bead over the wheel.
tmr2017-041 1
NOTICE Mount tire from beadlock side TIGHTENING TORQUE

only.
Beadlock screws 25 N•m ± 1 N•m
1.3 Seat the tire outer bead in the shoulder of (SECOND TORQUE) (18 lbf•ft ± 1 lbf•ft)
the beadlock inner ring and center the tire.
tmr2015-042-001_a
1. Tire outer bead

2. Beadlock inner ring shoulder
2. Install all beadlock screws. To avoid cross

threading, start all screws by hand. tmr2015-042-002_a
NOTICE Do not use an impact wrench for SECOND TIGHTENING SEQUENCE

installing beadlock screws. The risk of screw NOTE: The beadlock clamp ring should be in con-
breaking or screw stripping is high when using tact with the beadlock inner ring. The beadlock
an impact wrench. clamp ring can flex slightly to match the tire bead.
3. Tighten beadlock screws as per following spec- IT IS NORMAL.
ification and sequence. 6. Verify the gap between tire and beadlock clamp
NOTE: To ensure even pressure on the beadlock ring, it should be practically equal all around the
clamp ring, tighten screws a few turns at a time. ring.
TIGHTENING TORQUE
(FIRST TORQUE) (124 lbf•in ± 9 lbf•in)
tmr2015-042-003_a
A. Gap equal all around beadlock clamp ring
If the gap is not acceptable:

– Loosen all screws.
– Check tire position on wheel and reposition it if
necessary.
– Restart the tightening sequence as detailed.
7. Tighten beadlock screws a final time as per fol-
tmr2015-042-002_a
lowing specification and sequence.
FIRST TIGHTENING SEQUENCE
4. At this time check if the tire is still centered on

wheel. Reposition it if necessary.
5. Tighten beadlock screws as per the second
torque using the same sequence.
2 tmr2017-041
TIGHTENING TORQUE
(FINAL TORQUE) (18 lbf•ft ± 1 lbf•ft)
tmr2017-041-001_a
Check if tires are unidirectional.
tmr2015-042-002_b
FINAL TIGHTENING SEQUENCE
8. Inflate tire to seat the inner bead on wheel. Al-

ways use safe practices, such as a tire safety
cage.
WARNING
Never exceed tire recommended maximum tmr2011-033-002_a
pressure for seating beads. TYPICAL

1. Direction of rotation
WHEELS Tighten wheel lug nuts to the specified torque us-

ing the illustrated sequence.
Removing the Wheel
TIGHTENING TORQUE
Loosen nuts just enough to be able to unscrew
them once the vehicle will be off the ground. 120 N•m ± 10 N•m
Wheel lug nuts
Lift and support the vehicle. Refer to INTRODUC-
TION subsection.
Remove nuts, then remove wheel.
Inspecting the Wheel

Inspect wheel for wear or damage especially at
the mounting holes.
Installing the Wheel

At installation it is recommended to apply anti-
seize lubricantLOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070) on conical area only.
tmr2015-042-004_a
TIGHTENING SEQUENCE
tmr2017-041 3
NOTICE Always use the recommended

wheel lug nuts for the type of wheel. Us-
ing a different lug nut could cause damages to
the rim or studs.
4 tmr2017-041
Subsection XX (FRONT DRIVE)
FRONT DRIVE
SERVICE TOOLS
BACKLASH MEASUREMENT TOOL............................................. 529 036 387 ........................................... 10
CV BOOT CLAMP PLIER .............................................................. 529 036 120 ............................................. 5
CV JOINT EXTRACTOR................................................................. 529 036 005 ............................................. 5
MULTIFUNCTION DIFFERENTIAL TOOL...................................... 529 036 385 ........................................... 11
SPLINE DRIVER ............................................................................ 529 036 386 ..................................... 10–11
SERVICE PRODUCTS
LOCTITE 271 (RED)....................................................................... 293 800 005 ........................................... 13
SYNTHETIC GREASE .................................................................... 779162 ......................... 4–5, 7, 13–14
219100971-024 1
FRONT DRIVE SHAFTS AND PROPELLER SHAFTS
NEW NEW
XPS Synthetic
grease
Smart-Lok only
NEW
65 ± 5 N•m
(48 ± 4 lbf•ft)
NEW
XPS Synthetic
grease
NEW
NEW
31.5 ± 3.5 N•m
(23 ± 3 lbf•ft) NEW
250 ± 15 N•m
(184 ± 11 lbf•ft)
48 ± 6 N•m
(35 ± 4 lbf•ft)
XPS Synthetic
grease
NEW

219100971-100_b
2 219100971-024
FRONT DIFFERENTIAL
NEW 16.5 ± 2.5 N•m

(146 ± 22 lbf•in)
XPS Synthetic
grease
203 ± 13 N•m
NEW (150 ± 10 lbf•ft)
Loctite
271
37 ± 3 N•m
(27 ± 2 lbf•ft)
Loctite
271
2.7 ± 0.5 N•m

(24 ± 4 lbf•in)
NEW
23.5 ± 3.5 N•m
(17 ± 3 lbf•ft)
XPS Synthetic
grease
NEW
XPS Synthetic
grease

219100971-101_a
219100971-024 3
GENERAL 5. Remove wheel hub.

The procedure explained below is the same for Inspecting the Wheel Hub
the RH and LH sides unless otherwise specified.
Check wheel studs for damaged threads and over-
IMPORTANT all conditions
For any information concerning the inspection, Check wheel hub for cracks or other damages.
the disassembly and the assembly of a Check inner splines for wear or other damages.
Smart-Lok differential, refer to the SMART-LOK
DIFFERENTIAL subsection. Replace wheel hub and / or studs if any damage
is detected.
SYSTEM DESCRIPTION Installing the Wheel Hub
When one wheel is spinning above a certain rate The installation is the reverse of removal proce-
faster than the other wheel, the Visco-Lok® sys- dure. However, pay attention to the following.
tem progressively locks the wheels through its Apply grease all around drive shaft and wheel hub
multi-plate clutch. splines, and on the outer cylindrical surface.
In the event of a failure, the entire Visco-Lok pump SERVICE PRODUCT
and its carrier will have to be replaced. The Visco-
Lok pump itself is a non-serviceable item. SYNTHETIC GREASE (P/N 779162)
NOTE: If the pump was disassembled, its viscous
fluid would be lost and it could not be replaced.
PROCEDURES
WHEEL HUB
Removing the Wheel Hub
1. Lift and support vehicle. Refer to INTRODUC-
TION section.
2. Select the 4WD position and place the trans-
mission lever on "P".
tmr2017-042-008
3. Remove caliper from knuckle. Refer to
BRAKES subsection. Install Belleville washer with its domed side out-
4. Remove the following parts: wards.
– Wheel
– Cotter pin
– Castellated nut
– Belleville washer.
tmr2016-137-003
TYPICAL
tmr2016-137-002
TYPICAL
4 219100971-024
TIGHTENING TORQUE A l l m o d e ls
250 N•m ± 15 N•m Apply grease to the wheel side splines of the
Castellated nut shaft.
SERVICE PRODUCT
NOTE: Tighten further castellated nut if required
to align grooves with drive shaft hole. SYNTHETIC GREASE (P/N 779162)
Install a new cotter pin.
DRIVE SHAFT BOOT
FRONT DRIVE SHAFT Removing the Drive Shaft Boot
Removing the Front Drive Shaft 1. Remove the drive shaft from the vehicle.
1. Remove the wheel hub. Refer to WHEEL 2. Remove drive shaft boot clamps.
HUBin this subsection.
REQUIRED TOOL
2. Remove the knuckle. Refer to STEERING SYS-
TEM subsection. CV BOOT CLAMP PLIER
3. Strongly pull drive shaft out of differential. (P/N 529 036 120)
4. Discard the stop ring at the end of the shaft.
3. Dislodge the large boot end.
Inspecting the Front Drive Shaft 4. Separate the joint from the shaft. Two proce-
Inspect the condition of boots. If there is any dam- dures can be done.
age or evidence of leaking lubricant, replace them. Without the Special Tool
Refer to DRIVE SHAFT BOOT.
1. Clamp joint housing in a vise.
Check splines for excessive wear. Replace if nec-
2. Align shaft with joint.
essary.
3. Pull hard on shaft to remove from joint.
NOTE: If the splines on plunging joint are worn, a
check of differential inner splines should be done. 4. Remove boot from drive shaft.
5. Remove and discard the circlip.
Installing the Front Drive Shaft
With the Special Tool
cedure. However, pay attention to the following. REQUIRED TOOL
Install a new stop ring. CV JOINT EXTRACTOR
(P/N 529 036 005)
1
1. Place drive shaft in vice with the joint down-
ward.
2. Install the cv joint extractor on the bearing.
V07H0AA
1. Stop ring
M od els w ith S m art-L ok D iffere ntial

Apply grease to the differential side splines of the
shaft.
SERVICE PRODUCT
219100971-024 5
3. Remove the LH and RH front console panels.
tmr2017-042-001
tmr2013-088-003_a
TYPICAL - CV JOINT SHOWN 4. Remove the propeller shaft bearing bolts

1. Position joint extractor tool here
3. With a hammer, hit on the tool to separate joint

from shaft.
4. When joint and shaft are separated, remove
boot from drive shaft.
5. Remove and discard the circlip.
Installing the Drive Shaft Boot

Install the new circlip.
Pack bearing area with grease included with the tmr2017-042-002
new boot kit.

5. Dislodge the propeller shaft from the differen-
NOTE: Do not use or add other grease. tial side first by pushing both propeller shafts to-
wards the engine. When it is disengaged from
FRONT PROPELLER SHAFT the differential, move it towards front, beside
the differential to disengage from the rear pro-
Removing the Front Propeller Shaft peller shaft.
1. Remove the front RH side wheel. Refer to
6. Remove front propeller shaft from the cockpit,
WHEELS AND TIRES subsection. through the LH console panel opening.
2. Remove propeller shaft screw and nut on differ-
ential end.
tmr2017-042-003
tmr2016-137-004
6 219100971-024
Inspecting the Front Propeller Shaft

Inspect if propeller shaft is not bent or twisted.
Check propeller shaft splines for wear or damage.
Check both U-joint crosses. They should rotate
smoothly without any play.
Replace if required.
Installing the Front Propeller Shaft

Apply grease to splines on engine side. tmr2017-042-004
SERVICE PRODUCT 7. Slide the shaft towards rear, on the RH side of

the vehicle, under the engine magneto cover.
TIGHTENING TORQUE
31.5 N•m ± 3.5 N•m
Propeller shaft nut
Propeller shaft bearing 48 N•m ± 6 N•m
bolt (35 lbf•ft ± 4 lbf•ft)
REAR PROPELLER SHAFT

Removing the Rear Propeller Shaft
1. Remove the front and rear RH wheels. Refer to
WHEELS AND TIRES subsection. tmr2017-042-006
2. Remove the front propeller shaft.

3. Remove the LH rear console panel. Refer to PROPELLER SHAFT U-JOINTS
BODY subsection. Removing the Propeller Shaft U-Joint
4. Dislodge the rear propeller shaft from the gear- 1. Remove internal snap ring from bearing caps.
box.
5. Move the front end of the shaft towards inside
the cockpit.
tmr2016-137-022
2. In a vice, use a suitable box to lock the yoke

tmr2017-042-005
on one side, and a smaller one to push on the
U-joint cross on the other side.
6. Remove the circlip on the rear propeller shaft
and remove the bearing from it.
219100971-024 7
tmr2016-137-023
tmr2016-137-026
tmr2016-137-027
tmr2016-137-024
5. Remove bearing cap.
3. Squeeze the bearing cap in vice and hit the yoke
with a soft hammer to remove it.
tmr2016-137-028
tmr2016-137-025
6. Repeat steps to remove the remaining bearing
4. Press the cross on the other side of the yoke to caps.
disengage it. 7. Remove U-joint cross.
8 219100971-024
tmr2016-137-029 tmr2016-137-030
Installing the Propeller Shaft U-Joint Ensure U-joint is operating smoothly.

1. Use a vise to insert the first bearing cap flush
with the inner wall of the yoke. FRONT DIFFERENTIAL
Removing the Front Differential
1. Drain the differential. Refer to PERIODIC
2. Remove both drive shafts. Refer to REMOV-
ING THE FRONT DRIVE SHAFT in this subsec-
tion.
3. Remove the RH upper suspension arm. Refer
to FRONT SUSPENSION subsection.
4. Detach the front propeller shaft from the differ-
ential.
5. Remove the 4 retaining screws from the bot-
tom skid plate.
tmr2016-137-028
2. Install new U-joint cross in yoke and slide it in

the bearing cap.
NOTICE Ensure bearing needles are perfectly
positioned in caps to avoid damage to cross.
3. Fully seat bearing cap on one side.
tmr2017-042-007
6. Remove the differential from the RH side of ve-

hicle.
tmr2016-137-031
4. Install snap ring.

5. Install the second bearing cap, then snap ring.
219100971-024 9
Inspecting the Front Differential BACKLASH SPECIFICATION

(Assembled) 0.1 mm (.004 in) to 0.25 mm (.01 in)
NOTE: The following procedures are applica-
ble for all types of front differential except If backlash is out of specification, split front dif-
Smart-Lok. For any information concerning the ferential housing and adjust shim thickness as per
inspection, the disassembly and the assembly of following guideline.
a Smart-Lok differential, refer to the SMART-LOK
DIFFERENTIAL subsection. BACKLASH ADJUSTMENT GUIDELINE
Check if oil seals are brittle, hard or damaged. Re- BACKLASH

WHAT TO DO
place if necessary. MEASUREMENT
Remove shim(s) and
Backlash Inspection Below 0.1 mm (.004 in)
recheck backlash
When measuring backlash, the differential cover
Add shim(s) and recheck
should be upside down to pull the ring gear out of Above 0.25 mm (.01 in)
backlash
mesh.
1. Measure the backlash with a dial indicator.
REQUIRED TOOL
BACKLASH
MEASUREMENT TOOL
(P/N 529 036 387)
2. Place the backlash measurement tool at the

end of pinion gear.
tmr2016-137-007
BACKLASH SHIM
Preload Inspection
Install the spline driver tool on the pinion shaft.
REQUIRED TOOL
SPLINE DRIVER
(P/N 529 036 386)
Using a needle torque wrench, measure the drag

tmr2017-205-002 torque.
A. 23 mm (29/32 in)
3. Position the dial indicator tip against the tab at

a 90° angle and right in the dimple.
4. Gently, move the tab back and forth. Note the
result.
NOTE: While measuring the backlash, make sure
the ring gear is not moving.
5. Rotate pinion gear 1/2 turn and check backlash
again. Note the result.
6. Rotate pinion gear 1 turn and check backlash
again.
tmr2016-137-009_a
10 219100971-024
PRELOAD SPECIFICATION
Maximum 0.50 N•m (4 lbf•in)
If preload is out of specification, split front differ-

ential housing and check all bearings conditions.
Front Differential Disassembly

Differential Housing
1. Remove front differential housing screws.
tmr2016-137-012
2. Remove screws securing ring gear to Visco-Lok

unit.
tmr2016-137-010
2. Separate half housings.

3. Remove oil seals.
tmr2016-137-013
3. Separate ring gear from Visco-Lok unit.
tmr2016-137-011
Visco-Lok Carrier/Ring Gear

1. Remove Visco-Lok carrier/ring gear out of half
tmr2016-137-014
housing.
Pinion Gear
REQUIRED TOOL
MULTIFUNCTION
DIFFERENTIAL TOOL
(P/N 529 036 385)
SPLINE DRIVER
(P/N 529 036 386)
1. Remove and discard oil seal.
219100971-024 11
4.3 Slide the pinion and the spline driver in

the multifunctional tool until the nut is
engaged.
4.4 Turn the spline driver clockwise to un-
screw the pinion.
tmr2016-137-015
2. Unscrew the pinion nut.

2.1 Lock the multifunctional tool and the spline
driver together with a screwdriver.
2.2 Slide the tools until it engage the nut.
2.3 Unscrew the nut. tmr2016-137-018
5. Remove bearing from pinion gear.
tmr2016-137-016
3. Remove bearing and pinion gear together. tmr2016-137-019
NOTE: If pinion is hard to pull out, attach the pro-

6. Remove and discard the needle bearing.
peller shaft to it and pull while hitting the yoke
with a soft hammer.
Front Differential Assembly
Adjustment is required when any of the following
part is changed.
– Pinion gear
– Ring gear
– Viscolok unit
– Housing.
As a preliminary setup, install shim according to
the following table.
RECOMMENDED SHIM THICKNESS
0.5 mm (.02 in)
BACKLASH
tmr2016-137-017 (as a preliminary adjustment)
4. Remove nut from pinion.

4.1 Install the multifunctional tool in a vice.
4.2 Slide the spline driver on the pinion shaft.
12 219100971-024
tmr2016-137-007 tmr2016-137-021
BACKLASH SHIM
Apply grease on new oil seals and install.
Prior to finalizing assembly, proceed in this order:
SERVICE PRODUCT
– Temporarily assemble final drive using recom-
mended torques. SYNTHETIC GREASE (P/N 779162)
– Do not apply thread locker product.
– Do not install a new pinion nut.
– Check backlash.
– Check preload.
Visco-Lok Carrier/Ring Gear
Apply threadlocker on Visco-Lok / ring gear screws
and tighten to specification.
TIGHTENING TORQUE
37 N•m ± 3 N•m tmr2016-137-011
Visco-Lok / ring gear
+ Tighten differential housing screws to specifica-
screws
LOCTITE 271 (RED) tion.
(P/N 293 800 005)
TIGHTENING TORQUE
Check condition of seal. Replace if damaged. Differential housing 23.5 N•m ± 3.5 N•m
Pinion Gear
Install a new ball bearing.
Install a new O-ring.
Install a new needle bearing.
Apply threadlocker to pinion nut.
Install and tighten the pinion nut to specification.
TIGHTENING TORQUE
203 N•m ± 13 N•m
tmr2016-137-020
Pinion nut (housing
+
and shaft)
Check bearings. Replace with new bearings if LOCTITE 271 (RED)
necessary. (P/N 293 800 005)
Apply grease on new oil seal and install.
219100971-024 13
SERVICE PRODUCT
Installing the Front Differential

TIGHTENING TORQUE
Differential retaining 65 N•m ± 5 N•m
screw (48 lbf•ft ± 4 lbf•ft)
Refill the front differential with recommended

oil. Refer to PERIODIC MAINTENANCE PROCE-
DURES subsection.
14 219100971-024
Subsection XX (SMART-LOK DIFFERENTIAL)
SMART-LOK DIFFERENTIAL
SERVICE TOOLS
BACKLASH MEASUREMENT TOOL............................................. 529 036 387 ............................................. 9
MULTIFONCTION DIFFERENTIAL TOOL ..................................... 529 036 385 ........................................... 20
SPLINE DRIVER ............................................................................ 529 036 386 ....................................... 9, 20
219100903-013 1
SMART-LOK DIFFERENTIAL
NEW
12 ± 2 N•m
26 ± 3 N•m (8.5 ± 1.5 lbf•ft)
(19.5 ± 2.5 lbf•ft)
See adjustment procedure

NEW
NEW NEW
NEW
61 ± 7 N•m
(45 ± 5 lbf•ft)
NEW
12 ± 2 N•m
(8.5 ± 1.5 lbf•ft)

16 ± 3 N•m
(12 ± 2 lbf•ft)
NEW
3 N•m
8.5 ± 1.5 N•m
(6 ± 1 lbf•ft) NEW
203 ± 14 N•m 26 ± 3 N•m 12 ± 2 N•m
(150 ± 10 lbf•ft) (19.5 ± 2.5 lbf•ft) (8.5 ± 1.5 lbf•ft)
NEW

219100903-013-099
2 219100903-013
WIRING HARNESS AND CONNECTORS

Maverick X3 Model Shown
2X4_4X4_SW
219100903-013-299_a
219100903-013 3
GENERAL
The FDM electronically manages the pressure on
the clutch pack in order to optimize the traction
and handling characteristics of the vehicle while
in 4x4 mode.
4 219100903-013
219100903-013-399
SMART-LOK FRONT DIFFERENTIAL SYSTEM

1. The actuator motor
2. The front differential
3. A wiring harness
4. The Front Differential Module (FDM)
5. The 2 switches on the dash
219100903-013 5
9
8 10
2
3
4 5 6 7
11 12
1
13 15 17
14 19
16 21
18 20 24
22
25
23
26
29 27
31 28
30
32
219100903-013-199
1. Oil seal 17. Clutch pack

2. Speed sensor 18. Thrust washer
3. O-ring 19. Thrust bearing
4. Backlash shim 20. Ball ramp and return spring
5. Tone ring 21. Balls
6. Ball bearing 22. Right hand cover
7. Ring gear 23. Fill plug
8. Output gear 24. Oil seal
9. Spider gear 25. Actuator assembly
10. Spider gear housing 26. Needle bearing
11. Cross pin retainer 27. Drain plug
12. Fill shim 28. Pinion
13. Center case 29. Pinion bearing
14. Ball bearing 30. Nut
15. Retaining ring 31. Nut
16. Clutch pack adjustment shim 32. Pinion seal
6 219100903-013
LOCKING SEQUENCE
219100903-013-001
1. Left hand section

2. Middle section
3. Right hand section
219100903-013-007
When the FDM receives the lock signal from the Left hand section
front diff lock switch, it applies full current to the
actuator motor for 1,5 seconds.
219100903-013-002
The left hand section includes the ring gear, back-

219100903-013-006
lash adjustment, spider gears, and output gears.
1 second after receiving the lock signal, the FDM
will activate the lock solenoid.
Middle section
The FDM will remove current from the actuator
motor, and the locking pawl will maintain the dif-
ferential in full lock mode.
NOTE: You should be able to hear the actuator
motor turn the locking mechanism and the lock
solenoid engage.
DIFFERENTIAL
The smart-lok differential can be viewed in 3 main
sections.
219100903-013-003
The middle section contains the pinion.
219100903-013 7
Right hand section When the top of the front diff lock switch is
pressed, the FDM will begin the LOCKING SE-
QUENCE.
The front differential will remain locked until the
button is pressed again, the mode is changed, or
the unit is turned off.
FRONT DIFFERENTIAL MODULE

(FDM)
219100903-013-004
The right hand section contains the ball ramp and

clutch pack.
ACTUATOR MOTOR ASSEMBLY

The actuator motor assembly includes an electric
motor, reduction gears, and a solenoid that con-
trols the locking pawl.
219100903-013-039
219100903-013-005
219100903-013-040
1. Electric motor
2. Reduction gears
3. Solenoid and pawl The FDM controls the current to the actuator mo-
tor, which applies torque to the clutch pack.
The solenoid activates the locking pawl when the
front differential is locked. FDM Inputs
From the CAN bus:
SWITCHES – Estimated steering position
There are two switches: – Engine speed and torque
– 3 position combination toggle/pushbutton – Transmission gear position
switch (front 2x4, 4x4, diff lock) – Vehicle speed (from rear wheel speed sensor)
– Front differential mode switch (if applicable, ac- – TAS signal
cording to vehicle package) – Vehicle configuration identifier (CDID)
When the toggle switch is set to 4X4, the FDM Direct inputs:
electronically manages the front differential ac-
cording to the selected mode on the mode switch – Diff lock switch
(modes vary by model, see the OPERATOR'S – 4X4 switch
GUIDE). – Mode switch (if applicable, according to vehicle
package)
8 219100903-013
– Front wheel speed sensors

– Switched power supply from vehicle
FDM Outputs
– Actuator motor
– Lock solenoid
– Switch backlight
ADJUSTMENT
There are adjustment shims for the backlash and 219100903-013-021
the clutch pack. 1. Backlash shim

2. fill shim
The backlash must be adjusted and the left hand
side of the differential must be assembled before Inspecting and Adjusting Backlash
adjusting the clutch pack shim(s).
Do not damage the speed sensor.
PRELOAD When measuring backlash, the differential cover
should be upside down to pull the ring gear out of
Install the spline driver tool on the pinion shaft. mesh.
REQUIRED TOOL
SPLINE DRIVER
(P/N 529 036 386)
Using a needle torque wrench, measure the drag

torque.
219100903-013-022
1. Measure the backlash with a dial indicator.

REQUIRED TOOL
BACKLASH
MEASUREMENT TOOL
(P/N 529 036 387)
219100903-013-023
PRELOAD SPECIFICATION
2. Place the backlash measurement tool at the
Maximum 1.5 N•m (13 lbf•in) end of pinion gear.
If preload is out of specification, split front differ-
ential housing and check all bearings conditions.
BACKLASH
NOTE: Turn the pinion gear by hand 4 full turns
before checking backlash, there should be no tight
spots or binding.
If rebuilding the differential, check and adjust the
backlash without the fill shim.
219100903-013 9
Repeat until backlash is within specifications.

Then more on to MEASURING AND SELECTING
A FILL SHIM.
Measuring and Selecting a Fill Shim
NOTE: It is important to install the correct back-
lash shim first. Only then move on with measur-
ing and selecting a fill shim..
1. Measure and note the distance between the
middle casing and the bearing inner race no. A.
tmr2017-205-002 NOTE: Use a straight edge and a slide caliper.
A. 23 mm (29/32 in)
3. Position the dial indicator tip against the tab at

a 90° angle and right in the dimple.
4. Gently, move the tab back and forth. Note the
result.
NOTE: While measuring the backlash, make sure
the ring gear is not moving.
5. Rotate pinion gear 1/2 turn and check backlash
again. Note the result.
6. Rotate pinion gear 1 turn and check backlash
again.
BACKLASH SPECIFICATION 219100903-013-061
0.127 mm to 0.305 mm (.005 in to .012 in) 2. With the correct backlash shim installed and the
to 0.25 mm (.01 in) bearing resting on this shim, measure and note
the distance between the top of the differential
If backlash is out of specification, split front dif- gear assembly and the left hand cover.no. B.
ferential housing and adjust shim thickness as per
NOTE: Use a straight edge and a slide caliper.
following guideline.
BACKLASH ADJUSTMENT GUIDELINE
BACKLASH
WHAT TO DO
MEASUREMENT
Below 0.127 mm Install a thinner shim and
(.005 in) recheck backlash
Above 0.305 mm Install a thicker shim and
(.012 in) recheck backlash
219100903-013-062
Use a shim thickness equal or less than the calcu-

lation result.
FILL SHIM GUIDELINE
Measurement no. A -
= Fill shim thickness
measurement no. B
219100903-013-026
3. Choose the correct fill shim from the available
BACKLASH SHIM service kit.
10 219100903-013
CLUTCH PACK DIFFERENTIAL WILL NOT LOCK - CANNOT

HEAR ACTUATOR MOVING
Refer to REPLACING THE CLUTCH PACK in this
subsection. 1. Loose connection at connector
- Ensure FDM and all other connectors are corro-
FLUID LEVEL sion free and properly connected.
- Connect BUDS2 and check the FDM for faults to
NOTE: Refer to vehicle TECHNICAL SPECIFICA- explain the situation.
TIONSsubsection for fluid type and capacity. - If you cannot see the FDM in BUDS2, check FDM
1. Park the unit on a level surface. electrical connections.
- Monitor switch functions in measurement page.
2. Remove the fill plug.
- Validate mode selected (Diff lock) -The FDM
should try to lock, if it doesn't, follow the fault
troubleshooting procedure in BUDS2.
- Use BUDS2 and refer to fault codes P3400 and
P3401 for continuity test and actuator test.
DIFFERENTIAL WILL NOT LOCK - CAN

HEAR ACTUATOR MOVING
1. Lock solenoid not working
- Remove oil fill plug and observe ball ramp move-
ment. Refer to REPLACING THE CLUTCH PACK
in this subsection for proper movement and ad-
justment. If the ball ramp does not stay locked it
suggests that the lock solenoid is not engaging.
219100903-013-059
- Use BUDS2 and refer to fault codes P3402 and
P3403 for continuity test and actuator test.
3. The fluid should be level with the bottom of the
fill plug hole. CANNOT KEEP FRONT WHEELS LOCKED
TOGETHER IN LOCK MODE
TROUBLESHOOTING 1. Worn clutch pack or actuator/solenoid issue.
Connect BUDS2 to the vehicle's diagnostic con- - Use BUDS2 and refer to fault codes P3400 P3401
nector and read the vehicle. Correct any occurred (Actuator motor)
faults prior doing any troubleshooting. - Use BUDS2 and refer to fault codes P3402 P3403
If unsure, a good place to start is with the TEST- P3404, (solenoid)
ING THE FDM procedure in this subsection. - Use BUDS2 and refer to fault codes P3405 P3406
mechanical issues
The FDM is able to self diagnose the system.
- Use BUDS2 and refer to fault code P215A for
There are several electrical diagnostic, functional clutches issue (it could be also a left speed sen-
diagnostic, and input diagnostics available thru sor fault for this specific code)
BUDS2.
2. DPS fault, no steering angle calculation trans-
Wake-up the vehicle. Using BUDS2, connect to mitted on CAN
the FDM. Check for possible occurred faults to ex- - Check for fault codes, module updates, or miss-
plain the situation. If no connection: ing modules.
– Validate FDM connections
3. CAN system fault
– Validate switches using the measurement page
- Check for fault codes, module updates, or miss-
– Validate mode selected (Diff lock). The FDM ing modules.
should try to lock, if it fails, follow faults trou-
bleshooting procedure in BUDS2. 4. Worn clutch pack
- Check adjustment. Refer to REPLACING THE
CLUTCH PACK in this subsection.
DIFFERENTIAL WILL NOT UNLOCK

1. Ball ramp not resetting to open position
- Check ball ramp return spring.
219100903-013 11
2. Lock solenoid stuck TESTING A SPEED SENSOR

- Refer to BUDS2 fault codes for actuator, solenoid
and mechanical issues. It could be detectable by
the FDM. Check the ball ramp return spring.
- Try a new actuator.
PROCEDURES
TESTING BALL RAMP RETURN
SPRING
NOTICE Do not activate the actuator when it
is removed from the differential, it can damage
the actuator.
219100903-013-057
1. Remove actuator. 1. Left hand wheel speed sensor (wheel sensor)

2. Average wheel speed sensor (Carriage sensor)
2. Using a flat screwdriver on the ball ramp teeth,
try to move the ball ramp counterclockwise. PIN HEADER
A 12 volts
B Signal to FDM
C Ground
1. Turn ignition ON.

2. Lock and unlock front differential to validate
that it functions properly.
3. Verify sensor supply voltage at key-On between
pin-A and pin-C. Expect battery voltage.
4. Verify sensor pull-up voltage at key-On between
pin-B and pin-C. Expect more then 5 volts.
219100903-013-058
5. Verify continuity between pin-B of the sensor's
3. You should feel the resistance of the spring. connector and corresponding pin on the FDM.
Refer to WIRING DIAGRAM Expect close to
4. Remove the screwdriver and the ball ramp 0 .
should return to it's original position.
6. Inspect the sensor and tone ring.
5. If ball ramp turns freely (no resistance), remove
right hand cover and inspect return spring. Testing the Speed SensorSignal
NOTICE Back probing is not recommended
to maintain proper sealing of the electrical
connectors.
1. Lift front of vehicle so that front wheels are off
the ground.
2. Set transmission to 2WD and to Neutral.
3. Turn ignition ON.
12 219100903-013
NOTE: The left speed sensor measures the ex- TESTING THE FDM
act speed from the left wheel. To generate a sig-
nal on the average front wheel speed sensor in There are no specific tests for the FDM.
2WD mode, the right wheel has to be immobi- The FDM should be visible in BUDS2. Check for
lized, then, by turning the left wheel both wheels fault codes and updates.
sensors should signal a rotation. If the module is not visible in BUDS2, refer to the
4. Start procedure by turning the wheels manu- wiring diagram and check for the following.
ally and observing the measurement page in
PIN SPECIFICATION
BUDS2. If no signal is measured, check the
sensor's supply voltage. Refer to TESTING A FDM-1
12Vdc Power (hot at
SPEED SENSOR in this subsection. all times)
5. If only one sensor doesn't signal RPM and all FDM-7
12 Vdc MODULE
the electrical connections and wire continuity WAKE-UP at key on
are good for the faulty sensor, both sensors FDM-9 Ground
may be swapped to validate if it is the speed
sensor or a tone ring issue. FDM-2 CAN-HI
REQUIRED TOOLS FDM-3 CAN-LOW
If the FDM receives power, ground, and CAN

communication, test individual system com-
(P/N 529 035 868)
ponents and their wires to the FDM. Refer to
GENERAL for an overview of system compo-
SIGNAL TEST nents.
RESULT
TEST PROBES (WHILE ROTATING TESTING THE ACTUATOR
WHEELS)
NOTICE Do not bench test the actuator.
Alternate reading
PIN B PIN C between battery Perform the test with the actuator installed on the
voltage and 0 Vdc
differential.
NOTE: Since we measure pulsating voltage, the 1. Raise and support the front of the vehicle.
numeric display will continuously change. The 2. Wake up the unit by pressing the start/stop but-
analog display may be easier to follow. ton.
3. Ask an assistant to press the diff lock button
and listen for the motor.
4. You should hear the motor turn on for 1.5 sec-
onds.
5. You should hear the lock solenoid engage after
1 second.
6. The front wheels should be locked and should
not turn individually.
7. Ask the assistant to press the diff lock button
again, to unlock the differential.
smr2005-056-010_a
1. Analog display 8. You should hear the solenoid disengage.

9. The motor should wind down to it's original po-
If signal is not as per specification, remove sensor sition.
and inspect the tone ring.
10. You should be able to turn the front wheels
If tone ring is in good condition, replace the sen- individually.
sor.
REPLACING THE ACTUATOR
1. Disconnect the actuator's electrical connector.
219100903-013 13
2. Remove the retaining screws. REPLACING THE CLUTCH PACK

1. Remove the fill plug.
219100903-013-041
3. Remove the actuator. 219100903-013-059
2. Remove the drain plug, drain the fluid.
219100903-013-042
219100903-013-009
4. Apply differential fluid or white lithium grease

on the actuator's o-ring. 3. Remove the actuator assembly.
5. Install the new actuator.
6. Install and tighten the 3 retaining bolts on the
right hand cover.
219100903-013-010
4. Remove the right hand cover.
219100903-013-043
7. Install and tighten the remaining screw.

8. Connect the electrical connector.
14 219100903-013
219100903-013-012 219100903-013-015
5. Remove the thrust bearing and thrust washer. 8. Keep the original shim installed in it's place.
219100903-013-013 219100903-013-016
1. Thrust bearing
2. Thrust washer 9. Install the new clutch pack, thrust washer, and
thrust bearing.
6. Remove the clutch pack.
10. Install and torque right hand cover following
the sequence without any sealant.
219100903-013-014
7. Clean the sealant off of the middle and right 219100903-013-017
hand differential sections. COVER TORQUE SEQUENCE
NOTE: Make sure to clean the sealant in the 11. Install the actuator and torque retaining
grooves of the right hand cover. screws.
12. Connect the actuator motor to the electrical
harness.
13. Wake-up the unit by pressing the start/stop
button.
14. Observe the ball ramp through the fill plug
hole while someone else presses the diff lock
switch.
219100903-013 15
219100903-013-018 219100903-013-020
OBSERVE PROTRUSION PROTRUSION GOES PAST THE ACCEPTABLE RANGE, INSTALL

A THICKER SHIM
16. Once the clutch pack is properly adjusted, re-

move the right hand cover.
17. Apply sealant.
SEALANT APPLICATION
LOCTITE 5699
18. Install and torque right hand cover following

the sequence and specifications.
19. Install the differential on the unit.
20. Connect all electrical connectors.
219100903-013-060
ACCEPTABLE ADJUSTMENT RANGE 21. Adjust the differential fluid level, refer to
1. Detail on right hand cover FLUID LEVEL.
A. Acceptable range for protrusion
15. The protrusion on the ball ramp should be DISASSEMBLING THE

within the acceptable range as visible in the DIFFERENTIAL
fill hole when the differential is fully locked.
1. Remove the clutch pack. Refer to REPLACING
15.1 If the protrusion goes past the hole, in- THE CLUTCH PACK in this subsection.
stall a thicker shim.
2. Remove speed sensors.
15.2 If the protrusion stops before the hole,
install a thinner shim.
15.3 Repeat until protrusion is visible straight
thru the fill plug hole.
219100903-013-024
3. Remove the left hand cover.
219100903-013-019
PROTRUSION STOPS BEFORE THE HOLE, INSTALL A THINNER

SHIM
16 219100903-013
7. Remove the fill shim.
219100903-013-025
4. Inspect o-ring, replace if damaged.

219100903-013-028
8. Use 2 screwdrivers to pry off the tone ring. Dis-

card it.
219100903-013-027
5. Remove the backlash shim.

219100903-013-029
9. Use 2 screwdrivers to pry off the bearing. Dis-

card it.
219100903-013-026
6. Remove the differential gear assembly.
219100903-013-030
10. Mount the differential in a vise.

NOTICE Use aluminum angle bars to over
the jaws to protect the splines.
219100903-013-038
219100903-013 17
14. Remove the differential from the vise.

15. Straighten the locking tabs.
219100903-013-031
11. Remove the ring gear retaining screws. Dis-

card them.
219100903-013-034
16. Remove the cross pin retainer.
219100903-013-032
12. Remove the ring gear.

219100903-013-035
17. Remove the cross pins and coupler.
219100903-013-033
13. Remove the left hand output shaft.

219100903-013-036_1
18. Remove spider gears and right hand output

shaft.
219100903-013-036
18 219100903-013
219100903-013-037
219100903-013-044
ASSEMBLING THE 3. Install the ring gear and torque the new screws
DIFFERENTIAL to specifications in a criss-cross pattern.
Adjustment may be required when any of the fol-
lowing parts are replaced.
– Pinion gear
– Ring gear
– Bearing
– Clutch pack
– Housing.
Prior to finalizing assembly, proceed in this order:
– Temporarily assemble final drive using recom-
mended torques.
– Do not apply thread locker product.
– Do not install a new pinion nut. 219100903-013-046
– Check backlash.
4. Recheck torque on all screws.
– Check preload.
5. Install a new left hand bearing.
NOTICE Coat moving contact surfaces with
differential fluid during assembly.
1. Reassemble the spider gear housing, refer to
the illustration at the beginning of this section.
219100903-013-047
6. Install the right hand bearing.
219100903-013-045
2. Install the cross pin retainer and punch down

the tabs.
219100903-013 19
219100903-013-050 219100903-013-051
7. Install a new tone ring Check condition of o-ring. Replace if damaged.

12. Coat o-ring with differential fluid.
13. Install the left hand cover and o-ring.
14. Torque the left hand cover retaining screws.
15. Install the right hand side components. Re-
fer to REPLACING THE CLUTCH PACK in this
subsection.
16. Coat oil seals with differential fluid.
17. Install all oil seals.
18. Check the preload. Refer to PRELOAD in this
subsection.
219100903-013-048
19. Install the actuator.
20. Install the drain plug.
8. Install the previously removed backlash shim.
21. Install any other removed components like
speed sensors.
22. Place the differential on a level work surface.
23. Fill the differential with oil. Refer to FLUID
LEVEL.
24. Install the differential on the unit.
REPLACING THE PINION

REQUIRED TOOL
MULTIFONCTION
DIFFERENTIAL TOOL
219100903-013-049 (P/N 529 036 385)
9. Install the ring gear assembly without the fill SPLINE DRIVER
shim. (P/N 529 036 386)
10. Check the backlash, adjust if necessary. Refer
to BACKLASH in this subsection. 1. Remove and discard oil seal.
11. Install the applicable fill shim as specified in
the BACKLASH adjustment procedure in this
subsection.
20 219100903-013
4.3 Slide the pinion and the spline driver in

the multifunctional tool until the nut is
engaged.
4.4 Turn the spline driver clockwise to un-
screw the pinion.
219100903-013-052
2. Unscrew the pinion nut.

2.1 Lock the multifunctional tool and the spline
driver together with a screwdriver.
2.2 Slide the tools until it engage the nut.
2.3 Unscrew the nut. 219100903-013-055
5. Remove bearing from pinion gear.
219100903-013-053
3. Remove bearing and pinion gear together. 219100903-013-056
NOTE: If pinion is hard to pull out, attach the pro-

6. Remove and discard the bearing.
peller shaft to it and pull while hitting the yoke
with a soft hammer. Installation is the reverse of removal procedure.
219100903-013-054
4. Remove nut from pinion.

4.1 Install the multifunctional tool in a vice.
4.2 Slide the spline driver on the pinion shaft.
219100903-013 21
Subsection XX (REAR DRIVE)
REAR DRIVE
SERVICE TOOLS
CV BOOT CLAMP PLIER .............................................................. 529 036 120 ............................................. 3
CV JOINT EXTRACTOR................................................................. 529 036 005 ............................................. 3
SERVICE PRODUCTS
SYNTHETIC GREASE .................................................................... 779162 ......................................... 2–3
NEW
XPS Synthetic
grease
NEW
250 ± 15 N•m
(184 ± 11 lbf•ft)
NEW
NEW XPS Synthetic

grease
tmr2017-043-100_a
219100971-025 1
PROCEDURES
WHEEL HUB
Removing the Wheel Hub
1. Lift and support vehicle. Refer to INTRODUC-
TION section.
2. Select the 4WD position, place the transmis-
sion lever on "P".
3. Remove caliper from knuckle. Refer to
BRAKES subsection.
tmr2017-042-008
4. Remove the following parts:
– Cotter pin Install Belleville washer with its domed side out-
– Castellated nut wards.
– Belleville washer.
tmr2016-137-003
TYPICAL
tmr2016-137-002
TYPICAL TIGHTENING TORQUE

5. Remove wheel hub. 250 N•m ± 15 N•m
Castellated nut
Inspecting the Wheel Hub
Check wheel studs for damaged threads and over- NOTE: Tighten further castellated nut if required
all conditions to align grooves with drive shaft hole.
Check wheel hub for cracks or other damages. Install a new cotter pin.
Check inner splines for wear or other damages.
DRIVE SHAFT
Replace wheel hub and / or studs if any damage
is detected. Removing the Rear Drive Shaft
1. Remove the wheel hub. Refer to procedure in
Installing the Wheel Hub this subsection.
The installation is the reverse of removal proce- 2. Remove the knuckle. Refer to REAR SUSPEN-
dure. However, pay attention to the following. SION subsection.
Apply grease all around drive shaft and wheel hub 3. Strongly pull drive shaft out of gearbox.
splines, and on the outer cylindrical surface.
NOTE: Keep track of the O-ring between the drive
SERVICE PRODUCT shaft and the gearbox.
SYNTHETIC GREASE (P/N 779162) 4. Discard the stop ring at the end of the shaft.
2 219100971-025
Inspecting the Rear Drive Shaft 4. Remove boot from drive shaft.
Inspect the condition of boots. If there is any dam- 5. Remove and discard the circlip.
age or evidence of leaking lubricant, replace them.
Refer to DRIVE SHAFT BOOT in this subsection. With the Special Tool
Check splines for excessive wear. Replace if nec- REQUIRED TOOL
essary. CV JOINT EXTRACTOR
NOTE: If the splines on the drive shaft joint are (P/N 529 036 005)
worn, a check of differential inner splines should
be done. 1. Place drive shaft in vice with the joint down-
ward.
Installing the Rear Drive Shaft 2. Install the cv joint extractor on the bearing.
Install a new stop ring.
V07H0AA
1. Stop ring
tmr2013-088-003_a
Apply grease all around splines at both ends. TYPICAL - CV JOINT SHOWN
1. Position joint extractor tool here
SERVICE PRODUCT
3. With a hammer, hit on the tool to separate joint
SYNTHETIC GREASE (P/N 779162) from shaft.
Ensure the O-ring is properly installed. 4. When joint and shaft are separated, remove
boot from drive shaft.
DRIVE SHAFT BOOT 5. Remove and discard the circlip.
Removing the Drive Shaft Boot Installing the Drive Shaft Boot
1. Remove the drive shaft from the vehicle. The installation is the reverse of the removal pro-
2. Remove drive shaft boot clamps. cedure. However, pay attention to the following.
REQUIRED TOOL
Install the new circlip.
Pack bearing area and inside of the drive shaft
CV BOOT CLAMP PLIER boot with grease included with the new boot kit.
(P/N 529 036 120)
NOTE: Do not use or add other grease.
3. Dislodge the large boot end.
4. Separate the joint from the shaft. Two proce-
dures can be done.
Without the Special Tool
1. Clamp joint housing in a vise.
2. Align shaft with joint.
3. Pull hard on shaft to remove from joint.
219100971-025 3
Subsection XX (STEERING SYSTEM)
STEERING SYSTEM
SERVICE TOOLS
STEERING ALIGNMENT TOOL..................................................... 529 036 059 ............................................. 4
SERVICE PRODUCTS
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ............................... 10, 12–13
SYNTHETIC GREASE (EUR) .......................................................... 779231 ........................................... 10
SYNTHETIC GREASE .................................................................... 779162 ........................................... 10
219100971-026 1
See tightening Loctite 767 Loctite 767

procedure (antiseize (antiseize
lubricant) lubricant)
See tightening
procedure 0.65 ± 0.15 N•m
NEW (6 ± 1 lbf•in)
NEW
NEW
See tightening
procedure
Loctite 767 Synthetic
(antiseize grease
lubricant)
NEW
See tightening
procedure
NEW
60 ± 5 N•m
(44 ± 4 lbf•ft)
See tightening 105 ± 15 N•m

procedure (77 ± 11 lbf•ft)
NEW
NEW
Loctite 767
(antiseize
lubricant)
105 ± 15 N•m
(77 ± 11 lbf•ft)
NEW
NEW
NEW NEW = Component must be replaced when removed.
219100971-026_002_a
2 219100971-026
GENERAL ALIGNING THE WHEELS

NOTICE Never perform arc welding in the 1. Place vehicle on a level surface.
DPS area. Otherwise, poor DPS operation 2. Inflate tires to recommended pressure.
might occur.
3. Find rack and pinion center to center as follows:
ADJUSTMENT 3.1 Calculate the total steering wheel rota-
tions from side to side.
ALIGNING THE STEERING 3.2 Position the steering wheel at half the to-
tal rotations.
COMPONENTS
4. Check steering wheel position:
IMPORTANT: This procedure may solve most of
the DPS steering issues and must be carried out 4.1 If steering wheel is centered (within ± 3°),
before a torque offset reset procedure. go to step 6.
NOTE: The steering components alignment pro- 4.2 If steering wheel is off center of more than
cedure will ensure that no axial or radial loads 3°, go to step 5.
are applied to the DPS shaft which would result
in poor DPS operation. All steering components
must be aligned with the rack and pinion, and
torqued starting from the rack and pinion, then
upwards sequentially to each component from
there.
1. Ensure the rack and pinion is centered. Refer
to ALIGNING THE WHEELS.
2. Ensure steering wheel is within 8° of horizontal
position.
3. Loosen the fasteners retaining the following
steering components sufficiently to provide
free movement of the component: A
– Pinch bolts on upper and lower steering col- tmr2017-045-210_a
umn U-joints A. Steering wheel angle ± 3°
– All fasteners on the DPS support. 5. Reposition steering wheel on steering shaft as
4. Re-torque the fasteners to specification using follows:
the specified sequence. Refer to STEERING
NOTICE Make sure rack and pinion does
SYSTEM TIGHTENING SEQUENCE in this sub-
section. not move during steering wheel reposi-
tioning.
5. Perform the STEERING SYSTEM SELF TEST
procedure. Refer to DYNAMIC POWER 5.1 Remove steering wheel. Refer to RE-
STEERING (DPS) subsection. MOVING THE STEERING WHEEL.
NOTICE The steering system tightening se- 5.2 Reinstall steering wheel to the closest
quence must be strictly followed. Failure to centered position.
do so may result in a steering component 6. Center steering wheel.
misalignment, poor DPS operation due to an
induced erroneous torque on DPS shaft, or the
impossibility to perform a torque sensor reset.
A magnetized component in contact with DPS
shaft might also affect the ability to reset the
torque sensor.
IMPORTANT: Make sure the pinch bolt is en-
gaged in the shaft groove where applicable.
6. Carry out a steering alignment. Refer to ALIGN-
ING THE WHEELS if needed.
219100971-026 3
A
tmr2017-045-201_a
A. Steering wheel centered vmr2008-068-005_a
TYPICAL
7. Remove two wheel lug nuts from a rear wheel.
8. Install steering alignment tool using proper 14. Slowly move rope back until it makes contact
spacers. with spacer.
REQUIRED TOOL
STEERING ALIGNMENT
TOOL (P/N 529 036 059)
9. Move vehicle to place the tool, level with the

ground.
vmr2008-068-007
TYPICAL
15. Keep rope in this position.

16. Measure distance of the front wheel between
rope and rim as follows:
– At the front of rim
– At the rear of rim.
vmr2008-068-006_a
REAR WHEEL
1. Steering adjustment tool
2. Angle gauge or level
10. Place a rope around vehicle tires

11. Using an elastic, link both ends together.
12. Adjust rope at the center of the wheels.
13. From the front of vehicle, near the front of rim,
move rope so that it does not touch the first
spacer of tool.
vmr2008-068-008
TYPICAL — AT THE FRONT OF RIM
4 219100971-026
A
vmr2008-068-009
TYPICAL — AT THE REAR OF RIM
17. Calculate the difference between the rear and tmr2017-045-212_a
the front measurement. FRONT VIEW

A. Measure distance
18. The difference must be as per the following
specification: 4. Roll vehicle forward so that the tires make a
complete a 180° rotation.
TOE OUT
NOTE: Distance from ground no. B to mark on tire
7.7 mm ± 5.1 mm (.303 in ± .201 in) must equal distance from ground no. A in step 2
for a proper measurement.
19. If the wheel toe measurement is out of specifi-
cation adjust tie-rod length. Refer to ADJUST-
ING TOE.
20. Repeat procedure for the other wheel.
Adjusting Toe
1. If the front wheel toe measurement is out of
specification lock steering wheel at center.
2. Place one mark on each (LH and RH) tire with
a chalk. The marks must be at the same height
(measured) on each front tire.
B
tmr2017-045-211_a
FRONT LH VIEW AFTER ROTATION

1 same two marks as step 3.
6. Calculate the difference between the front and
the rear measurements.
7. Loosen tie-rod end locking nut.
A
tmr2017-045-202_a
FRONT LH VIEW
1. Mark tire
A. Distance from ground to mark

center of the wheels, level with the marks on
the tires.
219100971-026 5
10. Recheck that vehicle toe is within limits by re-

peating procedure.
1
TROUBLESHOOTING
CUSTOMER COMPLAINT ABOUT THE
STEERING SYSTEM
1. DPS or mechanical failure.
- Refer to TROUBLESHOOTING in the DPS sub-
section.
UNEQUAL TURNING RADIUS

tmr2017-044-301_a 1. Rack and pinion not centered during steering
1. Tie-rod end locking nut system parts installation.
- Refer to ALIGNING THE WHEELS in this subsec-
8. Turn tie-rod adjustment sleeve until distance tion.
measured in step 2 is equal for each wheel.
NOTE: Adjustment sleeve and inner tie rod will
turn together.
WARNING
The minimum inner tie-rod and tie rod end
engagement in adjustment sleeve must be
25 mm (1 in).
tmr2017-045-207_a
A. Minimum engagement length
MINIMUM INNER TIE-ROD AND TIE ROD

END ENGAGEMENT IN ADJUSTMENT
SLEEVE LENGTH A
25 mm (1 in)
9. Tighten tie-rod adjustment sleeve locking nuts

to specification.
TIGHTENING TORQUE
34 N•m ± 2 N•m
Tie-rod end locking nut
6 219100971-026
PROCEDURES
STEERING SYSTEM TIGHTENING SEQUENCE
3
1
2
1
1 1
D C
2
4
5 3 1
219100971-026_008_d
219100971-026 7
TIGHTENING TORQUE
no. 1 - 5 Apply torque on bolts 120 N•m (89 lbf•ft)
STEP A 35 N•m to 45 N•m
no. 6 Apply torque on nut
(26 lbf•ft to 33 lbf•ft)
35 N•m to 45 N•m
STEP B no. 1 Apply torque on nut
22 N•m ± 2 N•m
STEP C no. 1 - 3 Apply torque on bolts
35 N•m to 45 N•m
no. 1 Apply torque on nut
STEP D
21 N•m to 28 N•m
no. 2 - 3 Apply torque on bolts
STEERING WHEEL
Removing the Steering Wheel
1. Remove steering wheel cap using a small
screwdriver.
2. Remove nut securing steering wheel to shaft.
Discard the nut.
3. Remove steering wheel by pulling it upwards.
Installing the Steering Wheel

tmr2017-044-216_a
Prior to installing the steering wheel, place front
wheels parallel with the vehicle. 2.2 Unplug and remove the gauge.
Tighten steering wheel retaining nut to specifica-
tion.
TIGHTENING TORQUE
60 N•m ± 5 N•m
Steering wheel nut
Check front wheel alignment. Refer to ALIGNING

THE WHEELS in this subsection.
STEERING SHAFT
Removing the Steering Shaft
1. Remove the steering wheel. Refer to proce-
dure in this subsection. tmr2017-044-217_a
NOTE: Remove steering wheel only if the steer-

3. Remove the bolt securing the bottom of the tilt
ing shaft must be replaced.
mechanism shock.
2. Remove the multifunction gauge.
2.1 Remove the gauge trim.
8 219100971-026
tmr2017-044-218_a tmr2017-044-221_a
4. Remove bolts retaining the pivot support of the 7. Remove circlip retaining the steering shaft to its
tilt mechanism. support.
tmr2017-044-219_a
tmr2017-044-222_a
5. Remove the pinch bolt securing the steering 8. Remove steering shaft.
shaft to the DPS.
2
1
2
tmr2017-044-223_a
tmr2017-044-220_a
1. Steering shaft
2. O-rings
6. Pull steering wheel to extract the steering shaft 3. Bushings
with the tilt mechanism.
Inspecting the Steering Shaft
Inspect if steering shaft is not bent or twisted.
Check steering shaft splines for wear or damage.
219100971-026 9
Check U-joint crosses. They should rotate Install steering shaft U-joint on DPS shaft. Align
smoothly without any play. the large tooth of the steering shaft U-joint with
Replace shaft if required. the indexation spline of the DPS shaft.
Installing the Steering Shaft

The installation is the reverse of the removal pro- 1
cedure. However, pay attention to the following
details.
Prior to installing the steering shaft, place front
wheels parallel with the vehicle.
Apply antiseize on splines.
SERVICE PRODUCT
LOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070)
Lubricate O-rings on steering shaft, and all around tmr2017-044-305_a

steering shaft on both side of O-rings. 1. Large tooth
SERVICE PRODUCT
Install pinch bolt. Do not torque yet.
Scandinavia: SYNTHETIC Install bolts retaining the pivot support of the tilt
GREASE (EUR) (P/N 779231)
mechanism.
All other countries: SYNTHETIC GREASE
(P/N 779162)
Make sure bushings are well inserted in the steer-

ing shaft support.
Align indexation spline on DPS shaft with the mark
on the DPS housing.
tmr2017-044-303_a
IMPORTANT: Before tightening U-joint pinch nut,

pull steering shaft to verify if the pinch bolt is cor-
rectly inserted in the DPS shaft groove.
Tighten pinch nut of steering shaft to specifica-
tion.
tmr2017-044-304_a
1. Indexation spline TIGHTENING TORQUE

2. DPS housing mark
35 N•m ± 3 N•m
Steering shaft pinch nut
Apply antiseize on splines. (26 lbf•ft ± 2 lbf•ft)
SERVICE PRODUCT Reinstall all other removed parts.

(P/N 293 800 070)
10 219100971-026
STEERING COLUMN
Removing the Steering Column
1. Remove pinch bolt securing the upper U-joint of
the steering column.
tmr2017-044-212_a
4. Loosen the bolts securing rack and pinion to

frame.
tmr2017-045-223_a
2. From inside of the vehicle, remove the steering

column rubber protector. Cut locking tie secur-
ing the protector on rack and pinion.
tmr2017-044-213_a
LH SIDE OF VEHICLE
tmr2017-044-211_a
3. Remove pinch bolt from steering column lower

U-joint.
tmr2017-044-214_a
RH SIDE OF VEHICLE
5. Remove the steering column.
Inspecting the Steering Column

Check steering column for wear, twisting or bend-
ing.
219100971-026 11
Ensure universal joints are not worn and move 4. On the LH side of the vehicle, detach the stabi-
freely. lizer bar link from the stabilizer bar.
Replace steering column if necessary.
Installing the Steering Column

Prior to installing the steering column, position
front wheels parallel with the vehicle.
Apply antiseize on splines.
SERVICE PRODUCT
(P/N 293 800 070)
Position steering column in vehicle and insert up- tmr2017-044-209_a

per U-joint on DPS output shaft.
Loosely install a M8 pinch bolt with a new M8 nut 5. Detach the shock absorber from the suspen-
to secure the upper U-joint. sion arm.
Engage the pinion shaft of the rack and pinion
in the lower steering column U-joint. Make sure
steering wheel remains centered.
Loosely install rack and pinion retaining bolts.
Loosely reinstall the M8 pinch bolt with a new M8
nut to secure the lower U-joint.
Tighten all fasteners as outlined in STEERING
SYSTEM TIGHTENING SEQUENCE.
NOTICE The steering system tightening se-
quence must be strictly followed. Failure to
do so may result in a steering component
induced erroneous torque on DPS shaft, or the tmr2017-044-210_a
impossibility to perform a torque sensor reset.

6. From inside of the vehicle, remove the steering
Check front wheel alignment. Refer to ALIGNING column rubber protector. Cut locking tie secur-
THE WHEELS in this subsection. ing the protector on rack and pinion.
RACK AND PINION

Servicing the Rack and Pinion
The rack and pinion cannot be serviced except for
replacement of the boots and tie rods.
Removing the Rack and Pinion

2. Remove both front wheels.
3. Detach tie-rod ends from knuckles. Refer to
REPLACING THE TIE ROD END in this subsec- tmr2017-044-211_a
tion.
12 219100971-026
7. Remove pinch bolt from steering column lower 10. Remove rack and pinion from vehicle.
U-joint.
Installing the Rack and Pinion
Find rack and pinion center as follows:
– Calculate the total pinion shaft rotations from
side to side.
– Position the pinion shaft at half the total rota-
tions.
– Using a paint marker, make an alignment mark
on pinion and on the rack housing.
tmr2017-044-212_a
8. Remove the bolts securing rack and pinion to 1

frame.
2
tmr2017-044-215_a
1. Alignment mark on pinion

2. Alignment mark on rack housing
Ensure steering wheel is centered (horizontal).

Apply antiseize on the splines of the lower U-joint
of the steering column.
tmr2017-044-213_a
SERVICE PRODUCT
LH SIDE OF VEHICLE
(P/N 293 800 070)
Position rack and pinion in frame and engage the

pinion shaft in the steering column U-joint. Make
sure steering wheel remains centered.
Loosely install rack and pinion retaining bolts.
SYSTEM TIGHTENING SEQUENCE.
NOTICE The steering system tightening se-
quence must be strictly followed. Failure to
do so may result in a steering component
tmr2017-044-214_a
induced erroneous torque on DPS shaft or the
RH SIDE OF VEHICLE impossibility to perform a torque sensor reset.
9. Free the rack and pinion form the steering col- Check steering alignment. Refer to ALIGNING
umn U-joint. THE WHEELS in this subsection.
219100971-026 13
TIE ROD ADJUSTMENT SLEEVE 2. Remove tie rod end bolt.

Inspecting the Adjustment Sleeve
Before removing any components: 1
1. Raise front wheels off the ground.
2. Turn steering wheel from stop to stop.
3. Ensure steering wheel turns smoothly.
Before replacing the tie rod adjustment sleeve, in-

spect the following:
– Knuckle must not be damaged.
– Tie rod end bolt must not be bent.
tmr2017-044-201_a
2 1. Tie rod end bolt
3. Remove tie rod end.
tmr2017-044-208_a
1. Knuckle
2. Tie rod end bolt
– Rack and pinion shaft must not be loose.
– Frame welds must be intact.
– Rack and pinion support and mounting holes
tmr2017-044-206_a
must not be cracked or deformed.
4. Hold inner tie rod and unscrew tie rod adjust-
Removing the Adjustment Sleeve ment sleeve.
1. Loosen both tie rod adjustment sleeve jam
nuts.
tmr2017-044-207_a
1. Inner tie rod

tmr2017-044-205_a
1. Tie rod adjustment sleeve jam nut
14 219100971-026
Installing the Adjustment Sleeve

Reverse removal procedure, pay attention to the 1
following:
1. Adjust inner tie rod and tie rod end to the nom-
inal engagement length.
tmr2017-044-201_a
A TYPICAL
1. Cotter pin
B 2. Tie-rod end retaining nut
3. Tie-rod end bolt
4. Unscrew and discard the tie-rod end.

5. Install new tie-rod end.
tmr2017-044-306_a
6. Adjust tie-rod end to the nominal engagement
A. Inner tie rod engagement length length.
B. Tie rod end engagement length
TIE-ROD END NOMINAL ENGAGEMENT LENGTH
TIE ROD NOMINAL ENGAGEMENT LENGTH
31 mm (1.22 in)
Inner tie rod 36 mm (1-13/32 in)
Tie rod end 31 mm (1-1/4 in) WARNING
2. Lock inner jam nut. The minimum tie-rod end engagement
length must be 25 mm (1 in).
3. Carry out a steering alignment. Refer to ALIGN-
ING THE WHEELS in this subsection.
TIE-ROD END
Replacing the Tie-Rod End
1. Safely lift and support the front of vehicle. Re- 1
2. Remove front wheel.
3. Detach tie-rod end by removing:
– Cotter pin (discard) 2
– Tie-rod end retaining nut (discard)
– Tie-rod end bolt.
tmr2017-044-204_a
1. Locking nut
2. Retaining nut
7. Tighten locking nut(s) to specification.

TIGHTENING TORQUE
34 N•m ± 2 N•m
Tie-rod end locking nut
8. Attach tie-rod end to steering knuckle.
219100971-026 15
9. Install a NEW tie-rod end retaining nut and Installing the Knuckle
tighten to specification. The installation is the reverse of the removal pro-
TIGHTENING TORQUE cedure.
105 N•m ± 15 N•m
Tie-rod end retaining nut
(77 lbf•ft ± 11 lbf•ft) WHEEL BEARINGS
Inspecting the Wheel Bearing
10. Install a NEW cotter pin. Both ends of cotter
pins must be folded.
(Maintenance)
Refer to PERIODIC MAINTENANCE PROCE-
11. Install front wheel.
DURES subsection.
12. Check steering alignment. Refer to ALIGNING
THE WHEELS in this subsection. Inspecting the Wheel Bearing (During
Component Removal)
KNUCKLE Whenever the drive axle or knuckle is removed,
check wheel bearing as follows:
– Check if wheel bearing turns freely and
smoothly.
– Check seal condition.
5 Removing the Wheel Bearing

8
1. Remove knuckle from vehicle. Refer to RE-
7 MOVING THE KNUCKLE in this subsection.
6 3
1 2. Remove and discard circlip.
3. Install knuckle on a press.
4
2 4. Use an appropriate bearing remover.
tmr2017-044-200_a
5. Remove bearing from knuckle.
FRONT KNUCKLE ASSEMBLY
1. Wheel cap
2. Cotter pin
3. Axle nut
4. Conical disc washer
5. Wheel hub with disc brake assembly
6. Circlip
7. Bearing
8. Knuckle
Removing the Knuckle

2. Remove front wheel.
3. Remove wheel hub. Refer to FRONT DRIVE
subsection.
4. Detach tie-rod end from knuckle. Refer to TIE- tmr2011-034-109
ROD END in this subsection. NOTE: It may be necessary to heat the knuckle to
5. Detach upper and lower suspension arms from remove bearing.
knuckle. Refer to FRONT SUSPENSION sub-
section. WARNING
6. Remove knuckle from vehicle. Clean all grease, outside and inside, from
knuckle before heating it.
Inspecting the Knuckle
Check knuckle for cracks or other damages.
16 219100971-026
Installing the Wheel Bearing

To ease wheel bearing installation:
– Place bearing in a freezer for 10 minutes.
– Place knuckle in oven to 100°C (212°F) for
30 minutes maximum.
When knuckle is cooled down, install a NEW cir-
clip.
219100971-026 17
Subsection XX (DYNAMIC POWER STEERING (DPS))
DYNAMIC POWER STEERING (DPS)

SERVICE TOOLS
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ....................................... 7, 10
SERVICE PRODUCTS
219100903-014 1
Loctite 767
(antiseize lubricant)
Loctite 767
NEW
See tightening
sequence
NEW
See tightening See tightening
sequence sequence
NEW
NEW
See tightening
sequence
Loctite 767

219100903-014-100_a
2 219100903-014
GENERAL The greater the power steering assist, the greater

the load on the electrical system.
NOTICE Never perform arc welding in the
DPS area. Otherwise, poor DPS operation When the electrical system is under high load
might occur. (battery not at full charge, operating the vehicle
for prolonged periods at slow speed and low RPM
which, requires higher power steering assist), the
DPS SYSTEM DESCRIPTION battery power reserve will gradually decrease.
(FEATURES) This further increases the load on the charging
system and the electrical system voltage will
The Dynamic Power Steering (DPS) provides
drop. When system voltage has dropped to a low
a computer controlled, variable power assist,
threshold voltage, so does power steering assist.
achieved by an electric motor to optimize the
amount of steering input required by the rider. NOTE: It is important to maintain the battery at a
full state of charge to ensure proper DPS opera-
tion.
DPS Assist Mode

The DPS system provides three rider selectable
modes of operation.
The system automatically adjusts to the speed of
the vehicle and driving conditions. the modes are
designed to meet the preference of the driver.
The following DPS modes are preset in the vehi-
cle.
DPS MODE
219100903-014-005 DPS MAX. Maximum steering assist
The DPS system uses the following parameters to DPS MED. Medium steering assist
determine how much steering assist it provides: DPS MIN. Minimum steering assist
– DPS mode
– Engine RPM
– Battery/electrical system voltage
DPS SYSTEM DESCRIPTION
– Vehicle speed
(COMPONENTS)
– DPS shaft torque sensor input DPS Unit
– DPS internal temperature. The DPS unit is a self contained unit that includes
The amount of steering assist provided is de- the steering gear, the DPS module, the DPS mo-
pendent on the steering wheel effort (steering tor, and the torque sensor.
torque), electrical power available, vehicle speed
and the DPS assist mode selected.
The greater the steering wheel effort (torque), the
greater the assist will be.
The slower the vehicle speed, the greater the as-
sist will be.
If the electrical system is activated but the engine
is not running, DPS assist will be provided for ap-
proximately 30 seconds. DPS assist will resume
once the engine is started.
Steering torque may also come from the wheels
due to rough terrain. This will produce steering
kickback that is reduced by the DPS module, while 219100899-015-002
providing feedback to the driver. TYPICAL DPS UNIT
219100903-014 3
The DPS module provides DC power to the mo- NOTICE The internal torque sensor is very
tor. The amount and duration of that DC power is sensitive to external magnetic source. All
determined by the inputs to the DPS module. The components touching the DPS unit must be
direction in which the motor turns is changed by kept in a non-magnetic area and avoid any
reversing the polarity of the circuit current. contact with magnetized components. When
The DPS motor does not "spin", but rather turns in DPS shaft (or touching components) is in con-
very small increments based on the amount, du- tact with a magnetized part or source, this will
ration, and direction of DC power delivered by the affect the torque reading values and inadver-
DPS module. tently affect the behavior of the DPS unit.
Should the DPS unit fail, vehicle steering is still DPS Switch
available with moderate increase in steering ef-
fort. The DPS switch is used to change the DPS mode.
DPS Unit Protection

An internal protection system is integrated in the
DPS electronic module.
This system protects the electronic components
when the DPS works too hard and the internal
temperature reaches a critical level, or when the
battery voltage becomes too low.
The internal protection system decreases the
assistance level available to protect its electronic
board. The normal assistance level will return
when riding conditions are back to normal and
the internal temperature decreases, and/or when
the battery voltage increases above a threshold 219001761-076_f
voltage. TYPICAL
1. DPS switch
This reaction is a normal protective behavior of the
unit and does not necessarily raise a fault. It provides a "voltage ground" to the multifunction
gauge that tells the gauge the operator wants to
Steering Torque Sensor change DPS operating mode.
The steering column is connected to the top of When the button is held for 2 seconds, the gauge
the DPS shaft. A small area of the DPS shaft is signals the DPS (through CAN bus) to switch to
magnetized. Inside the DPS unit, a torque sensor the following DPS mode.
surrounds the magnetized area of the DPS shaft.
Repeatedly pressing the DPS switch toggles the
When the steering wheel is turned, torque is ap- DPS through its operating modes. The DPS mode
plied to the shaft which tends to twist the shaft selection message will be seen scrolling in the
slightly, deforming the magnetic field in the shaft. multifunction gauge.
The sensor detects the torque by measuring the
deviation of the magnetic field.
The torque sensor is very sensitive and can de-
tect very small changes in the magnetic field. The
harder the steering wheel is turned, the greater
the magnetic deviation, the greater the power
steering assist.
4 219100903-014
2. No power to DPS unit.

- Carry out a TESTING THE DPS FUSE as detailed
in this subsection. Replace as required.
- Carry out a TESTING THE DPS INPUT VOLTAGE
as detailed in this subsection. Repair or replace
wiring/connectors as required.
- Carry out a TESTING THE DPS IGNITION SIGNAL
VOLTAGE as detailed in this subsection. Repair or
replace wiring/connectors as required.
3. No ground to DPS unit.
- Carry out a TESTING THE DPS GROUND CIR-
CUIT as detailed in this subsection. Repair or
replace wiring/connectors as required.
4. No engine RPM signal from ECM.
- If engine RPM can be displayed in the multifunc-
tion gauge when the engine is running, carry out
tmr2014-022-013
a TESTING THE DPS UNIT COMMUNICATION
LINK (CAN) CONTINUITY as detailed in this sub-
ADJUSTMENT section. Repair or replace wiring/connector as
required.
- If engine RPM cannot be displayed in the multi-
ALIGNING THE STEERING function gauge, check for fault codes. Carry out
COMPONENTS service actions.
Refer to STEERING SYSTEM subsection for the 5. No DPS mode signal from multifunction gauge.
complete procedure. - Ensure DPS switch circuit is functioning correctly
(continuity to ground).
NOTICE The steering system tightening se- - Check for multifunction gauge (CLUSTER) or
quence must be strictly followed. Failure to communication fault codes.
do so may result in a steering component - Check if a software update is required for the mul-
misalignment, poor DPS operation due to an tifunction gauge.
induced erroneous torque on DPS shaft, or the - Ensure continuity of CAN bus from multifunction
impossibility to perform a torque sensor reset. gauge to DPS unit as detailed in this subsection.
A magnetized component in contact with DPS Repair or replace wiring/connector as required.
shaft might also affect the ability to reset the - Replace multifunction gauge.
torque sensor.
LOW POWER STEERING ASSIST
TROUBLESHOOTING 1. DPS mode selection.
CUSTOMER COMPLAINT ABOUT THE - If DPS is selected to DPS MIN mode, switch to
a higher assist mode and ensure DPS assist has
STEERING SYSTEM increased.
1. DPS or mechanical failure. 2. Low battery voltage.
- Perform the STEERING SYSTEM SELF TEST pro- - Check battery terminals. Clean, repair, replace or
cedure in this subsection. tighten as required.
- Test battery. Recharge or replace battery as re-
NO POWER STEERING ASSIST quired.
1. DPS malfunction. - Carry out a TESTING THE DPS SYSTEM LOAD as
- If the CHECK ENGINE light is on and a CHECK detailed in this subsection.
DPS message is visible in the multifunction 3. Low input voltage to DPS unit.
gauge, check for fault codes and carry out ser-
vice action. - Carry out a TESTING THE DPS INPUT VOLTAGE
as detailed in this subsection. Ensure power
connector pin (DPS2-A) is clean, corrosion free,
tight, and make good contact. Repair or replace
wiring/connectors as required.
219100903-014 5
4. Faulty DPS ground circuit. 4. DPS unit not responding to mode change signal
- Carry out a TESTING THE DPS GROUND CIR- from multifunction gauge.
CUIT. Ensure DPS ground connector pin (DPS2-B) - Ensure DPS unit is properly connected and that
and frame ground post are clean, corrosion free, connector contacts are clean and in good condi-
tight, and make good contact. Repair or replace tion.
wiring/connector as required.
- Ensure DPS unit has a good ground.
ASYMMETRICAL POWER STEERING - Ensure DPS unit receives proper input voltages.
ASSIST (SIDE TO SIDE)
TORQUE SENSOR CANNOT BE RESET
1. Unequal tire pressure.
1. Mechanical problem or DPS parts.
- Adjust tire pressure as per tire decal or TECHNI-
CAL SPECIFICATIONS - VEHICLE. - Refer to RESETTING THE TORQUE OFFSET in
this subsection.
2. Vehicle alignment.
2. Torque offset too great.
- Ensure all steering components are undamaged
and in good working order. Repair or replace as - Refer to RESETTING THE TORQUE OFFSET in
required. this subsection.
- Carry out a steering alignment , refer to ALIGN-
ING THE WHEELS in the STEERING SYSTEM PROCEDURES
subsection.
3. Steering system components misaligned. STEERING SYSTEM SELF TEST
- Carry out the ALIGNING THE STEERING COM- This test verifies the DPS torque reading on the
PONENTS procedure as detailed in the STEER- entire steering angle range. It will not test any in-
ING SYSTEM subsection.
ternal function or any performance of the DPS it-
4. DPS malfunction. self and it will not verify the accuracy of the vehi-
- Carry out a TESTING THE DPS CURRENT as de- cle wheel alignment.
tailed in this subsection. It is made to detect:
5. Torque sensor not reset to zero. – Steering component misalignment
- When all other possibilities have been eliminated, – Magnetized component in contact with DPS
carry out the RESETTING THE TORQUE OFFSET main shaft.
procedure detailed in this subsection.
If the test fails, the BRP diagnostic software will
DPS ASSIST MODE CANNOT BE provide a description of the failure and suggest a
CHANGED corrective action.
1. Communication problem, faulty gauge, faulty To initiate the test:
DPS, faulty wiring or connections. 1. Connect the vehicle to the BRP diagnostic soft-
- Check for multifunction gauge (CLUSTER) or ware(BUDS2). Refer to COMMUNICATION
communication fault codes. TOOLS subsection.
- Check wiring and connectors. Repair or replace 2. In BUDS2, go to:
as required.
– Functions page.
2. No DPS switch signal to multifunction gauge. – DPS button.
- Disconnect multifunction gauge and check conti- – Routines tab.
nuity of DPS switch circuit to ground.
3. Follow the instructions on the screen.
3. No DPS mode signal from multifunction gauge
to DPS unit. 4. Click on Validate Steering Assembly.
- Check continuity of CAN bus from multifunction The test will run by itself, then the result will be
gauge to DPS unit. displayed.
- If the CAN bus circuit and mode switch circuit test
good, replace gauge. NOTICE Ensure to perform corrective action
as per the procedures outlined in this subsec-
tion.
6 219100903-014
STEERING SYSTEM TIGHTENING NOTE: Torque reading must be stable and not ex-
SEQUENCE ceeding 2Nm during procedure. Torque sensor re-
set may not be possible if the torque value is over
Refer to STEERING SYSTEM subsection for the the 10Nm above the original setting.
complete sequence. With the steering wheel centered and no effort
is applied, if the indicated Torque Sensor value
RESETTING THE TORQUE is over the threshold value of 1.5Nm, a steering
OFFSET imbalance may be noticeable.
Before resetting the torque offset: If all steering components are undamaged, in
good working order, and the steering compo-
– Carry out ALIGNING THE STEERING COMPO-
nents were correctly aligned, repeated torque
NENTS, see procedure in this subsection.
offset reset procedures will not solve the prob-
– The vehicle must be properly aligned and the lem if the torque offset is greater than ±10Nm.
steering centered. DPS unit replacement may be required.
The torque offset resetting procedure can only
then be carried out as a last resort if one of the DPS UNIT
following conditions exist:
– Left and right steering imbalance (steering ef- NOTICE Never perform arc welding in the
fort) DPS area. Otherwise, poor DPS operation
– Unequal self centering might occur.
– The torque offset is within ±10Nm.
1. Position the steering wheel at the center posi- Testing the DPS Fuse
tion. A 40 A DPS fuse located near the battery provides
2. Connect the vehicle to the BRP diagnostic soft- power for the DPS motor.
TOOLS subsection.
3. Check if a software update is available and war-
ranted for the DPS. In BUDS2, go to:
– Flash page.
– DPS or Vehicle button.
– Flash tab.
If an update is available, install it before resetting
the torque offset.
REQUIRED CONDITIONS TO ALLOW THE
RESET PROCEDURE
219001761-209_a
DPS unit temperature above freezing point.
DPS FUSE LOCATION
Steering wheel should be free and centered. 1. Battery
2. DPS fuse
There MUST NOT be any effort applied to the
steering column. 1. Remove the DPS fuse cap to expose the fuse
Torque sensor value must be within offset threshold contacts.
value of ± 10Nm. 2. Using a FLUKE 115 MULTIMETER (P/N 529 035
Engine not running. 868) set to VDC, test for a voltage drop across
the DPS fuse while the DPS is in operation.
4. To reset the torque offset, select:
– Settings page.
– DPS or Vehicle button.
– Initialization tab.
5. Select Torque Sensor Offset.
219100903-014 7
Testing the DPS Input Voltage

1. Disconnect the DPS connector.
529035868
3. If a voltage is measured, turn power off and re-

move fuse.
4. Check fuse continuity, fuse contacts and fuse
box contact condition. Replace fuse as re-
quired. 219100903-014-004
DPS Wire Identification 2. Test for 12 Vdc DPS motor power at DPS2 har-
ness connector as per following table.
For circuit details, refer to WIRING DIAGRAM.
MULTIMETER PROBE POSITIONS VOLTAGE
DPS connector
pin C
E K DPS connector Battery

Battery ground
pin D voltage
DPS connector
pin E
If NO voltage is measured, test the DPS fu se. If

good, check wires and connector pins. Replace or
A F repair defective parts and reset fault codes.
If battery voltage is measured, carry out the fol-
lowing TESTING THE DPS IGNITION SIGNAL
vmr2017-113-015_a
VOLTAGE.
DPS CONNECTOR HARNESS SIDE
NOTE: This test may also be carried out by con-
DPS CONNECTOR necting a 12 Vdc test light between the DPS PWR
FUNCTION PIN COLOR
harness connector (pin A), and the battery (-) neg-
ative terminal. The test light must come on bright.
12 volt input (from
C RD/PK
fuse F2) Testing the DPS Ignition Signal
12 volt input (from Voltage
D RD/PK
fuse F2) 1. Disconnect DPS connector.
12 volt input (from
E RD/PK
fuse F2)
12 volt switched input
G OR/GN
(from fuse F4)
CAN HI J WH/BE
CAN LO K WH/BK
Ground A BK
Ground B BK
Ground F BK
8 219100903-014
219100903-014-004 219100903-014-004
TYPICAL TYPICAL
2. Set the ignition switch to ON. 2. Test for continuity between DPS and battery
3. Test for 12 Vdc power to the DPS module at ground.
DPS1 harness connector as per following table. MULTIMETER PROBE
READING
POSITIONS
MULTIMETER PROBE POSITIONS VOLTAGE
DPS connector
DPS connector
Battery (harness side)
(harness side) Battery ground
voltage pin A
pin G
DPS connector
Continuity
If NO voltage is measured, test fuse F4 in fuse box (harness side) Battery ground
(close to 0 )
no. 1 (PF1). pin B
If fuse F4 is good, check wires and connector pin DPS connector
from DPS unit to main relay 2 in fuse box no. 1 (harness side)
(PF1). Replace or repair defective parts and reset pin F
fault codes.
If there is NO continuity or a high resistance is
If battery voltage is measured, carry out the fol-
measured, check wires and connector pins from
lowing TESTING THE DPS GROUND CIRCUIT.
DPS unit to chassis ground post. Replace or re-
NOTE: This test may also be carried out by con- pair defective parts and reset fault codes.
necting a 12 Vdc test light between the DPS con-
If there is good continuity, carry out the follow-
trol harness connector (pin A), and the battery (-)
ing TESTING THE DPS UNIT COMMUNICATION
negative terminal. The test light must come on
LINK (CAN) CONTINUITY.
bright.
NOTE: This test may also be carried out by
Testing the DPS Ground Circuit connecting a 12 Vdc test light between each
1. Disconnect the DPS connector. GROUND connector pin and the battery (+) posi-
tive terminal. The test light must come on bright.
Testing the DPS Unit Communication

Link (CAN) Continuity
DPS unit must receive a "MODE" signal from the
multifunction gauge and an RPM signal to provide
power steering assist. If the DPS mode changes
when the DPS mode switch is activated for 2 sec-
onds, then the system is functioning correctly. If
the DPS does not respond, check for applicable
faults using the diagnostic software before carry-
ing out this test.
Disconnect the DPS connector and the diagnostic
connector.
219100903-014 9
Test continuity of CAN Bus Wires as per following

table.
MULTIMETER PROBE
POSITIONS
DPS RESISTANCE
CONNECTOR DIAGNOSTIC @ 20°C (68°F)
(HARNESS CONNECTOR
SIDE)
Pin J Pin 1
Less than 1
Pin K Pin 2
If resistance measured is out of specification,

check wires and connector pins. Carry out re-
pairs as required and reset fault codes.
If resistance measured is good, replace the DPS
unit and reset fault codes.
mmr2009-023-027_a
Testing the DPS System Load VDC SELECTED TO MANUAL RANGE 6 0
REQUIRED TOOL 6. Press the MIN MAX button on the multimeter
FLUKE 115 to engage the MIN function.
MULTIMETER (P/N 529
035 868)
If the charging system cannot sustain normal volt-

age when the DPS is operating, DPS ASSIST may
be reduced or nonexistent. Carry out the follow-
ing steps.
1. Measure the battery voltage. Recharge if volt-
age is low.
2. Ensure the vehicle transmission is set to PARK.
3. Start the engine.
4. Note the voltage on the multimeter with the en-
gine running (charging system voltage).
5. Press the RANGE button repeatedly to select
Manual Range 6 0.
mmr2009-023-027_e
1. MIN function selected
7. Turn the steering wheel momentarily against

the steering hard stops to each side.
NOTE: Do not hold steering against steering hard
stops for and extended period of time.
8. Read the MIN charging system voltage
recorded while the steering wheel was turned
against each stop.
10 219100903-014
DPS SYSTEM LOAD TEST REFERENCE VALUES

STEERING VOLTAGE 0 N•m ± 1 N•m
PROBE POSITIONS TORQUE SENSOR
POSITION READING (0 lbf•in ± 9 lbf•in)
Battery (-) Battery (+) LH stop At least DPS CURRENT 0 Amp

terminal terminal RH stop 12 Vdc
4. Turn the steering wheel side to side, mo-
NOTE: Turning the steering wheel momentar- mentarily against each steering hard stop and
ily against the steering hard stops generates observe the DPS Torque Sensor value. The
maximum DPS load (maximum current draw on torque value should increase with steering ef-
electrical system). Electrical system must sustain fort applied to the steering wheel.
at least 12 Vdc for proper DPS operation. The DPS Current value should increase propor-
tionately to the torque applied, and decrease with
the torque as steering assist is provided.
NOTE: The increase and decrease in torque and
current readings is very brief as steering assist
is quickly provided. Current draw should remain
within green scale but may momentarily peak to
or exceed 60 amps, then drop off close to 0 amps
as torque applied is nulled out by steering assist.
If steering is held against hard stops the torque
and current readings will remain high.
If current draw tends to remain high, carry out the
following:
– ALIGNING THE STEERING COMPONENTS
– RESETTING THE TORQUE OFFSET (only if
steering components alignment did not solve
the problem)
vmr2010-003-007 – DPS unit replacement.
If the electrical system cannot sustain at least NOTE: The ALIGNING THE STEERING COMPO-
12 Vdc, check the following: NENTS procedure must always be carried out be-
fore even considering a torque offset reset.
– Battery
– Battery connections 5. Turn steering to LH stop and hold at least 8 Nm.
Note DPS current value.
– DPS unit power and ground connections
– Charging system 6. Turn steering to RH stop and hold at least 8 Nm.
Note DPS current value.
– Frame and engine ground studs.
7. Repeat previous two steps while holding at (+
If the previously listed items test good, carry out
or -) 5 Nm. Note DPS current value.
the following TESTING THE DPS UNIT CURRENT.
LH and RH DPS current readings should be the
Testing the DPS Unit Current same for the same applied torque.
1. Connect vehicle to the BRP diagnostic software If the ALIGNING THE STEERING COMPONENTS
(BUDS2). Refer to COMMUNICATION TOOLS and RESETTING THE TORQUE OFFSET proce-
subsection. dures have been carried out, and the current or
2. In BUDS2, go to: steering imbalance is too great, the DPS unit will
require replacement to resolve the problem.
– Measurements page.
– DPS button.
– Custom tab.
3. With the vehicle engine running in PARK and
without any steering effort, the reading should
be as per following table.
219100903-014 11
Removing the DPS Unit

NOTICE Before proceeding with the DPS
removal, remove the DPS fuse, see TESTING
THE DPS FUSE for location. Handle the DPS
unit with extreme care as it is very sensitive to
physical shock. Store unit in a secure area. If
the DPS unit is dropped, it must be replaced
even if only minimal damage is apparent.
1. Disconnect the electrical connectors from the
DPS unit.
219100903-014-002_a
4. Remove screws securing the DPS to its sup-

port.
219100903-014-004
2. Remove the steering shaft. Refer to STEERING

SYSTEM subsection.
219100903-014-003
5. Remove the DPS from the vehicle.
Inspecting the DPS Unit

Inspect DPS shaft seals. If damaged, replace DPS
unit.
Inspect DPS shaft splines. If damaged, replace
DPS unit.
Inspect and clean terminal contacts.
Installing the DPS Unit

219100903-014-001_a
NOTICE The following installation sequence
3. Remove pinch bolt securing the upper U-joint of MUST be strictly followed (see procedure de-
the steering column. tails in upcoming paragraphs). Failure to do so
may result in DPS misalignment and poor DPS
operation due to an induced erroneous torque
on DPS shaft or the impossibility to perform a
torque sensor reset.
Align front wheels parallel to rear wheels.
Apply LOCTITE 767 (ANTISEIZE LUBRICANT)
(P/N 293 800 070) on splines of the steering
column upper U-joint.
12 219100903-014
Engage steering column on the DPS input shaft. 2. Slowly turn steering wheel from one side to the
Ensure block tooth in steering column U-joint is other 3 times.
aligned with machined tooth on DPS input shaft. Make sure:
Loosely reinstall the M8 pinch bolt with a new M8 – Assistance and travel are equal when turning
nut to secure the U-joint. right or left
Loosely install DPS unit on its support (DO NOT – Steering system operates smoothly through all
tighten screws yet) its range.
Install steering shaft. Refer to STEERING COL- 3. Lower vehicle on the ground.
UMN subsection. DO NOT torque pinch bolt yet. 4. Repeat step 2.
RESULT ACTION
SYSTEM TIGHTENING SEQUENCE in the STEER-
ING COLUMN subsection. Uneven/incorrect Troubleshoot steering
steering behavior problem
New DPS Unit
New DPS units do not come with the required NOTE: A verification carried out with the engine
software programmed into the unit. A DPS unit not running and a weak battery may result in
fault will be generated when the vehicle is pow- unsatisfactory DPS performance. In doubt, retest
ered up. The check engine light will come on and with the engine running.
a CHECK DPS message will appear in the multi- 5. Perform the STEERING SYSTEM SELF TEST
function gauge. procedure in this subsection.
The new DPS unit will require 2 mandatory up- 6. Carry out a test ride of the vehicle to ensure
dates. The first update is required for the DPS to proper operation of the DPS unit.
recognize what type of vehicle it is installed in, the
second to upload the software required for proper
operation on that vehicle.
When DPS unit installation is complete, carry out
the following steps.
TOOLS subsection.
2. Select the Flash page.
3. A message window will appear asking you if
you would like to update the DPS module; se-
lect YES and follow the instructions. When a
second window appears asking you the same
question, select YES again.
4. Once the correct DPS software file is installed,
go to the Faults page and clear the fault codes.
5. Carry out: RESETTING THE TORQUE OFFSET
(if required) as described in this subsection.
6. Test drive the vehicle to ensure proper DPS op-
eration.
DPS System Final Verification
With the front wheels off the ground:
1. Enable DPS unit (turn ignition switch ON or start
engine).
NOTE: Steering assist will be provided for 30 sec-
onds with the ignition switch ON and engine not
running.
219100903-014 13
Subsection XX (SUSPENSION ADJUSTMENTS)
SUSPENSION ADJUSTMENTS
SERVICE PRODUCTS
BRAKE AND PARTS CLEANER PRO S2 ....................................... 779245 ........................................... 3
GENERAL WARNING
The procedure described below is the same for The left and right shock adjustment on front
the RH and LH sides, unless otherwise instructed. or rear suspension must always be set to the
same position. Never adjust one shock only.
Uneven adjustment can cause poor handling
ADJUSTMENT and loss of stability, which could lead to an
Choice of suspension adjustments vary with ve- accident.
hicle load, personal preference, riding speed and
terrain condition. Lift the vehicle. Spring length should be mea-
sured without load on the wheels.
The best way to set up the suspension, is to start
from factory settings, then customize each adjust- Spring length should be equal on both sides.
ment one at a time. Adjust by loosening lock ring and turning adjuster
Front and rear adjustments are interrelated. It ring as desired.
may be necessary to readjust the rear shock ab- NOTE: Do not increase the front/rear spring
sorbers after adjusting front shock absorbers for preload by more than 15 mm (.59 in) over the
instance. factory setting.
Test run the vehicle under the same conditions;
trail, speed, load, etc. Change one adjustment
and retest. Proceed methodically until you are
satisfied.
Following are guidelines to fine-tune suspension.
SUSPENSION ADJUSTMENTS
219001761-072_a
TYPICAL
Step 1: Loosen top locking ring
Step 2: Turn adjusting ring accordingly
tmr2017-047-001_a
Step 3: Tighten top locking ring
1. Preload adjustment
2. Low speed and high speed compression damping adjuster Adjusting Shock Damping
3. Rebound adjuster
4. Crossover rings adjustment Perform adjustments one position (click) at a time.
Test run the vehicle under the same conditions.
Adjusting Spring Preload Proceed methodically until you are satisfied.
NOTE: Spring preload affects ground clearance. To adjust compression and rebound to factory set-
Shorten the spring for a firmer ride and rough rid- tings, proceed as follows:
ing condition or when pulling a trailer (if equipped 1. Turn adjuster clockwise until it stops.
with hitch). 2. Turn adjuster counterclockwise by the specified
Lengthen the spring for a softer ride and smooth amount. Refer to the factory settings table in
riding condition. the TECHNICAL SPECIFICATIONS.
219100971-028 1
Low Speed Compression Damping

Low speed compression damping controls how
the shock absorber reacts to a low suspension ve-
locity (slow compression strokes, in most cases
when riding at lower speeds).
RESULT ON BIG
ACTION
BUMPS
Increasing low speed Firmer compression
compression damping damping (slow
force compression)
Decreasing low speed Softer compression
compression damping damping (slow
force compression)
tbl2013-009-048_b
TYPICAL - HIGH SPEED COMPRESSION DAMPING (USE A 17

MM WRENCH)
1. Adjustment screw
2. Increases damping (stiffer)
3. Decreases damping (softer)
Rebound Damping
tbl2013-009-048_a
TYPICAL - LOW SPEED COMPRESSION DAMPING

1. Adjustment screw
High Speed Compression Damping

High speed compression damping controls how
the shock absorber reacts to a high suspension
tbl2013-009-049_a
velocity (quick compression strokes, in most
TYPICAL
cases when riding at higher speeds). 1. Rebound adjuster
2. Increases rebound (stiffer)
RESULT ON SMALL 3. Decreases rebound (softer)
ACTION
BUMPS
Increasing high speed Firmer compression Adjusting Spring Crossover
compression damping damping (fast Dual compression rate crossover point can be
force compression) modified on the rear shocks by adjusting the
Decreasing high speed Softer compression crossover ring position.
compression damping damping (fast
force compression)
2 219100971-028
tmo2015-017-308_a
CROSSOVER ADJUSTMENT - REAR SHOCK

A. Spring preload
B. Crossover ring position
Clean threads with parts cleaner.

SERVICE PRODUCT
BRAKE AND PARTS CLEANER PRO S2 (P/N 779245)
Lubricate crossover ring threads with penetrating

oil before adjusting.
Unlock jam nut and turn crossover ring.
Adjust to desired crossover rate.
Lock jam nut.
tmr2015-045-105_a
ADJUSTING SPRING CROSSOVER
219100971-028 3
Subsection XX (FRONT SUSPENSION)
FRONT SUSPENSION
NEW NEW
120 ± 10 N•m
(88.5 ± 7 lbf•ft)
Suspension
grease
85 ± 10 N•m
(63 ± 7 lbf•ft)
NEW
Suspension
grease
Suspension
3.0 ± 0.5 N•m grease
(2 ± 1.5 lbf•in)
NEW
65 ± 2 N•m
(48 ± 1.5 lbf•ft)
NEW
120 ± 10 N•m
NEW (88.5 ± 7 lbf•ft)
3.0 ± 0.5 N•m
(2 ± 1.5 lbf•in) NEW
NEW
120 ± 10 N•m
(88.5 ± 7 lbf•ft) 65 ± 2 N•m NEW
Suspension (48 ± 1.5 lbf•ft)
grease
NEW
62.5 ± 7.5 N•m
(46 ± 6 lbf•ft)
48 ± 6 N•m
(35 ± 4 lbf•ft)
NEW NEW
105 ± 15 N•m
(77 ± 11 lbf•ft)
NEW

219100971-029-001_a
219100971-029 1
GENERAL – A gurgling noise, after completing one full com-

pression and extension stroke.
The procedure explained below is the same for
– Check for dent on the rod.
the RH and LH sides unless otherwise noted.
Replace if any faults are present.
ADJUSTMENT Shock Absorber Spherical Bearing
For suspension adjustments refer to SUSPEN- For shock absorber spherical bearings inspection,
SION ADJUSTMENTS subsection. cleaning and replacement, see SUSPENSION in
PERIODIC MAINTENANCE PROCEDURE subsec-
PROCEDURES tion.
SHOCK ABSORBER Installing the Shock Absorber

Removing the Shock Absorber cedure. However, pay attention to the following.
1. Safely lift and support the vehicle of the ground. Make sure to install the proper type of shock ab-
Refer to INTRODUCTION subsection. sorber. Find the P/N on the lower cap of the cylin-
2. Remove bolts and nuts retaining shock ab- der.
sorber.
3. Remove shock absorber.
Inspecting the Shock Absorber

Remove spring from shock absorber. Refer to
SPRINGS in REAR SUSPENSION subsection.
Secure the end of shock body in a vise with its rod
upward.
tmr2013-092-015_a
1. Shock P/N
Make sure to install the shock absorber with the

reservoir towards inside.
tmr2013-092-016_a
TYPICAL
1. Clamp here
NOTICE Do not clamp directly on shock

body.
Extend and compress the piston several times
over its entire stroke. Check that it moves
smoothly and with uniform resistance.
Check the following conditions that will denote a
defective shock:
– A skip or a hang back when reversing stroke at
mid travel.
tmr2017-046-009
– Seizing or binding condition except at extreme
FRONT BODY MODULE REMOVED FOR CLARITY
end of either stroke.
– Oil leakage.
2 219100971-029
Make sure to install the shock absorber with LOWER SUSPENSION ARM
the rebound adjuster facing towards the rear, if
equipped. Removing the Lower Suspension Arm
1. Remove wheel, refer to WHEELS AND TIRES
subsection.
2. Remove bolt and nut securing lower ball joint to
knuckle.
tmr2013-092-017_a
TYPICAL - RH SIDE SHOWN

1. Rebound adjuster
TIGHTENING TORQUE
tmr2013-092-003_a
105 N•m ± 15 N•m
Shock absorber nuts TYPICAL
(77 lbf•ft ± 11 lbf•ft) 1. Ball joint nut
Ensure left and right shocks have the same cal- 3. Remove the following retaining nuts.
ibration. Refer to SUSPENSION ADJUSTMENT
subsection.
SPRINGS
Removing the Spring
1. Remove shock absorber from vehicle. Refer to
SHOCK ABSORBERS in this subsection.
Prior to remove the springs, mark the preload and
crossover ring locations.
2. Unscrew the preload adjustment ring to unload
springs.
3. Remove spring cap from shock absorber. tmr2017-046-001
4. Remove spring from shock absorber.
Inspecting the Spring

Inspect the spring for damage.
Installing the Spring

cedure.
tmr2017-046-002
219100971-029 3
4. Slide the bumper and the arm towards front un- UPPER SUSPENSION ARM
til it clears the screws, and remove the arm
from vehicle. Removing the Upper Suspension Arm
1. Safely lift and support the vehicle off the
ground. Refer to INTRODUCTION subsection.
subsection.
3. Remove fasteners retaining brake hose to sus-
pension arm.
tmr2017-046-003_a
tmr2017-046-006_a
4. Remove and discard cotter pin securing ball

joint nut.
tmr2017-046-004_a
tmr2013-092-007_a
tmr2017-046-005_a TYPICAL
1. Ball joint cotter pin
Installing the Lower Suspension Arm 5. Remove ball joint nut and washer.
Refer to exploded view for appropriate tightening
torques.
Lubricate suspension arm. Refer to PERIODIC
4 219100971-029
tmr2017-046-007
9. Remove suspension arm.

tmr2013-092-008_a
TYPICAL
Installing the Upper Suspension Arm
1. Ball joint nut The installation is the reverse of the removal pro-
2. Ball joint washer
6. Carefully move brake hose aside. Refer to exploded view for appropriate tightening
7. Using a plastic hammer, carefully hit on the torques.
knuckle side to separate ball joint from knuckle. Install a new cotter pin to secure ball joint nut.
NOTE: A ball joint remover can be used if the ball Both end of cotter pin must be folded.
joint is jammed into knuckle. Lubricate suspension arm. Refer to PERIODIC
NOTICE Never hit on suspension arm to MAINTENANCE PROCEDURES subsection.
avoid damaging it permanently.
SUSPENSION ARM BUSHINGS
Removing the Suspension Arm
Bushings
1. Remove suspension arm from vehicle. Refer
to REMOVING THE SUSPENSION ARM in this
subsection.
2. Remove wear plates, inner sleeves and inner
bushings from suspension arm.
tmr2013-092-009
TYPICAL - CAREFULLY HIT ON KNUCKLE SIDE
8. Remove the following fasteners.
tmr2013-092-011_a
TYPICAL - LOWER SUSPENSION ARM

1. Wear plate
2. Inner sleeve
3. Inner bushing
219100971-029 5
tmr2013-092-012_a
TYPICAL - UPPER SUSPENSION ARM

1. Wear plate
tmr2013-092-014_a
2. Inner sleeve
3. Inner bushing TYPICAL - UPPER BALL JOINT
1. Circlip
Installing the Suspension Arm 3. Install suspension arm on a press.
Bushings
4. Use an appropriate ball joint remover.
Lubricate suspension arm. Refer to PERIODIC
BALL JOINTS
Removing the Ball Joint
1. Remove suspension arm from vehicle. Refer
to REMOVING THE SUSPENSION ARM in this
subsection.
2. Remove circlip from ball joint.
tmr2011-035-021
TYPICAL
5. Remove ball joint from suspension arm.

NOTICE Make sure that suspension arm is
properly supported on the press during ball
joint removal.
tmr2013-092-013_a
TYPICAL - LOWER BALL JOINT Installing the Ball Joint

1. Circlip
Install a new circlip to secure ball joint.
6 219100971-029
STABILIZER BAR
Removing the Stabilizer Bar
Remove wheel, refer to WHEELS AND TIRES
subsection.
Remove the following retaining nuts and screws
on both sides of vehicle.
tmr2017-046-008
Remove stabilizer bar.
Inspecting the Stabilizer Bar

Check stabilizer bar for cracks, bending or other
damages.
Check stabilizer bar links for cracks, wear or play.
Installing the Stabilizer Bar

torques.
Lubricate stabilizer bar. Refer to PERIODIC MAIN-
219100971-029 7
Subsection XX (REAR SUSPENSION)
REAR SUSPENSION
NEW Suspension
105 ± 15 N•m grease
(77 ± 11 lbf•ft)
NEW
5 ± 0.5 N•m
(44 ± 4 lbf•in)
NEW
Suspension
grease
0.8 ± 0.2 N•m
Suspension 105 ± 15 N•m
grease (77 ± 11 lbf•ft)
105 ± 15 N•m
(77 ± 11 lbf•ft)
NEW
105 ± 15 N•m
(77 ± 11 lbf•ft)
NEW
9 ± 1 N•m
(80 ± 9 lbf•in)
NEW
NEW
NEW
105 ± 15 N•m
(77 ± 11 lbf•ft) 9 ± 1 N•m
(80 ± 9 lbf•in)
NEW
NEW
tmr2017-047-100_a
219100903-016 1
GENERAL – Seizing or binding condition except at extreme

end of either stroke.
The procedure described below is the same for
– Oil leakage.
the RH and LH sides, unless otherwise instructed.
– A gurgling noise, after completing one full com-
pression and extension stroke.
ADJUSTMENT
Replace if any faults are present.
For suspension adjustments refer to SUSPEN-
SION ADJUSTMENTS subsection. Shock Absorber Spherical Bearing
For shock absorber spherical bearings inspection,
PROCEDURES cleaning and replacement, refer to SUSPENSION
in PERIODIC MAINTENANCE PROCEDURE sub-
SHOCK ABSORBERS section.
NOTE: It is recommended to replace shock ab- Installing the Shock Absorber
sorbers in pairs.
Removing the Shock Absorber cedure. However, pay attention to the following.
1. Safely lift and support the vehicle off the Make sure to install the proper type of shock ab-
ground. Refer to INTRODUCTION subsection. sorber. Find the P/N on the lower cap of the cylin-
der.
2. Remove bolts and nuts retaining shock ab-
sorber.
3. Remove shock absorber.
Inspecting the Shock Absorber

Remove spring from shock absorber. Refer to
SPRINGS in this subsection.
Secure the end of shock body in a vise with its rod
upward.
tmr2013-092-015_a
TYPICAL
1. Shock P/N
Make sure to install the shock absorber with the

reservoir towards rear and inside.
tmr2013-092-016_a
TYPICAL
1. Clamp here
NOTICE Do not clamp directly on shock

body.
Extend and compress the piston several times
over its entire stroke. Check that it moves
smoothly and with uniform 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
tmr2017-047-009
mid travel.
TOP VIEW - REAR BODY MODULE REMOVED FOR CLARITY
2 219100903-016
TIGHTENING TORQUE Inspecting the Stabilizer Bar

Shock absorber nuts 105 N•m ± 15 N•m Check stabilizer bar for cracks, bending or other
and bolts (77 lbf•ft ± 11 lbf•ft) damages.
Ensure left and right shocks have the same cal-
ibration. Refer to SUSPENSION ADJUSTMENT Installing the Stabilizer Bar
subsection. The installation is the reverse of the removal pro-
SPRINGS Install new stabilizer bar nuts and tighten to spec-
Removing the Spring ification.
1. Remove shock absorber from vehicle. Refer to Refer to exploded view for appropriate tightening
SHOCK ABSORBERS in this subsection. torques.
Prior to remove the springs, mark the preload and Lubricate stabilizer bar. Refer to PERIODIC MAIN-
crossover ring locations. TENANCE PROCEDURES subsection.
2. Unscrew the preload adjustment ring to unload
springs. SUSPENSION ARM
3. Remove spring cap from shock absorber. Removing the Suspension Arm
4. Remove spring from shock absorber. Remove wheel, refer to WHEELS AND TIRES
subsection.
Inspecting the Spring Remove shock absorber. Refer to SHOCK AB-
Inspect the spring for damage. SORBER REMOVAL in this subsection.
Replace if necessary. Remove fasteners securing brake hose line to up-
per suspension arm.
Installing the Spring
cedure.
STABILIZER BAR
Removing the Stabilizer Bar
Remove wheel, refer to WHEELS AND TIRES
subsection.
Remove the following retaining nuts on both sides
of vehicle.
tmr2017-047-003
TYPICAL
Remove the wheel hub. Refer to REAR DRIVE

subsection.
NOTICE Do not let caliper hangs by the hose
and do not stretch or twist hose.
Remove retaining nuts and bolts securing rear
suspension arms and toe link to knuckle.
tmr2017-047-002
Remove stabilizer bar from vehicle.
219100903-016 3
tmr2017-047-004
219100903-016-001_a
Remove suspension arm retaining nut and bolt,

and stabilizer bar link lower retaining nut and bolt.
219100903-016-002_a
tmr2017-047-005
3. Remove the arm protector from vehicle.
TYPICAL
Remove the arm from vehicle. Installing the Suspension Arm

Protector
Installing the Suspension Arm The installation is the reverse of the removal pro-
The installation is the reverse of the removal procedure.
cedure. However pay attention to the following.
Refer to exploded view for appropriate tightening REAR SUSPENSION ARMS
torques. Removing the Rear Suspension Arms
SUSPENSION ARM PROTECTOR subsection.
(If equipped) 2. Remove retaining nut and bolts securing rear
Removing the Suspension Arm suspension arms to knuckle and frame.
Protector
subsection.
2. Drill rivets.
4 219100903-016
tmr2017-047-006 tmr2017-047-010
TYPICAL KNUCKLE BUSHING CIRCLIP
3. Remove the arms from vehicle. 3. Use a press to remove the bearing from arm or
knuckle.
Installing the Rear Suspension Arms
The installation is the reverse of the removal pro- Installing the Bearing
cedure. However pay attention to the following. The installation is the reverse of the removal pro-
Refer to exploded view for appropriate tightening cedure. However, pay attention to the following.
torques. Install a new circlip.
Lubricate bearings. Refer to PERIODIC MAINTE-
SUSPENSION ARM AND NANCE PROCEDURES subsection.
KNUCKLE SPHERICAL BEARINGS
Removing the Bearing
REAR TOE LINK
1. Remove suspension arm or knuckle from vehi- Removing the Rear Toe Link
cle. Remove retaining nuts and bolt at both ends of toe
2. Remove the circlip. link.
tmr2017-047-008
tmr2017-047-007
TYPICAL
SUSPENSION ARM BEARING CIRCLIP
Remove rear toe link from vehicle.
Installing the Rear Toe Link

Install new nuts and tighten to specification.
torques.
219100903-016 5
Subsection XX (BRAKES)
BRAKES
SERVICE TOOLS
ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 3
SERVICE PRODUCTS
COSMO RUBBER GREASE .......................................................... 715 900 399 ........................................... 4
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 6
XPS BRAKES AND PARTS CLEANER (USA) ................................. 219 701 705 ........................................... 6
219100971-030 1
1.2 ± 0.1 N•m

(11 ± 1 lbf•in)
14 ± 1 N•m
(124 ± 9 lbf•in)
Cosmo rubber
grease
NEW
NEW
8.5 ± 1.5 N•m
(75 ± 13 lbf•in)
28.5 ± 1.5 N•m

28.5 ± 1.5 N•m (21 ± 1 lbf•ft)
(21 ± 1 lbf•ft)
10.5 ± 1.5 N•m

(89 ± 13 lbf•in)
NEW
50 ± 4 N•m
(37 ± 3 lbf•ft)
NEW Brake caliper
synthetic grease
NEW
33.5 ± 3.5 N•m
(25 ± 3 lbf•ft)

tmr2017-048-100_a
2 219100971-030
GENERAL
WARNING
Always check brake system operation after
removing or servicing a brake component. If
brake pedal feels spongy, make sure all com-
ponents are properly installed and system is
properly bled.
NOTICE Avoid spilling brake fluid on plastic,

rubber or painted parts. Protect these parts
with a rag when servicing brake system.
Sealing washers must be discarded and replaced
with new ones every time a Banjo fitting is un-
screwed. tmr2016-144-003_a
Always clean the area around a brake component Step 1: Position compression force gauge at distance A
Step 2: Push brake pedal from distance B
before servicing. A. 41 mm ± 5 mm (1.6 in ± .2 in)
B. 70 mm (2-3/4 in)
Use the following tools for electrical testing.
REQUIRED TOOL
FLUKE 115
MULTIMETER (P/N 529
035 868)
ECM ADAPTER TOOL

(P/N 529 036 166)
INSPECTION
BRAKE SYSTEM PRESSURE
VALIDATION
tmr2011-037-112
NOTICE Do not pump up the brake pedal re- BRAKE PEDAL LOAD AT 70 MM
peatedly before doing the validation.
Minimum 200 N (45 lbf)
REQUIRED TOOLS
2. If load reading is not in accordance with the
Compression force specification:
gauge
2.1 Clean and inspect the brake system.
Ruler
2.2 Bleed brake system.
1. Position a ruler perpendicularly to brake pedal. NOTE: Refer to PERIODIC MAINTENANCE
PROCEDURES
BRAKE LIGHT SWITCH
Brake Light Switch Location
Brake light switch is located underneath LH dash-
board on master cylinder.
219100971-030 3
Testing the Brake Light Switch 3. Remove / disconnect:

Resistance 1. Brake oil reservoir hoses
1. Disconnect brake light switch connector. 2. Master cylinder screws.
2. Check switch operation as follows. 4. Remove master cylinder from vehicle.
BRAKE LIGHT Inspecting the Master Cylinder
PIN RESISTANCE
SWITCH POSITION
Check boot for crack.
Firmly pushed Close to 0
1 2 Check rod for wear and scratch.
Released Infinite (OL)
Check master cylinder housing and reservoir for
Replace switch as required. leaks or damage.
If the switch tests good, verify wire continuity be- Installating the Master Cylinder
tween harness connector and ECM-B connector.
ECM-B HARNESS cedure. However, pay attention to the following.
CONNECTOR CONNECTOR RESISTANCE Install new sealing washers.
PIN WIRES
TIGHTENING TORQUE
C-3 RED/ORANGE Close to 0
Rear brake hose screw 28.5 N•m ± 1.5 N•m
NOTE: If only the LH taillight does not work, (21 lbf•ft ± 1 lbf•ft)
Brake light switch
check brake relay (R8) in fuse box 1.
SERVICE PRODUCT
Replacing the Brake Light Switch
1. Disconnect brake light switch connector. Push rod end lubrication COSMO RUBBER
Master cylinder boot GREASE (P/N 715
2. Drain front brake line. 900 399)
lubrication
3. Remove brake light switch from master cylin-
der. Refill and bleed brake system. Refer to PERIODIC
NOTE: Use shop rags to catch any spilled brake MAINTENANCE PROCEDURES subsection.
fluid. Adjust master cylinder rod. Refer to ADJUSTING
4. Install new sealing washers. THE MASTER CYLINDER ROD in this subsection.
5. Install new brake light switch on master cylin- Adjusting the Master Cylinder Rod
der.
1. Loosen locking nut of master cylinder rod.
TIGHTENING TORQUE
28.5 N•m ± 1.5 N•m
Brake light switch
6. Connect brake light switch connector.

7. Refill and bleed brake system. Refer to PERI-
tion.
MASTER CYLINDER
Removing the Master Cylinder
1. Drain brake system, refer to PERIODIC MAIN- tmr2016-144-010
TENANCE PROCEDURES subsection. TYPICAL
2. Remove / disconnect:
2. Move brake pedal up and down to check if there
1. Master cylinder push rod clip is a free play.
2. Brake light switch connector
3. Brake light switch and rear brake hose
screw.
4 219100971-030
TIGHTENING TORQUE
14 N•m ± 1 N•m
Rod locking nut
CALIPER
Removing the Caliper
1. Remove wheel. Refer to WHEELS AND TIRES
subsection.
2. If caliper is removed from vehicle for replace-
tmr2016-144-018 ment, remove brake hose screw.
TYPICAL
3. Rotate master cylinder rod to generate a free

play according to specification.
tmr2011-037-010_a
TYPICAL - FRONT CALIPER SHOWN

1. Brake hose
2. Sealing washers
tmr2016-144-011
TYPICAL 3. Remove screws securing caliper support to

knuckle.
tmr2016-144-012
TYPICAL tmr2011-037-009_a
A. Free play
TYPICAL - FRONT CALIPER SHOWN
1. Caliper screws
BRAKE PEDAL FREE PLAY
3.5 mm ± 1.5 mm (1/8 in ± 1/16 in)
4. Place caliper assembly onto a support.
NOTICE Do not let caliper hangs by the hose
4. Tighten locking nut of master cylinder rod to and do not stretch or twist hose.
specification.
Installing the Caliper
219100971-030 5
If caliper was removed for replacement: SERVICE PRODUCTS

– Install new sealing washers.
XPS BRAKES AND
– Refill and bleed brake system. Refer to PERI- United States PARTS CLEANER (USA)
ODIC MAINTENANCE PROCEDURES subsec- (P/N 219 701 705)
tion.
XPS BRAKES AND
TIGHTENING TORQUE All other countries PARTS CLEANER
(P/N 219 701 776)
28.5 N•m ± 1.5 N•m
Brake hose screw
5. Push caliper pistons inward.
50 N•m ± 4 N•m NOTE: To avoid damaging pistons, use an old pad
+
to push it into the caliper using a C-clamp.
Caliper retaining screw
LOCTITE 243 (BLUE) 6. Ensure brake pad spring is properly positioned
(P/N 293 800 060) onto caliper.
BRAKE PADS
Replacing the Brake Pads
1. Loosen brake pad pins.
2. Remove caliper from knuckle. Refer to RE-
MOVING THE CALIPER in this subsection.
3. Remove and discard brake pad pins and pads.
tmr2016-144-015
tmr2016-144-013
tmr2016-144-016
7. Install new brake pads.

8. Install new brake pad pins.
9. Install caliper on knuckle, refer to INSTALLING
THE CALIPER in this subsection.
10. Tighten brake pad pins to specification.
TIGHTENING TORQUE
tmr2016-144-014
10.5 N•m ± 1.5 N•m
Brake pad pin
4. Use brake cleaner to clean pistons end. (93 lbf•in ± 13 lbf•in)
6 219100971-030
BRAKE DISC
Inspecting the Brake Disc
Check disc surfaces for scratches or grooves on
both sides.
Measure thickness and warpage of the disc. En-
sure measures are as per specifications. Refer to
TECHNICAL SPECIFICATIONS.
NOTICE Do not machine Brake discs.
Replacing the Brake Disc

1. Remove caliper from knuckle. Refer to RE-
MOVING THE CALIPER in this subsection.
2. Remove wheel hub. Refer to FRONT DRIVE or
REAR DRIVE subsection.
3. Remove brake disc screws.
tmr2016-144-017
4. Replace brake disc.

5. Install new brake disc screws.
6. Tighten brake disc screws to specification.
TIGHTENING TORQUE
33.5 N•m ± 3.5 N•m
Brake disc screw
7. Install wheel hub, then caliper.

8. Install new cotter pin to secure wheel hub nut.
219100971-030 7
Subsection XX (BODY)
BODY
BODY
18
17
15
16 14
1 13
12
11
10
9
4 8
7
5 6
tmr2017-049-001_a
1. Front fender 10. Rear lateral panel

2. Fixed hood 11. Rear fender
3. Fascia cover 12. Cage trim
4. Radiator grille 13. Rear fender deflector
5. Front fascia 14. Rear rack
6. Front bulkhead 15. Roof
7. Front lateral panel 16. Rear facia
8. Central lateral panel 17. Air box cover
9. Door 18. Intercooler grille
219100903-017 1
219100903-017-200_a
1. Anti-Intrusion bar
2. Bumper
3. Bumper Skid Plate
4. Front Suspension Arm Protector
5. Rock Slider
6. Door Filler
7. Rear Suspension Arm Protector
2 219100903-017
COCKPIT
15
14 16
17
1
2
13
10
9 12
11
8 4
6 5
tmr2017-049-002_a
1. Upper console 10. Rear service cover

2. Console 11. Front console panel
3. Rear upper bulkhead cap 12. Floor panel
4. Steering column boot 13. Kick panel
5. Coolant hose boot 14. Dashboard deflector
6. Front bulkhead 15. Front service cover
7. Rear console panel 16. Dashboard
8. Rear lower bulkhead 17. Glove box
9. Rear upper bulkhead
219100903-017 3
FRONT GRILLE, FENDER, AND HOOD
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
1.6 ± 0.4 N•m

(14 ± 4 lbf•in)
1.6 ± 0.4 N•m

(14 ± 4 lbf•in)
2.5 ± 0.5 N•m 2.5 ± 0.5 N•m
(22 ± 4 lbf•in) (22 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
tmr2017-049-100_a
4 219100903-017
FRONT BUMPER
NEW
105 ± 15 N•m
(77 ± 11 lbf•ft)
NEW
7 ± 1 N•m 105 ± 15 N•m
(62 ± 9 lbf•in) (77 ± 11 lbf•ft)
7 ± 1 N•m
(62 ± 9 lbf•in)
NEW
219100903-017-201_a
219100903-017 5
CENTRAL LATERAL PANEL AND DOOR
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
4.5 ± 0.5 N•m

(40 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
tmr2017-049-101_a
6 219100903-017
4.5 ± 0..5 N•m

(40 ± 4 lbf•in)
219100903-017-202_a
219100903-017 7
SKID PLATES, SUSPENSION ARM PROTECTORS AND ROCK SLIDERS

2.5 ± 0.5 N•m
(22 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
219100903-017-203_a
8 219100903-017
REAR BULKHEAD AND CONSOLE SIDE PANELS
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
tmr2017-049-103_a
219100903-017 9
CONSOLE
2.5 ± 0.5 N•m
(22 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
5.5 ± 0.5 N•m

(49 ± 4 lbf•in)
1.6 ± 0.4 N•m
1.6 ± 0.4 N•m (14 ± 4 lbf•in)
(14 ± 4 lbf•in)
4.5 ± 0.5 N•m
(40 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
tmr2017-049-104_a
10 219100903-017
REAR FENDER AND REAR RACK
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
1.6 ± 0.4 N•m

(14 ± 4 lbf•in)
5.5 ± 0.5 N•m

(49 ± 4 lbf•in)
5.5 ± 0.5 N•m

(49 ± 4 lbf•in)
1.6 ± 0.4 N•m
(14 ± 4 lbf•in)
tmr2017-049-102_a
219100903-017 11
FRONT LH BULKHEAD AND DASHBOARD
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
2.5 ± 0.5 N•m
(22 ± 4 lbf•in)
tmr2017-049-105_a
12 219100903-017
FRONT RH BULKHEAD AND DASHBOARD

2.5 ± 0.5 N•m 2.5 ± 0.5 N•m
(22 ± 4 lbf•in) (22 ± 4 lbf•in)
2.5 ± 0.5 N•m

(22 ± 4 lbf•in)
tmr2017-049-106_a
219100903-017 13
SEATS
1.6 ± 0.4 N•m

(14 ± 4 lbf•in)
64.5 ± 6.5 N•m

(48 ± 5 lbf•ft)
NEW
64.5 ± 6.5 N•m

(48 ± 5 lbf•ft)
NEW
NEW

tmr2017-049-107_a
14 219100903-017
PROCEDURES
DECALS
Removing the Decal
Using a heat gun warm up one end of decal for a
few seconds until 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 be heated tmr2017-049-004_a
for a few seconds longer. If decal tends to stretch The installation is the reverse of the removal pro-
while pulling off, stop heating and wait a few sec- cedure.
onds to let it cool, then peel it off.
Removing and Installing the Backrest
Installing the Decal
Using isopropyl alcohol, clean the surface and dry
thoroughly.
Apply liquid soap to new decal and carefully posi-
tion it. Using a sponge or a squeegee, remove the
air bubbles and surplus water working from the
center toward the edges. Allow to air dry.
NOTICE Do not apply isopropyl alcohol or
solvent directly on decals. Use these products
in a well ventilated area.
SEAT
tmr2017-049-005_a
Removing and Installing the Seat BUTTON LOCKING TIE
tmr2017-049-003_a tmr2017-049-007_a
SEAT CROSS CUT BACKREST CROSS CUT

1. Seat cushion 1. Backrest cushion
2. Seat frame 2. Seat frame
3. Cushion wire frame 3. Cushion wire frame
219100903-017 15
Removing the Front Body Module

It is faster to remove front body panels and grille
as an assembly when servicing is required on the
radiator.
tmr2017-049-008_a
To Install the backrest, hook it to the seat frame.

Pass the locking tie through the seat base, around
the cushion wire frame, and back through the but-
ton head.
Tie, and cut the excess.
tmr2017-049-017
tmr2017-049-006_a
tmr2017-049-018_a
BACKREST CROSS CUT
1. Backrest cushion 1. Headlight connector
2. Seat frame 2. LED signature light connector
3. Button locking tie
FRONT BODY MODULE
tmr2017-049-019
UNDER THE FENDER
tmr2017-049-016
16 219100903-017
tmr2017-049-020_a tmr2017-049-023
1. Headlight lower adjustment screw

2. Headlight connector flange
3. Radiator fan support
Installing the Front Body Module
Refer to the exploded views for appropriate tight-
ening torques.
REAR BODY MODULE
tmr2017-049-021_a
tmr2017-049-015
Removing the Rear Body Module

It is faster to remove rear body panels and rack
as an assembly when servicing is required on the
engine / transmission package.
tmr2017-049-022_a
219100903-017 17
tmr2017-049-009 tmr2017-049-012_a
tmr2017-049-010_a tmr2017-049-014_a
tmr2017-049-013 tmr2017-049-015_a
Installing the Rear Body Module

Refer to the exploded views for appropriate tight-
ening torques.
tmr2017-049-011
18 219100903-017
Subsection XX (FRAME)
FRAME
NEW NEW
X rc Turbo R only
NEW
NEW
NEW
NEW
NEW

219100903-018-100_a
219100903-018 1
GENERAL
A replacement cage is available separately for ser-
vicing. However, the replacement frame comes
with the cage already installed.
Before replacing the cage, make sure the frame
is serviceable. A throughout inspection is recom-
mended.
Check for bending, cracks, weld damages or any
other damage, especially where body panels cov-
ers the frame.
Remove body panels if necessary. tmr2017-050-002
3. Remove seats, refer to BODY subsection.

PROCEDURES
4. Remove both rear bulkhead panels.
CAGE
WARNING
Never drill holes, weld or modify the cage.
Since this is an important protection com-
ponent, any modification might compromise
passenger safety.
Inspecting the Cage

Check cage for bending, cracks, weld damages or
any other damage.
WARNING tmr2017-050-004
Any damaged cage components must be re- 5. Remove front body module, refer to BODY sub-
placed. section.
Removing the cage

1. Remove rear body module, refer to BODY sub-
section.
tmr2017-050-009
6. Remove side panels
tmr2017-050-001
2. Remove service cover.
2 219100903-018
tmr2017-050-005
7. Remove dashboards.
tmr2017-050-018
CUTTING HEIGHT
2 mm to 4 mm (.079 in to .157 in)
tmr2017-050-006
8. Remove dashboard deflector.
tmr2017-050-012
WARNING
Always follow manufacturer guidelines when
using power tools. Use adequate face, ears
and hand protection. Serious injury may re-
sults from inadequate usage.
tmr2017-050-007
13. Remove excess welding material and residue
9. Tie the cage to a hoist to prevent it from falling from mounting points.
off when cutting.
10. Remove the center reinforcement.
11. Using a reciprocating saw, cut cage at mount-
ing points, just above the welds.
12. Put protective blankets on body to prevent
damage.
219100903-018 3
tmr2017-050-014 tmr2017-050-016
WARNING Installing the Cage

Always follow manufacturer guidelines when 1. Carefully lower the new cage on frame.
using power tools. Use adequate face, ears
2. Install the supplied mounting screws and nuts
and hand protection. Serious injury may re-
in holes and tight slightly.
sults from inadequate usage.
3. Align mounting points.
14. Use a buffer to get a smooth finish surface.
tmr2017-050-019
tmr2017-050-013
4. tighten nuts to specification.
SMOOTH SURFACE
TIGHTENING TORQUE
15. Apply rustproof paint to mounting area and let
dry. 107.5 N•m ± 17.5 N•m
M12 cage screws
5. Reinstall all removed parts.
FRAME
WARNING
Never modify the mounting points of the seat
belts. If they are found modified or damaged,
contact a BRP service representative.
4 219100903-018
Inspecting the Frame

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 except if
mentioned or required on an approved BRP Bul-
letin.
Replacing the Frame Insert

To install a new blind threaded insert, use a blind
threaded insert installer available at any automo-
tive parts retailer.
tmr2011-039-004
TYPICAL
After insert installation, ensure insert can hold the

torque applied to the screw it retains. Otherwise,
install a new insert.
Replacing the Frame

NOTE: Blind threaded inserts are not installed on
replacement frames. Make sure to order enough
inserts when replacing frame.
219100903-018 5
Subsection XX (ENGINE)
ENGINE
ENGINE
Type ROTAX® 900 ACE
4-stroke, Double Over
Configuration Head Camshaft (DOHC),
Engine dry sump,liquid cooled
Naturally-Aspirated
Declination Turbo Without Intercooler
Turbo With Intercooler
Number of cylinders 3
12 valves (self adjusting hydraulic
Number of valves
valve lifters)
Bore 74 mm (2.91 in)
Stroke 69.7 mm (2.74 in)
Displacement 899.31 cm³ (54.88 in³)
Engine with Turbo 9.1 ± 0.3
Compression ratio Naturally-Aspirated
11.3 ± 0.3
Engines
Maximum HP RPM 7500 RPM
Spark arrester approved by USDA
Exhaust system
Forest Service
Donaldson Airbox (high efficiency
Air filter
paper filter)
Intake valve opening 5° ATDC
Intake valve closing 25° ABDC
Exhaust valve opening 40° BBDC
Exhaust valve closing 5° BTDC
4.958 mm to 4.972 mm
New
Intake (.1952 in to .1957 in)
Valve stem diameter
4.956 mm to 4.970 mm
New
Exhaust (.1951 in to .1957 in)
New 0.005 mm (.0002 in)
Valve out of round
5.000 mm to 5.012 mm
New
Valve guide diameter (.1969 in to .1973 in)
New 31.35 mm (1.2343 in)
Valve spring free length
RTX903CARBSSV-013_rev1 1
ENGINE
1.05 mm to 1.35 mm
New
Intake (.041 in to .053 in)
Valve seat contact width
1.25 mm to 1.45 mm
New
Exhaust (.049 in to .057 in)
Cylinder head warpage Service limit 0.15 mm (.0059 in)
73.950 mm to 73.966 mm
New
Piston diameter (2.9114 in to 2.912 in)
0.037 mm to 0.067 mm
New
Piston/cylinder clearance (.0015 in to .0026 in)
Upper compression ring,
1st
rectangular
Piston ring type Lower compression ring,
2nd
tapered face
3rd Oil scraper ring
0.20 mm to 0.35 mm
Rectangular
(.008 in to .014 in)
0.30 mm to 0.50 mm
Tapered face New
(.012 in to .02 in)
Ring end gap 0.20 mm to 0.70 mm

Oil scraper ring
(.008 in to .028 in)
Rectangular 1.20 mm (.047 in)
Tapered face Service limit 1.20 mm (.047 in)
Oil scraper ring 1.20 mm (.047 in)
0.030 mm to 0.066 mm
Rectangular
(.0012 in to .0026 in)
0.020 mm to 0.056 mm
Tapered face New
(.0008 in to .0022 in)
Ring/piston groove 0.010 mm to 0.040 mm
clearance Oil scraper ring
(.0004 in to .0016 in)
Rectangular 0.120 mm (.0047 in)
Tapered face Service limit 0.120 mm (.0047 in)
Oil scraper ring 0.150 mm (.0059 in)
74.003 mm to 74.017 mm
Cylinder bore New
(2.9135 in to 2.9141 in)
Maximum New 0.030 mm (.0012 in)
Cylinder taper
Maximum New 0.008 mm (.0003 in)
Cylinder out of round
2 RTX903CARBSSV-013_rev1
ENGINE
25.967 mm to 25.980 mm
New
PTO (1.0223 in to 1.0228 in)
Camshaft bearing Service limit 25.940 mm (1.0213 in)

journal diameter 22.957 mm to 22.970 mm
New
MAG/Center (.9038 in to .9043 in)
26.000 mm to 26.021 mm
New
PTO (1.024 in to 1.024 in)
Camshaft holder bore Service limit 26.050 mm (1.026 in)

diameter 23.000 mm to 23.021 mm
New
MAG/Center (.906 in to .906 in)
0.020 mm to 0.054 mm
Camshaft journal radial New
All (.001 in to .002 in)
clearance
38.35 mm to 38.55 mm
Intake and Exhaust New
Camshaft lobe height (1.51 in to 1.518 in)
valve
28.354 mm to 28.370 mm
New
Hydraulic valve lifter diameter (1.1163 in to 1.1169 in)
Hydraulic valve lifter radial clearance Service limit 0.100 mm (.0039 in)
35.990 mm to 36.006 mm
New
Crankshaft bearing journal diameter (1.4169 in to 1.4176 in)
Crankshaft radial play Service limit 0.08 mm (.0031 in)
0.120 mm to 0.352 mm
New
Crankshaft axial play (.005 in to .014 in)
35.979 mm to 35.995 mm
New
Crankshaft pin diameter (1.4165 in to 1.4171 in)
MAG 0.050 mm (.002 in)
Crankshaft deflection Center Maximum 0.050 mm (.002 in)
PTO 0.050 mm (.002 in)
Crankshaft plain bearing inner diameter Service limit 36.080 mm (1.4205 in)
Connecting rod big end diameter Service limit 36.06 mm (1.4197 in)
Connecting rod big end radial play Service limit 0.08 mm (.0031 in)
0.100 mm to 0.352 mm
New
Connecting rod big end axial play (.004 in to .014 in)
ENGINE
17.010 mm to 17.020 mm
New
Connecting rod small end diameter (.6697 in to .6701 in)
16.996 mm to 17.00 mm
New
Piston pin diameter (.6691 in to .6693 in)
Connecting rod small end radial clearance Service limit 0.040 mm (.0016 in)
Chain guide groove depth Service limit 1 mm (.039 in)
New 46 mm (1.811 in)
Oil pressure regulator spring free length
Service limit 45 mm (1.772 in)
Oil pump radial clearance Service limit 0.25 mm (.0098 in)
Oil pump axial clearance Service limit 0.15 mm (.0059 in)
LUBRICATION SYSTEM
Type Wet sump
Oil filter Replaceable cartridge oil filter
At idle 80 kPa (11.6 PSI)
At 4000 RPM 270 kPa (39.16 PSI)
Minimum engine oil pressure at 100°C (212°F)
Between 6000 to
350 kPa (50.76 PSI)
7250 RPM
Engine oil and engine
Capacity 3.5 L (3.7 qt (U.S. liq.))
oil filter replacement
For the summer season, use XPS
synthetic blend oil (summer grade).
Engine oil For the winter season, use
XPS synthetic oil (all climate).
Recommended
If not available, use a 5W 40 motor
oil that meets the requirements
for API service classification
SG, SH or SJ
COOLING SYSTEM
Ethyl glycol/water mix (50%/50%).
Use premixed coolant
Coolant Type sold by BRP or
coolant specifically designed
for aluminum engines
Starts to open 65°C (149°F)
Thermostat
Fully open 88°C (190°F)
TURBO CHARGER
Rotor shaft bearing leakage test Service limit 50%
Rotor radial clearance Service limit Minimum of 0.1 mm (.004 in)
TURBO CHARGER
At 27 kPa (3.92 PSI) air pressure -.
1 mm ± 0.5 mm (.039 in ± .02 in)
movement
Without intercooler
At 42 kPa (6.09 PSI) air pressure
-.5 mm ± 0.5 mm (.197 in ± .02 in)
movement
Movement of waste gate actuator rod
At 49 kPa (7.11 PSI) air pressure -.
1 mm ± 0.5 mm (.039 in ± .02 in)
movement
With intercooler
At 63 kPa (9.14 PSI) air pressure
-.5 mm ± 0.5 mm (.197 in ± .02 in)
movement
Turbine flange warpage Service limit Maximum of 0.1 mm (.004 in)
TRANSMISSION
Quick Response System (QRS) CVT
Type
(Continuously Variable Transmission)
Engagement RPM 1650 ± 100 RPM
Drive belt width Service limit 30.00 mm (1.181 in)
Governor cup roller flat spot width Service limit 8.50 mm (.335 in)
8.025 mm to 8.175 mm
New
Governor cup roller inner diameter (.3159 in to .3219 in)
6.063 mm to 6.091 mm
New
Centrifugal lever pivot bolt diameter (.2387 in to .2398 in)
6.000 mm to 6.120 mm
New
Centrifugal lever bore diameter (.236 in to .241 in)
6.113 mm to 6.171 mm
Drive pulley sliding half centrifugal lever pivot bolt New
(.241 in to .243 in)
bore diameter
46.950 mm to 47.130 mm
New
Drive pulley sliding half large bushing (1.848 in to 1.856 in)
32.010 mm to 32.135 mm
New
Drive pulley sliding half small bushing (1.26 in to 1.265 in)
41.278 mm to 41.363 mm
New
Cam bushing inner diameter (1.625 in to 1.628 in)
41.278 mm to 41.363 mm
New
Driven pulley sliding half bushing (1.625 in to 1.628 in)
TRANSMISSION
Driven pulley roller inner diameter Service limit 8.5 mm (.335 in)
Driven pulley roller outer diameter Service limit 21.5 mm (.846 in)
Driven pulley roller thickness Service limit 14.75 mm (.581 in)
GEARBOX
Dual range (HI-LO) with park,
Type
neutral and reverse
Oil replacement 1.25 L (42.27 U.S. oz)
Capacity Internal repair or new
1.5 L (1.59 qt (U.S. liq.))
unit
Gearbox oil
XPS synthetic gear oil
75W140 (P/N 293 600 140)
Recommended
or a 75W140 API GL-5 synthetic
gear oil
Angle drive
20/21 = 0.952
sub-transmission
Intermediate 1 40/21 = 1.905
Intermediate 2 37/26 = 1.423
Gear ratios High 38/36 = 1.056
Low 39/15 = 2.600
Reverse 39/17 = 2.294
Final drive (fixed
48/14 = 3.429
gear)
High 9.810
Overall gear ratios Low 24.163
Reverse 21.321
5.25 mm to 5.35 mm
New
Coupling sleeve groove width (.207 in to .211 in)
4.95 mm to 5.05 mm
New
Coupling fork claw thickness (.195 in to .199 in)
5.10 mm to 5.20 mm
Shift fork claw thickness New
(.201 in to .205 in)
(high, low and reverse gear shift fork)
5.30 mm to 5.40 mm
New
Width of shift fork engagement groove (.209 in to .213 in)
24.987 mm to 25.000 mm
New
Intermediate gear bearing pin outer diameter (.9837 in to .9843 in)
GEARBOX
19.977 mm to 19.990 mm
New
MAG side (.7865 in to .787 in)
Countershaft
24.977 mm to 24.990 mm
New
CVT side (.9833 in to .9839 in)
16.980 mm to 16.991 mm
Bearing journal New
Main shaft (.6685 in to .6689 in)
MAG/CVT side
ELECTRICAL SYSTEM
Magneto generator output 644 W @ 6000 RPM
Ignition system type IDI (Inductive Discharge Ignition)
Ignition timing Not adjustable
Quantity 3
Make and type NGK LMAR9AI-8
Spark plug
0.7 mm to 0.8 mm
Gap
(.028 in to .031 in)
Forward 8300 RPM
Engine RPM limiter 20 km/h to 25 km/h
setting Reverse (12 MPH to 16 MPH)
(8300 RPM with Override)
FUEL SYSTEM
Electronic Fuel Injection (EFI) with
Fuel delivery Type iTC (Intelligent Throttle Control),
1 injector per cylinder
Throttle body 46 mm with ETA
ECO mode 1350 RPM ± 50 (not adjustable)
Idle speed
SPORT mode 1500 RPM ± 50 (not adjustable)
Subsection XX (VEHICLES - 2UP)
VEHICLES - 2UP
COOLING SYSTEM
Ethyl glycol/water mix (50%/50%).
Use premixed coolant sold
by BRP (EXTENDED LIFE
Type
Coolant PRE-MIXED COOLANT) or
coolant specifically designed
for aluminum engines
Capacity 4.8 L (1.27 U.S. gal.)
Comes ON 96°C (205°F)
Cooling fan activation
Goes OFF 91°C (196°F)
Radiator cap opening pressure 110 kPa (16 PSI)
ELECTRICAL SYSTEM
Type Maintenance free SLA
Voltage 12 volts
Battery
Nominal rating 18 A•h
Power starter output 1.34 kW
Headlight 2 x 20W LED
Taillight 2 x 3W LED
Signature lights 2 x 2W LED
Main 16 AWG
Fusible links
Main accessories 16 AWG
4WD actuator F7 10 A
Lights F11 10 A
DC Outlet
F12 20 A
Connector DC3
Accessories F14 30 A
Front fuse box
Tail lights F16 10 A
Smart-Lok F23 20 A
Accessories -
R3
Engine Control Module (ECM)
Brake Relay R8 -
219100971-031 1
ELECTRICAL SYSTEM
DPS power 40 A
Gauge
F4 10 A
Relay
Ignition coils
Fuel injectors F5 10 A
Fuel pump
Engine control module (ECM) F6 10 A
Rear fuse box D.E.S.S. F8 10 A
Cooling fan motor F9 25 A
Intercooler fan F17 25 A
EVAP/Oxygen Sensor F18 10 A
Cooling fan R1 -
Main R2 -
Intercooler fan R10 -
FUEL SYSTEM
Type Electrical (in fuel tank)
Fuel pump Operating Turbo 400 kPa ± 14 kPa (58 PSI ± 2 PSI)
pressure Turbo R 450 kPa ± 14 kPa (65 PSI ± 2 PSI)
Type Premium unleaded gasoline
Minimum Octane North America 87 (R+M)/2

Fuel rating Outside North America 92 RON
Recommended North America 91 (R+M)/2

Octane rating Outside North America 95 RON
Fuel tank capacity ± 40 L (10.6 U.S. gal.)
Fuel remaining when low fuel light turns ON ± 12 L (3.2 U.S. gal.)
DRIVE SYSTEM
Selectable 2WD / 4WD with
Models with Visco-Lok front
Visco-Lok auto-locking front
differential
differential, spiral gears
Front drive
Selectable 2WD / 4WD with
Models with Smart-Lok
Smart-Lok electronic locking
front differential
differential, spiral gears
Front drive ratio 3.6:1
Integrated to transmission,
Rear drive
helical gear
Rear drive ratio 3.43:1
Dual range (Hi-Lo) with park,
Gearbox
neutral and reverse
2 219100971-031
DRIVE SYSTEM
Visco-Lok 400 ml (14 U.S. oz)
Capacity
Front differential oil Smart-Lok 350 ml (11.83 U.S. oz)
Recommended 75W90 Synthetic gear oil API GL-5
1.25 L (42 U.S. oz) refill
Capacity
Gearbox oil (1.5 L (51 U.S. oz) when new)
Recommended 75W90 Synthetic gear oil API GL-5
CV joint grease CV joint grease
STEERING
Type Rack and pinion
Steering wheel Adjustable tilt steering
Turning radius 528 cm (208 in)
Front toe (vehicle on ground) 0.6° ± 0.4°
FRONT SUSPENSION
Double suspension arm with
Suspension type
stabilizer bar
Turbo 508 mm (20 in)
Suspension travel
Turbo R 559 mm (22 in)
Quantity 2
HPG shocks with piggyback
Turbo
reservoir. QS3 compression
X rc Turbo
adjustments
Shock absorber reservoir and dual speed
X ds
Type compression and rebound
adjustments
HPG shocks with remote
X rs
reservoir and bypass, dual
X rc Turbo
speed compression and rebound
R
adjustments
Preload adjustment type Threaded
REAR SUSPENSION
Torsional Trailing Suspension-arm
Suspension type Independent (TTX) with external
stabilizer bar
Turbo
X ds 508 mm (20 in)
X rc Turbo
Suspension travel
X rs
X rc Turbo Up to 610 mm (24 in)
R
219100971-031 3
REAR SUSPENSION
Quantity 2
Turbo
reservoir. QS3† compression
X rc Turbo
adjustments with bottom-out control
X ds
adjustments and bottom out control
X rs
reservoir with bypass, dual
X rc Turbo
speed compression and rebound
R
adjustments
FRONT SUSPENSION FACTORY SETTINGS

Turbo 36.8 mm (1.45 in)
X ds 38.5 mm (1.52 in)
Spring preload X rc Turbo 38.8 mm (1.53 in)
X rs
53 mm (2.09 in)
X rc Turbo R
Turbo
Compression damping Position 2
X rc Turbo
X ds
Compression damping
X rs 2 Turns
(low speed)
X rc Turbo R
X ds 2 Turns
Compression damping
(high speed) X rs
3 Turns
X rc Turbo R
X ds
Rebound damping X rs Position 12
X rc Turbo R
Turbo 122.8 mm (4.83 in)
X ds 120 mm (4.72 in)
Crossover ring position X rs
71 mm (2.8 in)
X rc Turbo R
X rc Turbo 101 mm (3.98 in)
REAR SUSPENSION FACTORY SETTINGS

Turbo 89 mm (3.5 in)
X ds 96.7 mm (3.81 in)
Spring preload X rc Turbo 89.1 mm (3.51 in)
X rs
105.8 mm (4.17 in)
X rc Turbo R
Maverick
Compression damping Maverick X rc Position 2
Turbo
4 219100971-031

X ds 3 Turns
Compression damping
(low speed) X rs
2 Turns
X rc Turbo R
X ds 2 Turns
Compression damping
(high speed) X rs
3 Turns
X rc Turbo R
X ds Position 15
Rebound damping X rs
Position 12
X rc Turbo R
Turbo 126.1 mm (4.96 in)
X ds 121.1 mm (4.77 in)
Crossover ring position X rs
154.6 mm (6.09 in)
X rc Turbo R
X rc Turbo 119.56 mm (4.71 in)
BRAKES
Quantity 2
Front brake 262 mm (10.3 in) ventilated brake
Type disc with hydraulic twin-pistons
calipers of 32 mm (1.26 in)
Quantity 2
Rear brake 248 mm (9.8 in) ventilated brake
Type disc with hydraulic twin-pistons
calipers of 28 mm (1.1 in)
Type DOT 4
Brake fluid
Capacity 310 ml (10.5 U.S. oz)
Caliper Floating
Brake pad material Sintered high performance
Minimum brake pad thickness 0.5 mm (.02 in)
Minimum brake disc thickness 4 mm (.157 in)
Maximum brake disc warpage 0.2 mm (.01 in)
219100971-031 5
TIRES
Loaded above 195 kg
(429.9 lb) : 179 kPa (26 PSI)
27 inches
Loaded up to 195 kg (429.9 lb)
: 193 kPa (28 PSI)
Loaded above 195 kg
(429.9 lb) : 159 kPa (23 PSI)
28 inches
: 152 kPa (22 PSI)
Front
Loaded above 195 kg
(429.9 lb) : 138 kPa (20 PSI)
29 inches
: 131 kPa (19 PSI)
Loaded above 195 kg
(429.9 lb) : 124 kPa (18 PSI)
30 inches
: 117 kPa (17 PSI)
Pressure
Loaded above 195 kg
(429.9 lb) : 179 kPa (26 PSI)
27 inches
: 234 kPa (34 PSI)
Loaded above 195 kg
(429.9 lb) : 207 kPa (30 PSI)
28 inches
: 152 kPa (22 PSI)
Rear
Loaded above 195 kg
(429.9 lb) : 186 kPa (27 PSI)
29 inches
: 138 kPa (20 PSI)
Loaded above 195 kg
(429.9 lb) : 214 kPa (31 PSI)
30 inches
: 165 kPa (24 PSI)
Turbo 28 x 9 x 14 (in)
X ds 29 x 9 x 14 (in)
Front
X rs
30 x 10 x 14 (in)
X rc
Size
Turbo 28 x 11 x 14 (in)
Rear X ds 29 x 11 x 14 (in)
X rs
30 x 10 x 14 (in)
X rc
Minimum tire thread depth 3 mm (.118 in)
6 219100971-031
WHEELS
Turbo
Cast aluminum wheels
X rc Turbo
Type X ds
X rs
Cast aluminum beadlock wheels
X rc Turbo
R
Front 14 x 7"
Turbo
14 x 8"
Rim size X ds
Rear
X rs
14 x 7"
X rc
Stud thread M12 x 1.5
120 N•m ± 10 N•m
Wheel nuts torque
CHASSIS
47 mm (1.85 in) diameter, high
Cage type
strength steel, ROPS-approved cage
DIMENSIONS
Turbo
335.3 cm (132 in)
X ds
Overall length X rs
X rc
337.8 cm (133 in)
X rc Turbo
R
Turbo
162.5 cm (64 in)
X ds
Overall width X rs 182.9 cm (72 in)

X rc Turbo 166.6 cm (65.6 in)
X rc Turbo R 169.4 cm (66.7 in)
Turbo
166.1 cm (65.4 in)
X ds
Overall height X rs 170.2 cm (67 in)

X rc Turbo 167.6 cm (66 in)
Wheelbase 259.1 cm (102 in)
219100971-031 7
DIMENSIONS
Turbo
136 cm (53.5 in)
X ds
Front X rs 156.3 cm (61.5 in)

Wheel track
Turbo
133.1 cm (52.4 in)
X ds
Rear X rs 153.4 cm (60.4 in)

Turbo
X ds 35.6 cm (14 in)
X rc Turbo
Ground clearance
X rs
R
LOADING CAPACITY AND WEIGHT

Turbo
666.9 kg (1,470 lb)
Turbo R
X ds 675.9 kg (1,490 lb)
Dry weight
X rs 720.9 kg (1,589.4 lb)
X rc Turbo 739.8 kg (1,631 lb)
X rc Turbo R 794.2 kg (1,751 lb)
Weight distribution (front/rear) 45/55
Total vehicle load allowed (including driver, passengers, all other loads
286 kg (630 lb)
and added accessories)
Turbo 982 kg (2,165 lb)
Turbo R 982 kg (2,165 lb)
X ds 991 kg (2,185 lb)
Gross vehicle weight rating
X rs 1 041.4 kg (2,296 lb)
X rc Turbo 1 055.1 kg (2,326 lb)
X rc Turbo R 1 109.5 kg (2,446 lb)
Cargo rack capacity 90 kg (200 lb)
8 219100971-031
Subsection XX (WIRING DIAGRAM INFORMATION)
WIRING DIAGRAM INFORMATION

GENERAL LINE LINE
FUNCTION DEFINITION
COLOR TYPE
WIRING DIAGRAM LOCATION Data
communication
The wiring diagrams are stored in the back cover between
Thin
pocket. Green Communication modules using
dotted
a protocol
WIRING DIAGRAM CODES (CAN, LIN,
& other)
Controls a
1 2 3 4 5 circuit by
providing an
Brown Thick Power control
on/off control
XX/XX-18 2-BF-A to activate the
V00G0FA circuit
1. Wire colors Alternative
2. Wire gauge Yellow Thick current exiting
3. Connector housing area
AC Volts
4. Connector identification the magneto
5. Wire location in connector
A ground that
Permanent
Wiring diagram with colored lines Thick is in permanent
ground
contact
The wiring diagram on the KNOWLEDGE CENTER Black
is in color. Module A ground that
Thin (analog/digital) is controlled by
Color Definition ground a module
NOTE: To find the color of the wire on the vehicle
skip to WIRE COLORS in this subsection. Wire Colors
The following colors refer to the color of the line It identifies the color of a wire. When a 2-color
drawn in the wiring diagram. scheme is used, the first color is the main color
while the second color is the tracer color.
LINE LINE
FUNCTION DEFINITION
COLOR TYPE
Thick
Unswitched
Hot at all times XX/XX
12 V
Red Sensor XX/XX -18 2-BF-A
Thin 3.3 and 5 V reference V06G1FA
voltage THE SHADED PART INDICATES THE WIRE COLOR

Orange Thick 55 - 60 V High voltage
Example: YL/BK is a YELLOW wire with a BLACK
Blue Thin Analog signal
Variable stripe.
voltage
Color Codes
Pulsed or
Cyan Thin Digital signal constant digital COLOR CODES
(on/off)
CODE COLOR CODE COLOR
Condition must
BEIGE
Pink Thick 12V switched be met to BG OG ORANGE
(TAN)
activate circuit
BN BROWN PK PINK
BU BLUE RD RED
tmr2017-053 1
COLOR CODES
CODE COLOR CODE COLOR B
BK VT A
BLACK VIOLET
B
GN GREEN WH WHITE
A
GY GRAY YE YELLOW
Wire Gauge
The number after wire color indicates the gauge B B
of a wire. A A
C C
18
B B
XX/XX- 18 2-BF-A
V06G1GA C C
A A
THE SHADED PART INDICATES THE WIRE GAUGE
Example: The number that follows the wire color

indicates the wire size used, in this case 18 gauge
wire. D D
A A
Connector Identification C C
The letters in the middle of the connector/pin con- A00E4WB B B
tact number Indicates the connector's function. If TYPICAL
there are many connectors in the same area, this
helps to identify which wire is in which connector. Following a circuit
To follow a circuit, search the in section of the
wiring diagram shown in the wiring diagram index.
XX/XX-18 2- BF -A In this example, the 60V comes from JT WH/RD
in section (-B-2).
V06G1JA
BF NOTE: The arrow indicates the direction of the
power in the circuit.
THE SHADED PART INDICATES A CONNECTOR
Wire Location in Connector

This is the wire position in the connector. The
number or letter given refers to the physical iden-
tification stamped or molded on the connector.
mmr2015-147-006_a
FROM JT WH/RD (-B-2)
XX/XX-18 A
2- BF- A In following example, the 60V goes to the IGN_M
connector pin 3 in section (-B-4).
V06G1KA
A
THE SHADED PART INDICATES THE CONNECTOR LOCATION
IN HOUSING
mmr2015-147-007_a
TO ING_M-3 (-B-4)
2 tmr2017-053
Splices in Wiring Harness

Splices in wiring harness are indicated on the
wiring diagram as follows.
1 2
JT
T - RD
RD/BU
mmr2010-043-001_a
vmr2016-149-004_a
1. Shrink tube
1. JT: Splice indication
2. Spliced wire color 4. Remove the shrink tube.
PROCEDURES
This section gives the procedures in order to
quickly repair electrical harness splices.
1. Make sure to perform the usual tests described
in ELECTRICAL SYSTEM sections before inves-
tigating the harness splices.
2. If an electrical issue can not be found with the
usual tests, locate the main harness splice that mmr2010-043-002
is involved in the faulty circuit and repair it as
per the SPLICES REPAIR PROCEDURE. NOTICE Be careful with the blade to
3. To repair a splice, we recommend the use of a avoid cutting wires insulation.
tin solder meeting the followings requirements 4.2 Slightly heat the shrink tube using a heat
or an equivalent. gun.
TIN SOLDER REQUIREMENTS
SN 60
PB 40
DIA 0.062
FLUX RA 2%
SPLICES REPAIR PROCEDURE

CASE 1: Wire Detached from Splice
mmr2010-043-003
WARNING 4.3 Remove the shrink tube with long nose pli-
Repairs described in this section should ers.
never be performed on harness sections that 5. Locate detached wire from splice.

grams.
splice.
tmr2017-053 3
mmr2010-043-001_a
1. Shrink tube
mbg2008-021-116_a
1. Detached wire
4. Remove the shrink tube.
2. Splice 4.1 Using a blade, cut the shrink tube.
6. Twist detached wire around splice.
mmr2010-043-002
NOTICE Be careful with the blade to

avoid cutting wires insulation.
4.2 Slightly heat the shrink tube using a heat
mbg2008-021-117_a
gun.
1. Twisted wire

CASE 2: Wire Broken from Splice

WARNING
mmr2010-043-003
never be performed on harness sections that 4.3 Remove the shrink tube with long nose pli-
can be exposed to water. ers.
5. Locate broken wire from splice.
grams.
splice.
4 tmr2017-053
mbg2008-021-118_a
1. Broken wire
2. Splice
6. Strip wire insulation at the end of broken wire.

7. Strip wire insulation below the splice.
mbg2008-021-119_a
1. Broken wire stripped

2. Splice wire stripped
8. Twist wire around stripped wire.
mbg2008-021-120_a
1. Twisted wire

NOTE: Always perform a solder on a bigger wire
(lower gage).
tmr2017-053 5
1 2 3 4 5 6 7 8 9 10
2019
INTERCOOLER
FT2F FAN
FT2 FT2_2 TAILLAMP
JT-BK2 A A A
A
FAN
B B B
B
BREAKER C W111 C C W90 W91 C
PF2 FUSE
FUEL PUMP
PF1 WH/OG-20 20 20
B
INJECTORS R10 : INTERCOOLER FAN
(-E-2)
IGNITION
B W32 B B W89 B
P
R2: MAIN RELAY RADIATOR LAMBDA R1: RADIATOR FAN INTERCOOLER R3 : ACC RELAY DC 1 R8 : BRAKE RELAY
KEY SWITCH ECM COILS 2X4 DC 3 ACC 2 HEADLAMP TAIL LAMP FDM BK-20 A VT/WH-20 W87 20 W88 A
FAN EVAP FAN SPEEDOMETER W678 A A
F-8: 10A F-6 : 10A F-9: 25A F-18: 10A F-5:10A F-17: 20A F-4 : 10A F-7: 10A F-12: 20A F-14: 30A F-11: 20A F-16: 10A F-23 20A JT-BK2 BK-20 20 20
BR2
MAVERICK SERIES
JT-13
A 270
JT-11
JT-12
(-E-2)
87a
TAILLAMP
30
87
30
87
30
87
30
87
30
87
85
86
85
86
85
86
85
86
85
86
A A
OG/BU-22 C2
RD/GY-16 D2
RD/GY-16 D1
RD/BG-16 C1
RD/BG-16 D4
D3
RD/BG-16 D4
RD/BG-16 C4
VT/BU-18 C3
RD/GY-16 A5
BG/WH-20 A4
OG/WH-22 A3
VT/BU-18 B1
BN/RD-16 B3
RD/GY-16 E3
BG/GN-16 E4
RD/GY-16 B5
BN/RD-16 B4
BN/WH-16 A1
GY/GN-20 A3
BN/YE-16 A1
VT/BU-18 F1
F2
OG/BN-22 C6
OG/GN-20 D4
RD/GN-12 D6
W90 W91
RD/YE-12 C4
RD/BG-16 C5
OG/GN-20 C6
RD/BG-16 E4
RD/BK-20 E3
RD/YE-12 B3
RD/BN-18 B4
RD/BG-16 E5
YE/BK-20 E6
RD/GN-12 A2
RD/YE-12 B2
RD/BN-14 B1
W120
RD/PK-16 A1
RD/BG-16 F5
VT/WH-20 F6
C C
B5
RD/OG-22 A6
VT/WH-20 B6
A5
C
20 20
B
WH/OG-20 WH/OG-20 W89
JT WH/OG W33 B B B
P
VT/WH-20 20
BG-20
W677 A A W87 W88 A
BK-20 20 B R2 20
JT VT/WH
A 270
JT RD/BG JT RD/YE
JT RD/GY
JT OG/GN OG/GN-20
JT VT/BU
RD/PK-16
RD/PK-16
DIAGNOSTIC
CONNECTOR
DB
C
D
K
E
J
6 +12V SWITCHED
JT RD/PK 5 W/U G CL K CH J +12 C +12 D +12 E
+12V DIRECT
4 ECM WAKE-UP
BK-16 3 GND DPS
2 CAN LO
1
CAN HI GN A GN B GN F
JT BK3
B B
W522 A
BK-18 B
W519 F
A
B
BK-18
FT
START
A B
RD/BK-22
JT-BK3 BK-18
W520
(-E-2)
STSW
JT-BK3
JT-BK3
FAN
GND_FAN
BK_TP-10
2
1
JT WH/BK
BG/WH-20
BK_TP-10 RADIATOR JT WH/BG
FAN
(-H-2)
(-H-2)
(-H-2)
VT/PK-22
FL-2
FL-1
RD1
1
BR/PK-22
16awg 16awg JT BG/WH
BG/WH-20
+1 3-
RD
WH/BG-22
WH/BK-22
OG/GN-20
RECTIFIER/ DPS BK/BG-22
REGULATOR FUSE
B
PF3
RD2-1
RD2-3
RD2-2
BU-22
40A
16
21
17
19
18
5
7
CL
PF3
YL YL YL
A
MAGNETO RD-14 CLUSTER
RD/BN-18
RD/BK-20
C BP1 JT RD/OG C
CL
20
6
BPR JT-RD/GN
P_BPA M 1
RD-6 VBATT
A
SS
3
JT-YE/BK
JT-BK3
POST+ BP2 M W41 9 GND
A
DESS BK-16
K
2
RD-6
DC3
POST-
A
B
BK-6 B
JT-BK5
2
1
1
JT BG
DC1
DC
1
A W42
SS
BK-20
B
VT/BU-18
B BK-18 16
B W703
FRA
2 1 PHASE A OUTLET
2
ACCESSORY POST
GR/BU-22
RD/BN-18
C 8
DC1
C
C
D
W673
A
B RD/BU-18
PHASE B
(-E-2)
A
BRK
OG/RD-22
OG/RD-22
YE/OG-22
BK-18
BG-20
STARTER BRAKE SWITCH
C
D
A
B
D D W667 15 SELENOID HI
OG/BN-20
BK/YE-20
FP
BN/RD-18
WH/BG-22
WH/BK-22
YE/RD-20
BK/BU-18
43 2 1
GY/GN-20
A B+ C D E E
3
2
W43
JT-BK5
+ -
DPSSW
FUEL BK/YE-20
M4 BG-20
PMP F F W38 8 ---

DPS
-FUEL LEVEL RD/BK-22
RD/BK-16
LEVEL
M1
G1
D1
H2
C2
C1
C3
E4
B2
A2
3 2
F2
L4
J4
J2
710001781
BAT1
(-E-3)
G G W702 11
B
FREQ IN 2
BG/GN-22
ECM CONNECTOR B
H H W679 10 FREQ IN 1
D 12V,18AH BG/BU-22 D
JT-RD/BK
BK-6 M
BAT2
BN1 JT1
B
M2
M3
C4
D4
D3
D2
A3
K3
E1
K1
B3
B1
E3
A1
F3
L1
L2
J3
J1
710005903/ 710006068/ 710005925
H
C
RD/BK-22
J
MUD TRAIL FDM
BK-16
OG/GN-22
GY/GN-22
OG/BK-22
GY/BK-22
OG/VT-22
WH/PK-22
GY/VT-22
BN/GN-20
RD/BK-20
RD/BK-20
BK/PK-22
BK-10 2
W712
W711
J
H
C
7 3 2 1 6 5 4 OUT
OFF
VT/BU-18 IN
6
5
RD/BK-16
BK/YE-20
BK-18
BK-18
BK-18
BN/GN-22
OG/VT-22
BN/GY-22
VT/OG-22
YE/GY-22
VT/GY-22
VT/GY-22
VT/YE-22
GN
RD
BK
W37
W45
RD/BK-22
2
ENGINE GROUND
C
D
B
A
E
F
BODY GROUND
PPS_F
RD/BK-20
2
1
6
D
C
A
B
W708 IN 8
HO2S1
OUT
W724
B_ A OUT C + F _ E OUT D +
BU/GN-20 14
W707 OUT OFF
WINCH
OVR
GY BK WH WH
2
1
B
A
TAS-1
1
2
3
1
2
3
S _ BU/BK-20 IN
MODE
W566 7
2
1
+
OXYGEN
SB
JT-BK/YE
1 2 3 RD/BK-22
8 SPORT 8
OVR 20 SENSOR W44 W699 4 GND
TAS BK/YE-20
C
BK/YE-20
A
B
3
ECO LOCK
OPEN W49
THROTTLE ACCELERATOR FREE
GN/BU-20
7 BK-22
LT BU-20
7 1 2 3
2
1
SEATBELT
BK-20
SENSOR
5
2
710003541
B A
MODE OVERRIDE
SW SW 710005761
2x4 LOCK
8
2x4
GN/BU-20 GN/BU-20
4x4
SMART
LT BU-20 LT BU-20
E 3 LOCK E
SW1-
SW2-
9 7 6 4 5 2 1
EVAP_CTRL_VLV
9
7
6
1
W668 3
IN RD OUT
WH-22
K
W599 SW3-
WINCH RELAY
D5
D4
WH/BU-22 5
W670 OUT
A
JT-WH BK BU YL
M BG/BK-20 12
W669 IN
BK-20 BK-20
WH-22 13
W700 IN BK-20 W725
BU/YE-20
RD-6
WINCH
50 50 M
JT-WH/BG W726
M W594 2 CB1 CB2 RD-6
CAN HI
WH/BG-22
JT-WH/BK
M W593 3 CAN LO
JT-OG/GN WH/BK-22
M W591 7 IGNITION
OG/GN-20
YE/BK-20
TO UNDER DASH POST (BAT-)
LED SWITCH WIRING
BK-20
DPSSW
RD/BU-18
HIBM
BK-18
W799
8
W797
BN/RD-18
F 8 F
BK/YE-20
1 2 4 5
OFF
WH/BU-20
W804
RD/BK-22
W807 RD/BK-22
W47
LOW
710004492
7 HI 3 6
BK/BU-22
RD/BN-18
W1
OVR
BG/GN-22
BG/BU-22
W796
HIBM
3
BU-20 6
8
W808
JT-7
JT-16
K
D-1
RD/BK-22
BK/BU-22
A
HIBM
JT-BU
W46
8
BK/YE-20
BK/YE-20
GN-22
GN-22
BU-22
BU-22
BK-22
BK-22
RD/BK-22
BN/RD-18
RD/BK-22
W48
BK-18
W803
W798
GND MODULE (LOGICAL)
W2
VT/BU-18
VT/BU-18
C
B
A
B
A
A W3
HL_R
HL_L
D
C
A
B
A
B
RD/BK-22
BK/BU-22
BK-1 JT-BK1 BK-18 JT-BK5 a=low
FT-A
L L
BK-2 0
BK-20
BK-22
C A B C A B b=ground
MODE
BK-14
COLOR IDENTIFICATION
JT-BK2 _ + _ + H H
c=high
BK-16
BK-20
BK-20
HALL HALL
HIC
HIC-01
8
MOTOR
D
E
H
B
F
(-C-8) (-D-8) (-A-5) HEADLAMP HEADLAMP

CODE COLOR CL-20 DPSSW-1 PF1-A12
(-A-5) (-A-7) (-A-7) DIFF LOCK SELENOID WHEEL CARRIAGE
{
FT2-B HIC5MR-A HIC5ML-A ACTUATOR PLUNGER SENSOR SENSOR
WH WHITE To Engine Harness
BK/BU-22
G G
BK BLACK
2X4
8
GN GREEN BK-10
BK-16 BK-22
JT-BK4
JT BK3
RD/BK-22
GY GRAY
BK-16
BK-16
BK-16
BK-16
BK-16
YE/BK-20
YE/BK-20
PK PINK LINE TYPES
(-C-9) (-C-9) (-C-8) (-B-3) (--)
RD RED 55 / 60 VOLTS DPS-F DPS-B DPS-A DB3 FDM
B
1
1
12 VOLTS SWITCHED SYMBOL LEGEND
SIG_L
A C A C
SIG_R
OG ORANGE S S
YE YELLOW 12 VOLTS UNSWITCHED SYMBOL IDENTIFICATION

S S
SIGNATURE SIGNATURE
VT VIOLET
5 OR 3.3 VOLTS JUNCTION (JT)
BN BROWN
DIGITAL SIGNAL CROSSED WIRE (NOT CONNECTED)
POWER CONTROL
BG BEIGE (TAN) WIRE DIRECTION TOWARD JUNCTION
H H
ANALOG SIGNAL
BU BLUE FEMALE TERMINAL
COMMUNICATION MODEL TITLE
LT GN LIGHT GREEN MALE TERMINAL All rights reserved.
A-D GROUND No parts of this document
may be reproduced in any

LT BU LIGHT BLUE FRAME GROUND
POWER GROUND MY
form without the prior
written permission
N/A NOT AVAILABLE AC VOLTAGE ENGINE GROUND 2019 of Bombardier Recreational
Products Inc. (BRP).

DATE
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
2019 ENGINE HARNESS
{
A A
900 ACE / 900 ACE TURBO

NC A
4WD ACT B W100 4
4 act
WH-22
4WD PWR F W101 3
4WD ACTUATOR
3 fb
LOCK
RD/BK-22
4WD STATUS H W102 1 4WD ACTUATOR
1 gnd
B BK/BG-22 B
M
FROM 4WD GND G W99 2
2 12v
BK-20
MAIN HARNESS
ENGINE
INTER-CONNECT EVAP C W787
GY/GN-18 JT-VT/GN
+12V HOT AT KEY ON D W783
VT/GN-16
+12V HOT AT KEY ON E W749
TCV- (-F-9)
VT/BU-18 COIL1 COIL2 COIL3
C C
VT/GN-16
VT/GN-16
VT/GN-16
VT/BU-18
JT VT/BU
W795
W750
W781
W782
VSS
VT/BU-18
W114
HALL VT/BU-18
VT/BU-18
+
W748
_
C B A
2 W115
BK WH RD
1
+ 2 1 + 2 1 + 2 1 1 2 1 2 1 2
A
3 + 3 + 3 +
COIL_1
COIL_2
COIL_3
CAM
D D
WH-18
W773
FUEL INJ FUEL INJ FUEL INJ
POSITION
BN/OG-18
YE/GN-18
BN/RD-18
BN/BU-18
BN/GY-18
BN/BK-18
BN/YE-18
W794
SENSOR
GY/GN-18
BK/GN-18
INJECTOR-1 INJECTOR-2 INJECTOR-3
BK/GN-18
W793
W784
W785
W786
W776
W777
W780
IGNITION COIL IGNITION COIL IGNITION COIL
W787
W772
M4
M2
M1
D4
E1
E2
B2
K1
A3
J1
A
E E
ECU CONNECTOR A
A
J2
L2
L1
F3
K3
A2
K4
E3
K2
B4
G1
F4
A1
G4
F2
G3
G2
C4
H1
H3
H2
C3
M3
F F
BN/BG-18
LT BU-20
WH/GR-20
JT VT/BU
OG/GY-20
(-C-6)
BK/OG-20
BG/OG-20
YE/WH-20
BK/OG-20
W768
BG/GY-18
BU/YE-20
PK/BU-20
BK/BU-18
BG/WH-18
BG/WH-20
WH/GY-20
BG/GN-18
BG/YE-20
BG/RD-20
GY/BU-20
BG/BU-18
BK/BN-20
PK/BU-20
YE/BU-20
BG/BK-20
W758
W759
W761
W760
W106
W105
W116
W771
W770
W763
W762
W764
W765
W767
W766
1
CPS-1
1
1
COLOR IDENTIFICATION
CODE COLOR _ _
+ 4 2 OUT OUT + 2 1
_ 3 1 2
_
t
1 3 6 5 3 2 1 4 3
+ +
WH
BK
BK
BK
OUT 2 1
WH WHITE 2k5
M
300
P HALL 2 1 t P P
G BK BLACK G
2k5 300
OPS GPBS
MAPTS MAP
GN GREEN
CTS KNOCK
GY GRAY ETA
420892596 (V-twin) ELECTRONIC THROTTLE
CPS TURBO-CONTROL
PK PINK LINE TYPES OPS GPBS CTS MAPTS BPS
KS1
RD RED 55 / 60 VOLTS
ETA
CPS VALVE
OG ORANGE 12 VOLTS SWITCHED SYMBOL LEGEND
YE YELLOW 12 VOLTS UNSWITCHED SYMBOL IDENTIFICATION
VT VIOLET
5 OR 3.3 VOLTS JUNCTION (JT)
BN BROWN
DIGITAL SIGNAL CROSSED WIRE (NOT CONNECTED)
POWER CONTROL
BG BEIGE (TAN) WIRE DIRECTION TOWARD JUNCTION
H ANALOG SIGNAL H
BU BLUE FEMALE TERMINAL
COMMUNICATION MODEL TITLE
LT GN LIGHT GREEN MALE TERMINAL All rights reserved.
A-D GROUND No parts of this document
may be reproduced in any

LT BU LIGHT BLUE FRAME GROUND
POWER GROUND MY
form without the prior
written permission
N/A NOT AVAILABLE AC VOLTAGE ENGINE GROUND 2019 of Bombardier Recreational
Products Inc. (BRP).

DATE
1 2 3 4 5 6 7 8 9 10
INTRODUCTION
This publication governs all warranty labor allowances 4. JOB REQUIREMENTS
for 2019 BRP SSV All the flat rate times mentioned in the following pages
1. HOW DOES IT WORK include the required operations such as: engine timing
(rotary valve and ignition), connecting rod(s) alignment,
We follow the procedures detailed in the BRP SSV cylinder head(s) torque or use of parallel bar, use of ig-
Shop Manual. The flat rate time is the maximum time nition tester, piston clearance/ring end gap measure-
allowed for a repair involving any given part. FLAT ment, crankshaft to crankcase measurement, cylinder
RATE TIME IS NOT CUMULATIVE. You must use the honing, engine leak test.
flat rate time given for the longest lasting operation.
NOTE: The Flat Rate Time Schedule was prepared by 5. ILLUSTRATIONS
skilled mechanics using the hand tool usually found in The illustrations contained in this manual do not neces-
workshops and all the special tools mentioned in the sarily show every components of a given system as
Shop Manual. Parts Catalog do. Their purpose is to facilitate recogni-
tion of parts related to a flat rate time. Item numbers
2. COMPILATION on illustrations correspond to the four digit Job
The Flat Rate Time Schedule is compiled as follows: Code.
The actual required time to perform the repair plus (+)
30% correction factor up to 3.0 hours or (+) 15% over 6. FLAT RATE TIME SUGGESTION
3.0 hours time to take into account, among others: SEND A WARRANTY CASE ON BOSSWeb INFO
– Vehicle handling CENTER
– Obtaining the parts In the case, you must provide the following information:
– Diagnosis Section Subject:
– Cleaning – Flat rate time suggestion
– Special compensation (rusted bolts).
Section Your Question:
3. HOW TO USE IT – Model year;
Refer to the system you need, locate part of series of – Model description;
parts replaced. List JOB CODE in the appropriate col- – Description job code;
umn on claim. – Job code;
SYSTEM PAGE – Present flat rate;
– Suggested flat rate;
01 ENGINE 04 – Detailed repair procedure;
02 CARBURETOR AND FUEL SYSTEM 17 To ensure that your case will be promptly and efficiently
processed please indicate the step by step repair pro-
03 IGNITION SYSTEM 22 cedure you performed.
04 STARTER 23
05 TRANSMISSION SYSTEM 24
06 BRAKE SYSTEM 33
STEERING SYSTEM AND FRONT
07 35
SUSPENSION
REAR SUSPENSION SYSTEM AND
08 TRACK 41
09 BODY 44
10 ELECTRICAL SYSTEM 56
NOTE: Unless otherwise specified, dismantling order

is: top to bottom, exterior to interior, front to rear.
All fractions of hours are in tenths:
0.1 = 6 minutes
0.2 = 12 minutes, and so on
LEGEND:
* REQUIRES PRIOR AUTHORIZATION BY DISTRIBUTOR.
INDICATE LABOUR TIME ON LINE “LABOUR ONLY“ OF
**
CLAIM.
INDICATE $$$ AMOUNT ON “SUB-CONTRACTED
***
LABOUR“ OF CLAIM.
IMPORTANT: Always use the longest flat rate time ap-
plicable to the repair performed.
Volume 3 - Can-Am 1
2019 TTF2019-003_MAVERICK.FM
INTRODUCTION
Cette publication détermine le temps de main-d’oeuvre REMARQUE: Sauf indication contraire, le démontage
couvert par la garantie pour les VCC BRP 2019. doit s’effectuer de haut en bas, de l’extérieur vers l’in-
térieur, de l’avant vers l’arrière.
1. UTILISATION DU MANUEL Toutes les fractions d’heures sont exprimées en dixiè-
En procédant de la façon indiquée dans le Manuel de mes:
réparation VCC BRP, chaque temps donné représente 0.1 = 6 minutes
le maximum permis pour une réparation portant sur 0.2 = 12 minutes, et ainsi de suite
cette pièce. LES TEMPS NE SONT PAS CUMULA-
TIFS. On doit inscrire le temps donné pour l’opération LÉGENDE:
qui prend le plus de temps. * AUTORISATION REQUISE AVANT LE REMPLACEMENT.
REMARQUE: Le Barème de temps à taux fixe a été INSCRIRE LE TEMPS À LA LIGNE «MAIN-D’OEUVRE
**
SEULEMENT».
préparé par des mécaniciens compétents utilisant les
outils que l’on retrouve normalement dans les ateliers *** INSCRIRE LE MONTANT $$$ À LA LIGNE «OUVRAGE
SOUS-CONTRACTÉ».
de réparation, en plus de tous les outils spéciaux men-
tionnés dans le Manuel de réparation. IMPORTANT: Toujours utiliser le temps donné à l’opé-
ration qui nécessite le plus de temps.
2. COMPILATION
4. TRAVAUX REQUIS
Le Barème de temps à taux fixe a été établi en compi-
lant le temps nécessaire pour faire la réparation plus (+) Tous les temps mentionnés dans les pages suivantes
un facteur de correction de 30% lorsqu’un travail dure incluent les opérations telles que: réglage du moteur
3.0 heures et moins, ou (+) 15% lorsqu’un travail dure (valve rotative et allumage), alignement de la ou des
plus de 3.0 heures. Cette compilation comprend, entre bielles, couple de serrage de la ou des culasses ou l’uti-
autres, les étapes suivantes: lisation de barres parallèles, utilisation du vérificateur
– Manutention du véhicule d’allumage, mesure du jet des pistons/jeu en bout des
segments, mesure de l’écart entre le vilebrequin et le
– Nettoyage carter, rectification du cylindre, vérification de fuite du
– Aller chercher les pièces, essais physiques moteur.
– Compensation spéciale (boulons rouillés)
– Diagnostic.
5. ILLUSTRATIONS
Contrairement aux Catalogues de pièces, les illustra-
3. UTILISATION DU BARÈME tions de ce manuel ne montrent pas nécessairement
Se reporter à la section désirée, repérer la pièce ou l’en- chacune des pièces qu’elles représentent, leur raison
semble de pièces remplacées et inscrire le CODE DE d’être étant plutôt de faciliter la reconnaissance des
TRAVAIL dans la colonne appropriée sur la formule de pièces reliées à un barème de temps à taux fixe. Les
réclamation. numéros d’items sur les illustrations correspondent
aux quatre derniers chiffres du code de travail.
SYSTÈME PAGE 6. SUGGESTION DE BARÈME DE TEMPS À
TAUX FIXE
01 MOTEUR 04
ENVOYEZ UNE REQUÊTE GARANTIE BOSSWeb
CARBURATEUR ET SYSTÈME DEPUIS LA SECTION INFO CENTRE
02 17
D’ALIMENTATION D’ESSENCE Dans cette requête, vous devez fournir les informations
03 SYSTÈME D’ALLUMAGE 22 suivantes:
Section Objet:
04 DÉMARREUR 23 – Suggestion de barème de temps à taux fixe
05 SYSTÈME DE TRANSMISSION 24 Section Votre Question:
06 SYSTÈME DE FREIN 33 – L'année modèle;
– Description du modèle;
SYSTÈME DE DIRECTION ET
07 33 – Description du code de travail;
SUSPENSION AVANT
– Code de travail;
SYSTÈME DE SUSPENSION ARRIÈRE ET
08 41 – Temps actuel;
CHENILLE
– Temps suggéré;
09 CARROSSERIE 44 – Détails de la marche à suivre;
10 SYSTÈME ÉLECTRIQUE 56 Pour s'assurer que votre demande sera traitée dans les
plus brefs délais et efficacement, s.v.p. nous fournir
toutes les étapes de réparation dans les détails de la
marche à suivre.
2 Can-Am - Volume 3
2019
2019
SSV/ VCC
ENGINE TYPE/
TABLE DESCRIPTION MODEL/MODÈLE
TYPE DE MOTEUR
9DKA/9DKB
MAVERICK 9DKC/9DKD 900T CVT
11 9DKE
MAVERICK XRC
7XKB/7XKC
MAVERICK
7XKD
7SKA/7SKB
7SKC/7SKD
MAVERICK Xds
7SKE/7SKF
7SKG/7SKM
12 9MKA/9MKB 903TCIC
MAVERICK XRC
9MKC/9MKD
7TKA/7TKB
7TKC/7TKD
7TKE/7TKF
MAVERICK Xrs
7TKG/7TKH
7TKJ/7TKK
7TKL/7TKM
7WKA/7WKB
13 MAVERICK MAX 903TC
7WKC/7WKD
7UKB/7UKC
MAVERICK MAX
7UKD
7VKA/7VKB
7VKC/7VKD
MAVERICK MAX Xds
7VKE/7VKF
14 7VKG
903TCIC
9NKA/9NKB
9NKC/9NKD
MAVERICK MAX Xrs
9NKE/9NKG
9NKH
15 MAVERICK XMR 6VKA 903TC
16 MAVERICK XMR 9LKA/9KLB 903TCIC
Volume 3 - Can-Am 3
2019
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
NO LABOR INVOLVED
01 00 0 0 0
AUCUNE MAIN D’OEUVRE
01 01 REMOVE AND REPLACE ENGINE (ASS’Y) 6.9 6.9 6.9
* REMPLACEMENT DU MOTEUR (COMPLET)
OIL PRESSURE SWITCH
01 03 0.3 0.3 0.3
INTERRUPTEUR DE PRESSION D’HUILE
HEAT SHEILD (EXHAUST)
01 04 DEFLECTEUR CHALEUR 0.3 0.3 0.3
FAN AND/OR FAN SUPPORT

01 08 0.7 0.7 0.7
VENTILATEUR ET/OU SUPPORT DE VENTILATEUR
SENDER TEMPERATURE (ENGINE)
01 18 CAPTEUR DE TEMPÉRATURE (MOTEUR) 0.4 0.4 0.4
THERMOSTAT
01 19 THERMOSTAT 1.5 1.5 1.5
COOLANT HOSE T-FITTING (ONE OR TWO)

01 21 BOYAU DE LIQUIDE DE REFROIDISSEMENT RACCORD EN T (1 OU 2) 0.5 0.5 0.5
RADIATOR INLET HOSE

01 37 BOYAU D’ENTRÉE DU RADIATEUR 0.6 0.6 0.6
WATER PUMP SHAFT (ALL PARTS)

01 38 4.5 4.5 4.5
ARBRE DE POMPE À L'EAU (TOUTES LES PIÈCES)
OIL TANK COVER AND GASKET
01 39 COUVERCLE DU RÉSERVOIR D’HUILE ET JOINT D’ÉTANCHÉITÉ 7.3 7.3 7.3
ENGINE DAMPER (1 OR ALL)

01 45 TAMPONS ANTI-VIBRATION DU MOTEUR (1 OU TOUS) 5.6 5.6 5.6
RADIATOR AND/OR GROMMMET

01 46 RADIATEUR ET/OU PASSE-FILS 1.0 1.0 1.0
CYLINDER HEAD GASKET

01 51 JOINT DE CULASSE 8.5 8.5 8.5
CRANKSHAFT BEARINGS PTO

01 63 1.4 1.4 1.4
ROULEMENTS DE VILEBREQUIN, COTE PDM
CRANKSHAFT
01 69 VILEBREQUIN 10.1 10.1 10.1
MUFFLER AND/OR EXHAUST GASKET AND/OR CLAMP

01 70 0.5 0.5 0.5
SILENCIEUX D’ÉCHAPPEMENT ET/OU JOINT D’ÉCHAPPEMENT ET/OU BRIDE DE SERRAGE
EXHAUST MANIFOLD
01 71 COLLECTEUR D'ÉCHAPPEMENT 0.7 0.7 0.7
COOLANT HOSE (RADIATOR TO TANK)

01 79 BOYAU DU SYSTÈME DE REFROIDISSEMENT (RÉSERVOIR AU RADIATEUR) 0.5 0.5 0.5
MUFFLER SUPPORT
01 87 SUPPORT DU SILENCIEUX 0.6 0.6 0.6
RUBBER MOUNT (MUFFLER)

01 88 TAMPON D'ANCRAGE (SILENCIEUX) 0.3 0.3 0.3
4 Can-Am - Volume 3
2019
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
ENGINE OIL FILTER

01 90 FILTRE À HUILE DU MOTEUR 0.3 0.3 0.3
OIL SIEVE AND/OR O-RING AND/OR COLLECTOR AND/OR RUBBER RING AND/OR COVER
01 96 CRIBLE D’HUILE ET/OU JOINT TORIQUE ET/OU COLLECTEUR ET/OU ANNEAU DE 7.7 7.7 7.7
CAOUTCHOUC ET/OU COUVERCLE
COOLING RESERVOIR
01 98 0.4 0.4 0.4
RÉSERVOIR D’ANTIGEL
RADIATOR OUTLET HOSE
01 100 BOYAU DE SORTIE DU RADIATEUR 0.6 0.6 0.6
PISTON, PIN, CIRCLIP, RINGS (1)

01 101 10.2 10.2 10.2
PISTON, GOUPILLE, CIRCLIP, SEGMENTS (1)
PISTONS, PINS, CIRCLIPS, RINGS (2)
01 102 PISTONS, GOUPILLES, CIRCLIPS, SEGMENTS (2) 10.3 10.3 10.3
PISTON,BEARING,PIN (3 PISTONS)
01 103 PISTON,ROULEMENT,AXE (3 PISTONS) 10.5 10.5 10.5
VALVE COVER AND/OR GASKET

01 109 COUVERCLE DE SOUPAPE ET/OU JOINT D’ÉTANCHÉITÉ 2.4 2.4 2.4
TIMING GEAR
01 111 PIGNON DE DISTRIBUTION 3.6 3.6 3.6
CYLINDER HEAD AND/OR GASKET

01 114 9.2 9.2 9.2
CULASSE ET/OU JOINT D’ÉTANCHÉITÉ
EXHAUST AND/OR INLET VALVE AND/OR SPRING AND/OR SEAL
01 116 VALVE ADMISSION ET/OU ÉCHAPPEMENT ET/OU RESSORT ET/OU ANNEAU D’ÉTANCHÉITÉ 8.4 8.4 8.4
WATER PUMP HOUSING AND/OR IMPELLER

01 119 CARTER DE LA POMPE À EAU ET/OU ROUE À AILETTES 1.0 1.0 1.0
OIL PUMP GEAR

01 132 ENGRENAGE DE LA POMPE À HUILE 4.2 4.2 4.2
OIL PIPE
01 133 TUYAU À L'HUILE 0.4 0.4 0.4
CRANKCASE RESEAL OR GASKET

01 138 9.0 9.0 9.0
RECELLEMENT DU CARTER ET/OU JOINT D’ÉTANCHÉITÉ
CRANKCASE REPLACEMENT
01 139 REMPLACEMENT DU CARTER 10.5 10.5 10.5
OIL PUMP GEAR (2)

01 146 4.2 4.2 4.2
ENGRENAGE POMPE À L'HUILE(2)
TIMING CHAIN
01 154 CHAÎNE D’ENGRENAGE 9.0 9.0 9.0
CHAIN GUIDE
01 179 GUIDE DE CHAÎNE 3.4 3.4 3.4
OIL RADIATOR AND/OR O-RING

01 182 RADIATEUR D'HUILE ET/OU JOINT D'ÉTANCHÉITÉ 0.5 0.5 0.5
Volume 3- Can-Am 5
2019
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
OIL PUMP COVER A/O SHAFT A/O ROTOR

01 183 COUVERCLE POMPE E/O ARBRE E/O ROTOR 4.4 4.4 4.4
OIL PUMP HOUSING A/O ALL PARTS

01 184 BOITIER POMPE HUILE E/O TOUTES PIECES 4.4 4.4 4.4
PTO HOUSING AND/OR GASKET

01 190 BOITIER PDM ET/OU JOINT 1.2 1.2 1.2
CHAIN TENSION GUIDE

01 191 GUIDE DE TENSION DE CHAÎNE 5.0 5.0 5.0
CHAIN TENSIONER (ASS’Y)

01 192 0.4 0.4 0.4
TENDEUR DE CHAÎNE (COMPLET)
WATER PUMP GEAR
01 200 ENGRENAGE DE LA POMPE À EAU 4.2 4.2 4.2
OIL DIPSTICK
01 215 0.3 0.3 0.3
JAUGE À HUILE
PRESSURE CAP
01 216 BOUCHON À PRESSION 0.3 0.3 0.3
KNOCK SENSOR
01 224 CAPTEUR DE CLIQUETIS 0.5 0.5 0.5
OUTPUT CRANKSHAFT SEAL (PTO SIDE)

01 245 ANNEAU ÉTANCHÉITÉ SORTIE VILEBREQUIN (CÔTÉ PDM) 1.4 1.4 1.4
WATER PUMP GEAR AND/OR SEAL

01 246 ARBRE POMPE À EAU ET/OU JOINT ÉTANCHÉITÉ 4.6 4.6 4.6
BREATHER GEAR AND/OR V-RING

01 248 2.5 2.5 2.5
RENIFLARD ET/OU ANNEAU ÉTANCHÉITÉ EN «V»
CRANKSHAFT POSITION SENSOR (CPS)
01 250 CAPTEUR POSITION DU VILEBREQUIN (CPV) 0.4 0.4 0.4
EXHAUST AND/OR INLET VALVES AND/OR SPRINGS AND/OR SEALS (4)

01 255 ÉCHAPPEMENT ET/OU VALVES ADMISSION ET/OU RESSORTS ET/OU ANNEAUX 8.0 8.0 8.0
D’ÉTANCHÉITÉ (4)
EXHAUST AND/OR INLET VALVES AND/OR SPRINGS AND/OR SEALS (8)
01 256 ÉCHAPPEMENT ET/OU VALVES ADMISSION ET/OU RESSORTS ET/OU ANNEAUX 8.2 8.2 8.2
D’ÉTANCHÉITÉ (8)
EXHAUST/INLET VALVES A/O SPRINGS A/O SEALS (12)
01 257 VALVES ADMISSION/ÉCHAPPEMENT E/O RESSORTS E/O ANNEAUX (12) 8.4 8.4 8.4
LONG BLOCK
01 264 ENSEMBLE CARTER - CYLINDRE - CULASSE 9.1 9.1 9.1
CRANKSHAFT PLAIN BEARINGS

01 274 PALIERS LISSE DU VILEBREQUIN 10.5 10.5 10.5
CAMSHAFT INTAKE/EXHAUST AND/OR CAMSHAFT BRACKETS

01 311 ARBRE A CAME ADMISSION/ECHAPPEMENT ET/OU SUPPORTS D'ARBRE A CAME 4.0 4.0 4.0
OIL SUMP COVER AND GASKET

01 315 7.5 7.5 7.5
COUVERCLE DU CARTER D'HUILE ET JOINT D'ÉTANCHÉITÉ
6 Can-Am - Volume 3
2019
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
THROTTLE PEDAL
01 320 PÉDALE D’ACCÉLÉRATEUR 0.4 0.4 0.4
PLUG SCREW
04 340 BOULON FILETE 0.3 0.3 0.3
OXYGEN SENSOR
01 352 CAPTEUR D’OXYGÈNE 0.4 0.4 0.4
INJECTORS (ALL)
01 353 INJECTEURS (TOUS) 1.0 1.0 1.0
TURBOCHARGER (ASS’Y)
01 369 2.5 2.5 2.5
TURBOCOMPRESSEUR (COMPLET)
OIL PRESSURE HOSE
01 370 BOYAU DE PRESSION D’HUILE 0.5 0.5 0.5
OIL RETURN HOSE

01 371 0.4 0.4 0.4
BOYAU DE RETOUR D’HUILE
FRONT HEAT SHEILD
01 375 DEFLECTEUR DE CHALEUR AVANT 0.3 0.3 0.3
SOLENOIDE VALVE
01 400 SOUPAPE SOLENOIDE 0.5 0.5 0.5
COOLANT TUBE (TURBO)

01 401 TUYAU DE REFROIDISSEMENT (TURBO) 0.6 0.6 0.6
HEAT SHIELD (TURBO)

01 402 DEFLECTEUR DE CHALEUR (TURBO) 0.3 0.3 0.3
TURBO GASKET
01 403 2.5 2.5 2.5
JOINT D'ETANCHEITE DU TURBO
VALVE(S) LIFTER
01 411 POUSSOIR DE SOUPAPE(S) 4.2 4.2 4.2
Volume 3- Can-Am 7
2019
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
900 ACE
01245
0163
01190
01274
01138
01139
01264
01315
mtf2014-006-001_a
8 Can-Am - Volume 3
2019
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
01101
01102
01103
900 ACE
01101
01102
01103
0169
mtf2014-006-002_a
Volume 3- Can-Am 9
2019
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
0190
900 ACE
01182
01192
0103
01215
01133
01184
01132
0139
0196
01146 01146
01183
01132
mtf2014-006-003_a
10 Can-Am - Volume 3
2019
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
01200 0118
01246
900 ACE
0138
0119
0138
01119
mtf2014-006-004_a
Volume 3- Can-Am 11
2019
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
01116
01411 01255
01256 900 ACE
01257
0171
01114
0151
01116
01255
01256
01257
mtf2014-006-005_a
2019
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
900 ACE
01111
01311
01192
01179
01248
01154
01191
01305
mtf2014-006-006_a
Volume 3- Can-Am 13
2019
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
0118
01119
0138
0138
01200
01246
ttf2017-004-001
2019
ENGINE SYSTEM
SYSTÈME MOTEUR 01
SYSTEM/SYSTÈME
01402
01400
01369
01403
01370
01401
01371
01402
ttf2017-004-002
Volume 3- Can-Am 15
2019
01
SYSTEM/SYSTÈME
ENGINE SYSTEM
SYSTÈME MOTEUR
0171 01352
0104
0171
0170
01375
ttf2017-004-003
2019
INTAKE AND FUEL SYSTEM
ADMISSION ET SYSTÈME D’ALIMENTATION D’ESSENCE 02
SYSTEM/SYSTÈME
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
NO LABOR INVOLVED
02 00 AUCUNE MAIN D’OEUVRE 0 0 0
AIR INTAKE SILENCER (ASS’Y)

02 01 SILENCIEUX D’ADMISSION D’AIR (COMPLET) 0.3 0.3 0.3
INTAKE ADAPTOR
02 16 ADAPTATEUR D’ADMISSION 0.5 0.5 0.5
AIR INTAKE TUBE

02 19 TUYAU D’ADMISSION D’AIR 0.3 0.3 0.3
REAR AIR INTAKE TUBE AND/OR SLEEVE

02 23 TUYAU D’ADMISSION D’AIR ARRIÈRE ET/OU DOUILLE 0.3 0.3 0.3
AIR TEMPERATURE SENSOR

02 46 CAPTEUR DE TEMPÉRATURE D’AIR 0.4 0.4 0.4
FUEL TANK
02 58 0.7 0.7 0.7
RÉSERVOIR D’ESSENCE
FUEL CAP
02 60 0.3 0.3 0.3
BOUCHON DU RÉSERVOIR À ESSENCE
AIR FILTER
02 69 0.3 0.3 0.3
FILTRE À AIR
INTAKE MANIFOLD
02 72 CONNECTEUR D’ADMISSION
1.0 1.0 1.0
FUEL RAIL (1 OR 2)
02 79 RAMPE D’ESSENCE (1 OU 2)
0.6 0.6 0.6
THROTTLE BODY (ASS’Y)

02 81 CARTER D’ACCÉLÉRATEUR (COMPLET)
0.5 0.5 0.5
AIR PRESSURE SENSOR

02 83 CAPTEUR DE PRESSION D'AIR
0.4 0.4 0.4
FUEL PUMP MODULE

02 89 MODULE POMPE À ESSENCE
0.4 0.4 0.4
FEMALE QUICK FITTING

02 94 CONNECTEUR RAPIDE FEMELLE
0.4 0.4 0.4
FUEL INJECTION HOSE (ASS’Y)

02 99 BOYAU À INJECTION D’ESSENCE (COMPLET)
1.0 1.0 1.0
FUEL PUMP NUT AND/OR GASKET

02 108 ECROU DE LA POMPE A ESSENCE ET/OU JOINT D'ETANCHEITE 0.3 0.3 0.3
PLENUM
02 115 CHAMBRE D’AIR 1.3 1.3 1.3
CHECK VALVE
02 119 0.3 0.3 0.3
SOUPAPE DE RETENUE
INTERCOOLER
02 122 0.5 0.5 0.5
REFROIDISSEUR
INTERCOOLER SUPPORT
02 123 SUPPORT DE REFROIDISSEUR 0.4 0.4 0.4
Volume 3 - Can-Am 17
2019
02
SYSTEM/SYSTÈME
ADMISSION ET SYSTÈME D’ALIMENTATION D’ESSENCE
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
INTERCOOLER HOSE
02 124 BOYAU INTERCOOLER 0.3 0.3 0.3
TURBO COMMANDE VALVE (TCV)

02 125 SOUPAPE DE COMMANDE TURBO (TCV) 0.4 0.4 0.4
FUEL TANK STRAP (ONE OR TWO)

02 128 SANGLE DE RESERVOIR D'ESSENCE (UNE OU DEUX) 0.7 0.7 0.7
FILLER NECK
02 129 0.3 0.3 0.3
GOULOT DE REMPLISSAGE
FILLER HOSE
02 130 0.3 0.3 0.3
BOYAU DE REMPLISSAGE
2019
SYSTEM/SYSTÈME
02108
0294
0289 02129
02130
0289
0258
0294
02128
ttf2017-004-004
2019
02
SYSTEM/SYSTÈME
ADMISSION ET SYSTÈME D’ALIMENTATION D’ESSENCE
0279
0246
02115
0283
0281
0216
ttf2017-004-005
2019
SYSTEM/SYSTÈME
02122
02123
02124
02124
0201
0201
0223
0219
ttf2017-004-006
2019
03
SYSTEM/SYSTÈME
IGNITION SYSTEM
SYSTÈME D’ALLUMAGE
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
NO LABOR INVOLVED
03 00 0 0 0
AUCUNE MAIN D’OEUVRE
MAGNETO (ASS’Y)
03 02 MAGNÉTO (COMPLET) 4.2 4.2 4.2
IGNITION COIL (EACH)

03 08 0.4 0.4 0.4
BOBINE D’ALLUMAGE (CHAQUE)
SPARK PLUG (1)
03 23 BOUGIE D’ALLUMAGE (1) 0.5 0.5 0.5
STATOR (ASS’Y)
03 27 STATOR (COMPLET) 4.0 4.0 4.0
SPARK PLUG (2)

03 31 BOUGIE D’ALLUMAGES (2) 0.6 0.6 0.6
MAGNETO COVER
03 32 COUVERCLE DE MAGNETO 4.0 4.0 4.0
MAGNETO GASKET COVER

03 33 4.0 4.0 4.0
JOINT D’ÉTANCHÉITÉ DU COUVERCLE DE MAGNETO
SPARK PLUG (3)
03 37 BOUGIES D’ALLUMAGE (3) 0.6 0.6 0.6
2019
STARTER SYSTEM
SYSTÈME DE DÉMARREUR 04
SYSTEM/SYSTÈME
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
NO LABOUR INVOLVED
04 00 0 0 0
AUCUNE MAIN-D’OEUVRE
ELECTRIC STARTER (ASS’Y)
04 02 DÉMARREUR (COMPLET) 0.4 0.4 0.4
STARTER RELAY
04 03 0.3 0.3 0.3
SOLÉNOÏDE DE DÉMARRAGE
STARTER DRIVE
04 19 LANCEUR DÉMARREUR 4.2 4.2 4.2
2019
05
SYSTEM/SYSTÈME
TRANSMISSION AND LINKAGE SYSTEM
SYSTÈME DE TRANSMISSION ET DE TRINGLERIE
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
05 00 NO LABOR INVOLVED
AUCUNE MAIN-D’OEUVRE IMPLIQUÉE
0 0 0
DRIVE PULLEY (ASS'Y) OR INNER HALF

05 01 POULIE MOTRICE (COMPLET) OU DEMIE-POULIE 0.4 0.4 0.4
GOVERNOR CUP AND/OR FIXED HALF

05 06 CUVETTE RÉGULATEUR ET/OU PARTIE FIXE POULIE 0.6 0.6 0.6
05 07 RAMPS AND/OR SCREWS

RAMPES ET/OU VIS
0.8 0.8 0.8
SPRING COVER AND/OR SPRING AND/OR BUSHING

05 08 COUVERCLE ET/OU RESSORT ET/OU DOUILLE POULIE 0.6 0.6 0.6
SLIDING HALF,BUSHING AND/OR LEVER ROLLER

5 10
DEMI-POULIE COULISSANTE,DOUILLE ET/OU ROULEAU
1.0 1.0 1.0
05 11 DRIVEN PULLEY FIXED HALF

DEMI-POULIE MENEE FIXE
0.7 0.7 0.7
DRIVEN PULLEY SLIDING HALF

05 12 DEMI-POULIE MENÉE COULISSANTE 0.6 0.6 0.6
05 13 DRIVEN PULLEY CAM AND/OR SPRING

CAME ET/OU RESSORT DE POULIE MENÉE
0.6 0.6 0.6
05 19 BELT
COURROIE
0.3 0.3 0.3
LEVER BUTTON
05 55 BOUTON DE LEVIER 0.3 0.3 0.3
05 56 LEVER (ASS’Y) AND/OR LEVER SPRING

LEVIER (COMPLET) ET/OU RESSORT DE LEVIER
0.5 0.5 0.5
05 59 SPEED SENSOR
CAPTEUR DE VITESSE
0.3 0.3 0.3
GEARSHIFT LEVER
05 66 LEVIER D'EMBRAYAGE 0.3 0.3 0.3
05 78 CVT COVER
COUVERCLE CVC
0.3 0.3 0.3
05 79 GASKET
JOINT D’ÉTANCHÉITÉ
0.3 0.3 0.3
ONE WAY CLUTCH, FLANGE, RING, SPRING

05 81 EMBRAYAGE À ROUE LIBRE, FLASQUE, ANNEAU, RESSORT 0.6 0.6 0.6
05 86 SLIDER SHOES
GLISSIÈRES
0.6 0.6 0.6
05 89 REMOVE AND REPLACE TRANSMISSION ASS'Y

REMPLACEMENT DE LA TRANSMISSION (COMPLET)
7.6 7.6 7.6
AIR INTAKE (CVT)

05 95 ENTRÉE D'AIR (CVC) 0.3 0.3 0.3
AIR OUTLET (CVT)

05 96 SORTIE D'AIR (CVC) 0.3 0.3 0.3
2019
05
SYSTEM/SYSTÈME
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
OUTPUT SHAFT
05 99 ARBRE DE SORTIE 8.4 8.4 8.4
GEARS BOX (ASS'Y)/MAIN SHAFT

05 101 BOÎTE D'ENGRENAGE (COMPLET)/ARBRE PRINCIPAL 8.5 8.5 8.5
SHIFT SHAFT (ASS'Y )

05 102 ARBRE D'EMBRAYAGE (COMPLET) 8.5 8.5 8.5
INDEX LEVER (ASS'Y)

05 104 LEVIER D'INDEXATION (COMPLET) 8.5 8.5 8.5
MAIN SHAFT SEAL

05 105 1.9 1.9 1.9
JOINT D'ÉTANCHÉITÉ DE L'ARBRE PRINCIPAL
ACTUATOR AND/OR FORK AND/OR SEAL
05 108 ACTUATEUR ET/OU FOURCHETTE ET/OU JOINT D'ÉTANCHÉITÉ 1.1 1.1 1.1
FORK AND/OR PIN

05 109 8.4 8.4 8.4
FOURCHETTE ET/OU GOUPILLE
SHIFTING SWITCH
05 113 INTERRUPTEUR D'EMBRAYAGE 0.3 0.3 0.3
SHIFT SHAFT SEAL

05 114 ANNEAU D’ÉTANCHEITÉ DU LEVIER D’EMBRAYAGE 0.4 0.4 0.4
CVT AIR GUIDE AND/OR O-RINGS

05 115 GUIDE D'AÉRATION ET/OU JOINT D'ÉTANCHÉITÉ 1.0 1.0 1.0
GEARBOX POSITION SENSOR

05 120 CAPTEUR DE POSITION D'ENGRENAGE 0.3 0.3 0.3
PRIMARY INLET AND/OR ADAPTER

05 159 0.3 0.3 0.3
ENTRÉE PRIMAIRE ET/OU ADAPTATEUR
FILTER
05 160 FILTRE 0.3 0.3 0.3
SHIFTING CABLE
05 161 CÂBLE D'EMBRAYAGE 1.0 1.0 1.0
COUNTERSHAFT SEAL
05 164 ANNEAU D'ÉTANCHÉITÉ DE L'ARBRE DE RENVOI 1.2 1.2 1.2
DRAIN PLUG (CVT)

05 165 BOUCHON DE VIDANGE (CVC) 0.3 0.3 0.3
FAN
05 187 VENTILATEUR 0.5 0.5 0.5
BEARING COVER
05 190 COUVERCLE ROULEMENT A BILLE 1.5 1.5 1.5
DRIVE SHAFT, ENGINE SUPPORT AND BEARINGS

05 203 8.0 8.0 8.0
ARBRE ENTRAINEMENT, SUPPORT MOTEUR ET ROULEMENTS
ENGINE SUPPORT (RIGHT SIDE)
05 204 SUPPORT MOTEUR (COTÉ DROIT) 3.0 3.0 3.0
TRANSMISSION DIPSTICK
05 205 JAUGE DE TRANSMISSION 0.3 0.3 0.3
Volume 3- Can-Am 25
2019
05
SYSTEM/SYSTÈME
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
FRONT DRIVE SHAFT OUTPUT SEAL

05 206 JOINT D’ÉTANCHÉITÉ SORTIE DE L’ARBRE D’ENTRAINEMENT AVANT 3.0 3.0 3.0
HOSE HOLDER
05 207 ATTACHE BOYAU 0.3
TOP AIR INTAKE (CVT)

05 208 ENTRÉE D'AIR SUPERIEUR (CVT) 0.3
TOP AIR OUTLET (CVT)

05 209 SORTIE D'AIR SUPERIEUR (CVT) 0.3
CAP
05 210 0.3
ENJOLIVEUR
2019
05
SYSTEM/SYSTÈME
05115
0579
0512
0519
0511
05133
0513
0501
0510
0507
0510 0506
0508
0586
0578
ttf2017-004-007
Volume 3- Can-Am 27
2019
05
SYSTEM/SYSTÈME
05191
05192
0559
05114
05113
05204
05205
05191
05192
05108 05120
05164
05203
05206
ttf2017-004-008
2019
05
SYSTEM/SYSTÈME
05104
05114
05188
05191
05192
05189
05191
05192
05190
05188
ttf2016-003-021
Volume 3- Can-Am 29
2019
05
SYSTEM/SYSTÈME
05102
05103
05103
05101
05109
05154
05101
05109
0599
ttf2016-003-022
2019
05
SYSTEM/SYSTÈME
05160
0596
0595 05159
0595
0596
0566
05161
0555
0556
ttf2017-004-009
Volume 3- Can-Am 31
2019
05
SYSTEM/SYSTÈME
05210
05208 05209
0566 05207
05208 05209
0559
05161
0596
0555
0595
0556
0595
ttf2019-003-001
2019
BRAKE SYSTEM
SYSTÈME DE FREIN 06
SYSTEM/SYSTÈME
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
NO LABOR INVOLVED
06 00 0 0 0
MASTER CYLINDER
06 06 MAÎTRE-CYLINDRE 1.0 1.0 1.0
FRONT CALIPER (RH OR LH)

06 09 0.5 0.5 0.5
ÉTRIER AVANT (DROIT OU GAUCHE)
FRONT BRAKE PAD (RH OR LH)
06 10 PLAQUETTE DE FREIN AVANT (DROIT OU GAUCHE) 0.3 0.3 0.3
FRONT BRAKE DISC (RH OR LH)

06 11 DISQUE DE FREIN AVANT (DROIT OU GAUCHE) 0.5 0.5 0.5
FRONT FLEXIBLE BRAKE HOSE

06 12 BOYAU FLEXIBLE DE FREIN AVANT 1.0 1.0 1.0
BRAKE SWITCH
06 19 INTERRUPTEUR DE FREIN 0.3 0.3 0.3
REAR BRAKE HOSE

06 25 1.6 2.2 1.6
BOYAU DE FREIN ARRIÈRE
REAR CALIPER
06 26 ÉTRIER ARRIÈRE 0.5 0.5 0.5
REAR BRAKE PAD

06 27 PLAQUETTE DE FREIN ARRIÈRE 0.3 0.3 0.3
REAR BRAKE DISC

06 28 DISQUE DE FREIN ARRIÈRE 0.5 0.5 0.5
MASTER CYLINDER RESERVOIR

06 34 RÉSERVOIR DU MAÎTRE-CYLINDRE 0.3 0.3 0.3
BRAKE PEDAL
06 35 0.5 0.5 0.5
PÉDALE DE FREIN
2019
06
SYSTEM/SYSTÈME
BRAKE SYSTEM
SYSTÈME DE FREIN
0634
0611
0610
0606
0635
0609
0612
0627
0625
0626
0628
ttf2017-004-010
2019
STEERING - FRONT DRIVE SYSTEM AND SUSPENSION
DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION 07
SYSTEM/SYSTÈME
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
NO LABOR INVOLVED
07 00 0 0 0
EXTERNAL BALL JOINT (RH OR LH)
07 13
JOINT À ROTULE EXTERNE (DROIT OU GAUCHE)
0.8 0.8 0.8
MAIN TUBE
07 24
TUBE PRINCIPAL
1.1 1.1 1.1
LOWER ARM AND/OR BALL JOINT (RH OR LH)

07 32
BRAS INFÉRIEUR ET/OU JOINT À ROTULE (DROIT OU GAUCHE)
0.7 0.7 0.7
UPPER ARM (RH OR LH)
07 33
BRAS DE SUSPENSION SUPÉRIEUR (DROIT OU GAUCHE)
0.7 0.7 0.7
FRONT SHOCK AND/OR SPRING AND/OR STOPPER AND/OR PROTECTOR AND/OR SEAT
(RH OR LH)
07 37 0.5 0.5 0.5
AMORTISSEUR AVANT ET/OU RESSORT ET/OU BUTÉE ET/OU SIÈGE ET/OU PROTECTEUR
(DROIT OU GAUCHE)
SABILIZER BAR
07 39
BARRE STABILISATRICE
0.5 0.5 0.5
FRONT DIFFERENTIEL (ASS’Y)

07 40
DIFFÉRENTIEL AVANT (COMPLET)
2.3 2.3 2.3
FRONT PROPELLER SHAFT (ASS’Y)

07 42 1.2 1.2 1.2
ARBRE DE PROPULSION AVANT (COMPLET)
CV JOINT (RH OR LH)
07 45
JOINT HOMOCINÉTIQUE (DROIT OU GAUCHE)
0.7 0.7 0.7
FRONT WHEEL HUB (SEAL AND/OR BEARING) (RH OR LH)

07 46
MOYEU DE ROUE AVANT (JOINT ET/OU ROULEMENT) (DROIT OU GAUCHE)
0.5 0.5 0.5
KNUCKLE (RH OR LH)
07 47
PORTE-FUSÉE (DROIT OU GAUCHE)
0.7 0.7 0.7
FRONT RIM AND/OR TIRE
07 50
JANTE AVANT ET/OU PNEU
0.4 0.4 0.4
INTERNAL BUSHING AND/OR CUSHION (LOWER AND/OR UPPER ARM) (RH OR LH)
07 72 DOUILLE INTERNE ET/OU COUSSIN (BRAS INFÉRIEUR ET/OU SUPÉRIEUR) (DROIT OU 0.4 0.4 0.4
GAUCHE)
BALL BEARING
07 82
ROULEMENT À BILLE
0.5 0.5 0.5
RING GEAR AND/OR CARRIER AND/OR SHIM

07 85
COURONNE DE LANCEMENT ET/OU SUPPORT ET/OU CALE
2.8 2.8 2.8
ACTUATOR
07 87
ACTUATEUR
0.3 0.3
RING GEAR DRIVE GEAR AND/OR BEARING AND/OR SHIM
07 88
PIGNON DE COMMANDE DE LA COURONNE ET/OU ROULEMENT À BILLE ET/OU CALE
2.8 2.8 2.8
COVER AND/OR PINION COVER AND/OR SEAL AND/OR BEARING

07 89 COUVERCLE ET/OU COUVERCLE DE PIGNON ET/OU JOINT D’ÉTANCHÉITÉ ET/OU 3.1 3.1 3.1
ROULEMENT À BILLE
BOOT WHEEL KIT AND/OR CV JOINT (RH OR LH)
07 90
ENSEMBLE DE SOUFFLET DE ROUE ET/OU JOINT CV (DROIT OU GAUCHE)
0.8 0.8 0.8
2019
07
SYSTEM/SYSTÈME
DIRECTION - SYSTÈME D’ENTRAÎNEMENT AVANT ET SUSPENSION
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
BOOT DIFFERENTIAL KIT AND/OR PLUNGING JOINT (RH OR LH)

07 91 ENSEMBLE DE SOUFFLET DE DIFFÉRENTIEL ET/OU JOINT PLONGEANT (DROIT OU 0.8 0.8 0.8
GAUCHE)
UNIT PACK KIT
07 94
ENSEMBLE JOINT CARDAN
1.5 1.5 1.5
UNIT PACKS KIT (2)

07 95 1.7 1.7 1.7
ENSEMBLE JOINTS CADRANS (2)
POWER STEERING
07 99
SERVODIRECTION
1.5 1.5 1.5
DIFFERENTIAL SEAL (1)

07 103
JOINT D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (1)
0.7 0.7 0.7
DIFFERENTIAL SEALS (2)
07 104
JOINTS D’ÉTANCHÉITÉ DU DIFFÉRENTIEL (2)
1.4 1.4 1.4
STEERING COLUMN SUPPORT AND/OR BUSHINGS
07 106
SUPPORT DE COLONNE DE DIRECTION ET/OU COUSSINETS
0.8 0.8 0.8
BELLOW
07 110 0.3 0.3 0.3
SOUFFLET
RACK AND PINION STEERING
07 115
DIRECTION À CRÉMAILLÈRE
1.8 1.8 1.8
STEERING SHAFT
07 116 0.9 0.9 0.9
ARBRE DU VOLANT
ADJUSTMENT CYLINDER
07 117
CYLINDRE D'AJUSTEMENT
0.3 0.3 0.3
STEERING WHEEL
07 118
VOLANT
0.3 0.3 0.3
DIFFERENTIAL OIL SEAL

07 120
ANNEAU D’ÉTANCHÉITÉ DU DIFFÉRENTIEL
1.5 1.5 1.5
HOSE (DIFFERENTIAL HOSE)

07 122
BOYAU (BOYAU DU DIFFÉRENTIEL)
0.3 0.3 0.3
PROPELLER SHAFT EXTENSION (ASS’Y)

07 130 1.2 1.2 1.2
EXTENSION D’ARBRE DE PROPULSION (COMPLET)
SPEED SENSOR
07 135
CAPTEUR DE VITESSE
0.3 0.3
CLUTCH PACK AND BALL RAMP

07 136
EMBRAYAGE ET RAMPE A BILLES
3.0 3.0
RING GEAR, SHIMS, SPIDER GEARS AND OUTPUT GEARS
07 137
COURONNE, CALES, SATELITTES ET PIGNONS DE SORTIE
3.1 3.1
2019
SYSTEM/SYSTÈME
0799
07106
07121
07118
0724
07115
07117
07110
0759
0760
0713
ttf2017-004-011
2019
07
SYSTEM/SYSTÈME
0737
0733
0739
0732
0747
ttf2017-004-012
2019
SYSTEM/SYSTÈME
0785
0740
07130 0785
0788
07120
0795
0745
0794
0791
0742
0746 0790
0782
0750
0750
ttf2017-004-013
2019
07
SYSTEM/SYSTÈME
0787
07103
07104
07120
0788
07136 07135
0740
07135
07137
07103
07104
ttf2019-003-002
2019
REAR DRIVE SYSTEM AND SUSPENSION
SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION 08
SYSTEM/SYSTÈME
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
NO LABOR INVOLVED
08 00 AUCUNE MAIN D’OEUVRE 0 0 0
REAR WHEEL HUB (RH)

08 05 0.3 0.3 0.3
MOYEU DE ROUE ARRIÈRE (DROIT)
SWING ARM
08 62 BRAS OSCILLANT
1.0 1.0 1.0
REAR WHEEL HUB (LH)

08 109 MOYEU DE ROUE ARRIÈRE (GAUCHE)
0.3 0.3 0.3
REAR SHOCK (RH OR LH)
08 111 AMORTISSEUR ARRIÈRE (DROIT OU GAUCHE)
0.5 0.5 0.5
REAR RIM AND/OR TIRE

08 114 JANTE ARRIÈRE ET/OU PNEU
0.4 0.4 0.4
CV JOINT (RH OR LH)
08 120 0.7 0.7 0.7
JOINT HOMOCINÉTIQUE (DROIT OU GAUCHE)
STABILIZER BAR
08 121 BARRE STABILISATRICE
0.6 0.6 0.6
BOOT WHEEL KIT AND/OR CV JOINT (RH OR LH)
08 125 ENSEMBLE DE SOUFFLET DE ROUE ET/OU JOINT CV (DROIT OU GAUCHE)
0.8 0.8 0.8
BOOT DIFFERENTIAL KIT AND/OR PLUNGING JOINT (RH OR LH)

08 126 ENSEMBLE DE SOUFFLET DE DIFFÉRENTIEL ET/OU JOINT PLONGENT (DROIT OU GAUCHE)
0.8 0.8 0.8
RADIAL BALL BEARINGS

08 127 ROULEMENTS À BILLE RADIALES
0.9 0.9 0.9
UNIT PACK KIT
08 128 1.8 1.8 1.8
ENSSEMBLE JOINT CADRAN
UNIT PACKS KIT (2)
08 129 ENSSEMBLE JOINTS CARDANS (2)
2.0 2.0 2.0
TIE ROD
08 142 BARRE ACCOUPLEMENT
0.3 0.3 0.3
BALL JOINT
08 170 JOINT ROTULE
0.3 0.3 0.3
SWAY BAR LEVER

08 171 0.3 0.3 0.3
LEVIER BARRE STABILISATRICE
KNUCKLE (RIGHT OR LEFT)
08 172 PORTE FUSÉE (DROIT OU GAUCHE)
0.7 0.7 0.7
Volume 3- Can-Am 41
2019
08
SYSTEM/SYSTÈME
SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION
08111 08121
0862
07142
08171
07142
07142
08111
08172
ttf2017-004-014
2019
SYSTÈME D’ENTRAÎNEMENT ARRIÈRE ET SUSPENSION 08
SYSTEM/SYSTÈME
08120 08114
08125
08114
08126
08105
ttf2017-001-015
Volume 3- Can-Am 43
2019
09
SYSTEM/SYSTÈME
BODY AND ACCESSORIES
CARROSSERIE ET ACCESSOIRES
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
NO LABOR INVOLVED
09 00 0 0 0
AUCUNE MAIN D’OEUVRE IMPLIQUÉE
LUGGAGE RACK KIT
09 13 ENSEMBLE PORTE-BAGAGE 0.9 0.9 0.9
CONSOLE
09 17 0.3 0.3 0.3
CONSOLE
FRONT BUMPER
09 26 PARE-CHOCS AVANT 0.7 0.7 0.7
FRONT FASCIA
09 28 FASCIA AVANT 0.5 0.5 0.5
FRAME
09 *49 CHASSIS 24.0 27.5 24.0
FRONT FENDER AND/OR SUPPORT (RH OR LH)

09 57 AILE AVANT ET/OU SUPPORT (DROIT OU GAUCHE) 0.3 0.3 0.3
MIRROR
09 65 0.3 0.3 0.3
RETROVISEUR
FRONT SKID PLATE
09 93 PLAQUE DE PROTECTION AVANT 0.6
EACH DECAL (1)

09 95 CHAQUE AUTOCOLLANT (1) 0.3 0.3 0.3
SEAT AND/OR BACKREST

09 110 SIÈGE ET/OU DOSSIER 0.3 0.3 0.3
SEAT BASE ASS'Y

09 111 BASE DE SIÈGE COMPLET 0.3 0.3 0.3
FRONT LIGHT FASCIA

09 120 0.3 0.3 0.3
FASCIA DE LUMIÈRE AVANT
FRONT GRILL
09 168 GRILLE FRONTALE 0.3 0.3 0.3
FRONT PLATE
09 195 0.4
PLAQUE AVANT
SERVICE COVER
09 227 COUVERCLE DE SERVICE 0.3 0.3 0.3
BUMPER COVER
09 229 COUVRE PARE-CHOC 0.3 0.3
REAR PANEL (LEFT OR RIGHT)

09 231 PANNEAU ARRIÈRE (GAUCHE OU DROIT) 0.4 0.4 0.4
MIDDLE SIDE PANEL (LEFT OR RIGHT)

09 239 PANNEAU LATÉRAL CENTRAL (GAUCHE OU DROIT) 0.6 0.6 0.6
CONSOLE SUPPORT
09 244 0.3 0.3 0.3
SUPPORT DE CONSOLE
CENTER PANEL
09 246 PANNEAU CENTRAL 0.5
2019
CARROSSERIE ET ACCESSOIRES 09
SYSTEM/SYSTÈME
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
LOWER MOULDING (RH OR LH)

09 280 ENJOLIVEUR INFÉRIEUR (DR OU GA) 0.3 0.3 0.3
GLOVES BOX
09 289 BOÎTE À GANTS 0.3 0.3 0.3
DASHBOARD
09 290 TABLEAU DE BORD 1.1 1.1 1.1
REAR SIDE PANEL (RIGHT OR LEFT)

09 306 PANNEAU LATÉRAL ARRIÈRE (DROIT OU GAUCHE) 0.3 0.3 0.3
BOTTOM FRONT SIDE PANEL (RH OR LH)

09 308 0.5
PANNEAU LATERAL AVANT BAS (DR OU GA)
CENTRAL SKID PLATE
09 336 PLAQUE DE PROTECTION CENTRALE 0.6 0.6 0.6
REAR SKID PLATE

09 337 0.6 0.6 0.6
PLAQUE DE PROTECTION ARRIÈRE
AIR INLET COVER
09 338 COUVERCLE D'ADMISSION D'AIR 0.3 0.3 0.3
FLOOR PANEL (LEFT)

09 339 PANNEAU DE PLANCHER (GAUCHE) 0.4 0.4 0.4
FLOOR PANEL (RIGHT)

09 340 PANNEAU DE PLANCHER (DROIT) 1.1 1.1 1.1
FRONT BULKHEAD (LEFT)

09 341 CLOISON AVANT (GAUCHE) 1.1 1.1 1.1
FRONT BULKHEAD (RIGHT)

09 342 0.8 0.8 0.8
CLOISON AVANT (DROITE)
REAR BULKHEAD (LEFT)
09 343 CLOISON ARRIÈRE (GAUCHE) 0.4 0.4 0.4
REAR BULKHEAD (RIGHT)

09 344 CLOISON ARRIÈRE (DROITE) 0.4 0.4 0.4
LATERAL CONSOLE PANEL (LEFT)

09 345 PANNEAU LATÉRAL DE CONSOLE (GAUCHE) 0.3 0.3 0.3
LATERAL CONSOLE PANEL (RIGHT)

09 346 PANNEAU LATÉRAL DE CONSOLE (DROIT) 0.3 0.3 0.3
FIXE CONSOLE PANEL (LEFT)

09 347 PANNEAU FIXE DE CONSOLE (GAUCHE) 0.6 0.6 0.6
LEVER INDICATOR
09 349 INDICATEUR DE VITESSE 0.3 0.3 0.3
HEAD REST
09 364 0.3 0.3 0.3
APPUI-TÊTE
SAFETY BELT
09 365 CEINTURE DE SÉCURITÉ 0.3 0.3 0.3
BUCKLE BELT
09 366 VERROU CEINTURE 0.3 0.3 0.3
Volume 3- Can-Am 45
2019
09
SYSTEM/SYSTÈME
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
HANDHOLD (LEFT)
09 368 POIGNÉE DE MAINTIEN (GAUCHE) 0.3 0.3 0.3
CAGE KIT
09 385 ENSEMBLE DE CAGE 3.4 3.4 3.4
ROOF
09 386 TOIT 0.3 0.3 0.3
CENTER HOOD
09 400 CAPOT CENTRAL 0.5 0.5 0.5
FRONT CONSOLE
09 406 0.3 0.3 0.3
CONSOLE AVANT
DASH BOARD PANEL (RIGHT OR LEFT)
09 409 PANNEAU DE TABLEAU DE BORD (DROIT OU GAUCHE) 0.4 0.4 0.4
REAR FLOOR (RIGHT)

09 428 1.2
PLANCHER ARRIERE (DROIT)
REAR FLOOR (LEFT)
09 429 PLANCHER ARRIERE (GAUCHE) 1.2
REAR LATERAL CONSOLE PANEL (LEFT)

09 431 PANNEAU LATERAL DE CONSOLE ARRIERE (GAUCHE) 0.3
REAR LATERAL CONSOLE PANEL (RIGHT)

09 432 PANNEAU LATERAL DE CONSOLE ARRIERE (DROIT) 0.3
REAR CENTRAL CONSOLE

09 433 CONSOLE ARRIERE CENTRALE 0.3
CENTER CAGE KIT

09 434 0.3 0.3 0.3
ENSEMBLE DE CAGE CENTRALE
INTERCOOLER AIR SCOOP
09 441 PRISE D’ADMISSION D’AIR DU REFROIDISSEUR 0.3 0.3 0.3
LATERAL CAGE LEG (RH OR LH)

09 446 MONTANT DE CAGE LATERAL (DROIT OU GAUCHE) 0.3 0.3 0.3
REAR FENDER MOULDING

09 454 ENJOLIVEUR D'AILE ARRIERE 0.5 0.5 0.5
REAR ROOF
09 470 TOIT ARRIERE 0.4
FRONT LATERAL PANEL

09 480 PANNEAU LATERAL AVANT 0.4 0.4 0.4
UPPER DASH
09 481 TABLEAU DE BORD SUPERIEUR 1.1 1.1 1.1
LOWER DASH (RIGHT)

09 483 0.3 0.3 0.3
TABLEAU DE BORD INFERIEUR (DROIT)
LOWER DASH (LEFT)
09 484 TABLEAU DE BORD INFERIEUR (GAUCHE) 0.4 0.4 0.4
FRONT BULKHEAD COVER

09 485 COUVERCLE DE CLOISON AVANT 0.6 0.6 0.6
2019
SYSTEM/SYSTÈME
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
REAR LOWER BULKHEAD

09 487 CLOISON INFERIEUR ARRIERE 2.2 2.2 2.2
REAR SERVICE COVER

09 490 COUVERCLE DE SERVICE ARRIERE 0.3 0.3 0.3
UPPER FRONT DEFLECTOR

09 496 DEFLECTEUR AVANT SUPERIEUR 0.3 0.3 0.3
OUTSIDE DOOR PANEL

09 506 PANNEAU DE PORTE EXTERIEUR 0.3 0.3 0.3
DOOR FRAME (ASS'Y)

09 511 0.4 0.4 0.4
CHASSIS DE PORTE (COMPLET)
CAGE COVER
09 521 ENJOLIVEUR DE CAGE 0.3 0.3 0.3
REAR FASCIA
09 522 0.3 0.3 0.3
CARENAGE ARRIERE
REAR LATERAL COVER
09 523 COUVERCLE LATERAL ARRIERE 0.3 0.3 0.3
FASCIA COVER
09 524 COUVERCLE DE CARENAGE 0.3 0.3 0.3
FUEL TANK CAP COVER

09 525 COUVERCLE DU BOUCHON RESERVOIR ESSENCE 0.3 0.3 0.3
REAR BULKHEAD CAP

09 526 CAPUCHON DE CLOISON ARRIÈRE 0.3 0.3 0.3
HOSE SUPPORT
09 527 1.5 1.5 1.5
SUPPORT DE TUYAU
BELT BAR
09 528 BARRE DE CEINTURE 0.5 0.5 0.5
TROLLEY AND RAILS

09 529 CHARIOT ET RAILS 0.4 0.4 0.4
SIDE PANEL COVER

09 531 COUVERCLE PANNEAU LATERAL 0.4
FRONT INTRUCTION BAR

09 545 BARRE ANTI-INTRUSION AVANT 0.3
Volume 3- Can-Am 47
2019
09
SYSTEM/SYSTÈME
09524 09168
0957
0928
09386 09506 09480 09400
09239
09521 09120
09231 09511
09454
09336
09525
09523
09338 09337
0913
09441 09506
09522
09231
ttf2017-004-016
2019
SYSTEM/SYSTÈME
09289
09344
09290
09343
09483 09409 09526
0965
09347
09340 09490
09227
09346
09406 09481 09368
09345 09349 09487

09496 09244
09339
09485
0917
09280 09290
09527
09342
09341
09496 09409
ttf2017-004-017
Volume 3- Can-Am 49
2019
09
SYSTEM/SYSTÈME
09385
09528
0926
09446
09493
09434
ttf2017-004-018
2019
SYSTEM/SYSTÈME
09110
09111
09364
09529
09365
09529
09366
ttf2017-004-019
Volume 3- Can-Am 51
2019
09
SYSTEM/SYSTÈME
09521
09454
09506 09523
09521
09523
09231
09506 09511 09511

09231
09525 09231
09480
09454
09511
09308
09231
09239
09480 09511 09506
09506
09308
09120 09239
ttf2018-003-005
2019
SYSTEM/SYSTÈME
09938
09470
09522
09386
09441
09524
0957
09400
0957 09337
0928
09168
09336
0953
09195
ttf2018-003-006
Volume 3- Can-Am 53
2019
09
SYSTEM/SYSTÈME
09526
0965
09526
09432 09344
09368
09490
09531 0917 09343
09368
09428 09246 09349
09433 09487
09409
09347
09289
09527 09431
09346
09227
09246
09340 09290
09483 09290 09345
09481 09409
09290
09496
09496 09428 09531
09280
09342
09339
09485 09341
ttf2018-003-007
2019
SYSTEM/SYSTÈME
09385
09446
09446
09528
0926
09434
09229
09493
09545
ttf2019-003-004
Volume 3- Can-Am 55
2019
10
SYSTEM/SYSTÈME
ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
NO LABOR INVOLVED
10 00 0 0 0
IGNITION SWITCH
10 01 INTERRUPTEUR D’ALLUMAGE 0.3 0.3 0.3
HEADLIGHT SWITCH
10 04 0.3 0.3 0.3
INTERRUPTEUR DE PHARE
HEADLAMP AND/OR HEADLAMP SUPPORT (ASS’Y) (RH OR LH)
10 09 PHARE AVANT ET/OU SUPPORT (COMPLET) (DROIT OU GAUCHE) 0.3 0.3 0.3
VOLTAGE REGULATOR
10 10 RÉGULATEUR DE TENSION 0.3 0.3 0.3
BATTERY
10 13 BATTERIE 0.3 0.3 0.3
FUSE BOX
10 14 BOÎTE-FUSIBLE 0.8 0.8 0.8
TAIL LAMP HOUSING (ASS’Y)

10 29 0.3 0.3 0.3
BOÎTIER DE FEU ARRIÈRE (COMPLET)
DC OUTLET PLUG
10 31 PRISE D’ACCESSOIRE DC 0.3 0.3 0.3
ELECTRONIC MODULE
10 34 MODULE ÉLECTRONIQUE 0.4 0.4 0.4
ENGINE HARNESS
10 41 CÂBLAGE MOTEUR 2.0 2.0 2.0
WINCH ASS'Y
10 45 TREUIL COMPLET 0.4 0.4
WINCH SOLENOID
10 46 0.4 0.4
SOLÉNOIDE DE TREUIL
WINCH SWITCH
10 47 INTERRUPTEUR DE TREUIL 0.3 0.3
MULTIFUNCTION GAUGE
10 49 0.3 0.3 0.3
CADRAN MULTIFONCTION
MAIN WIRE HARNESS
10 51 CÂBLAGE PRINCIPAL 2.7 2.7 2.7
STARTING RELAY
10 52 RELAIS DE DÉMARRAGE 0.3 0.3 0.3
RELAY
10 67 RELAIS 0.3 0.3 0.3
REAR HARNESS
10 75 CABLAGE ARRIERE 0.5 0.5 0.5
SWITCH
10 83 0.3 0.3 0.3
INTERRUPTEUR
START BUTTON
10 111 BOUTON DE DÉMARRAGE 0.3 0.3 0.3
2019
ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE 10
SYSTEM/SYSTÈME
MAX TURBO
TURBO XRM
MAVERICK
MAVERICK
MAVERICK
TURBO
SYSTÈME
CODE
SYSTEM
DESCRIPTION
11/12 13/14 15/16
OVERRIDE SWITCH
10 112 INTERRUPTEUR DE NEUTRALISATION 0.3 0.3 0.3
WINCH HARNESS
10 146 HARNAIS DU TREUIL 0.7 0.7
SIGNATURE BEAM (RH OR LH)

10 159 PHARE SIGNATURE (DROIT OU GAUCHE) 0.4 0.4 0.4
FRONT DIFFERENTIAL HARNESS

10 164 HARNAIS DU DIFFERENTIEL AVANT 0.6 0.6
FRONT DRIVE MODULE (FDM)

10 165 0.4 0.4
MODULE ENTRAINEMENT AVANT (FDM)
FDM SUPPORT
10 166 SUPPORT FDM 0.4 0.4
STARTER HARNESS
10 167 0.8 0.8 0.8
HARNAIS DU DEMARREUR
2019
10
SYSTEM/SYSTÈME
ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE
1009
1031
1049 1083 1009

1052 1083
10159
1001 10111
1029
1051
1029
1013
1010
ttf2017-004-020
2019
ELECTRICAL SYSTEM
SYSTÈME ÉLECTRIQUE 10
SYSTEM/SYSTÈME
1083 10159
10164
1046 1075
10159
10146
1047
10165 1052
1075
10166
1031 1049
10111
1083
1045 1051
1001
1010 10167
1009 1013
10159
ttf2019-003-003
2019
WARNING
To reduce risk of serious injury or death, read this
Operator’s Guide and safety labels, watch the safety
video and:
2019
Be prepared
• Fasten seat belts and make sure nets and/or doors
are securely latched in place.
• Wear an approved helmet and protective gear.
• Each rider must be able to sit with back against
seat, foot flat on the floor or on footrest, and hands
on steering wheel or handholds. Stay completely
Operator’s
inside the vehicle.
Drive responsibly
• Avoid loss of control and rollovers.
Guide
• Avoid abrupt maneuvers, sideways sliding, skidding
or fishtailing and never do donuts.
• Avoid hard acceleration when turning, even from
MAVERICK Series
Includes
a stop.
• Slow down before entering a turn.
• Plan for hills, rough terrain, ruts and other changes Safety, Vehicle
in traction and terrain.
• Avoid paved surfaces. and Maintenance Information
• Avoid side hilling (riding across slopes).
Be Qualified and Responsible

• Do not allow careless or reckless driving.
• Driver must be at least 16 years old with a valid
driver's license.
• Do not operate after using drugs or alcohol.
• Do not allow operation on public roads (unless
designated for off-highway vehicle access) –
collisions with cars and trucks can occur.
• Do not exceed vehicle seating capacity.
MAVERICKTM Series
WARNING
Read this guide thoroughly. It contains important safety information.
Minimum age: Operator: 16 or older with a valid driver's license. Keep this Operator’s Guide in the vehicle.
219 001 949 The removal or modification of evaporative emission-related parts on this OHRV is illegal.
OPERATOR’S GUIDE MAVERICK Series / ENGLISH Violators may be subject to civil and/or criminal penalties under California and federal law.
GUIDE DU CONDUCTEUR Série MAVERICK / ANGLAIS
2019
FAIT AU / MADE IN CANADA U/M:P.C.
®™ AND THE BRP LOGO ARE TRADEMARKS OF BOMBARDIER RECREATIONAL PRODUCTS INC. OR ITS AFFILIATES.
©2018 BOMBARDIER RECREATIONAL PRODUCTS INC. ALL RIGHTS RESERVED. PRINTED IN CANADA. 2 1 9 0 0 1 9 4 9 Original Instructions
WARNING
YOUR VEHICLE CAN BE HAZARDOUS TO OPERATE. A collision or rollover
can occur quickly, if you fail to take proper precautions, even during routine
maneuvers such as turning and driving on hills or over obstacles.
For your safety, understand and follow all the warnings contained in this
Operator's Guide and on the labels on your vehicle. Failure to follow these
warnings can result in SEVERE INJURY OR DEATH!
Keep this Operator's Guide with the vehicle at all times.
WARNING
Disregarding any of the safety precautions and instructions contained in
this Operator's Guide, SAFETY VIDEO and on-product safety labels could
result in severe injury including the possibility of death!
WARNING
This vehicle may exceed the performance of other vehicles you may have
ridden in the past. Take time to familiarize yourself with your new vehicle.
CALIFORNIA PROPOSITION 65 WARNING

WARNING: Operating, servicing and maintaining an off-road
vehicle can expose you to chemicals including engine
exhaust, carbon monoxide, phthalates, and lead, which are
known to the State of California to cause cancer and birth
defects or other reproductive harm. To minimize exposure,
avoid breathing exhaust, do not idle the engine except
as necessary, service your vehicle in a well-ventilated
area and wear gloves or wash your hands frequently
when servicing your vehicle. For more information go to
www.p65warnings.ca.gov/products/passenger-vehicle.
In Canada, products are distributed by Bombardier Recreational Products Inc.
(BRP).
In USA, products are distributed by BRP US Inc.
The following trademarks are the property of Bombardier Recreational

Products Inc.:
Can-Am® DPS™ ROTAX® XPS™
D.E.S.S.™ Maverick™ X™
This document contains the trademark of the following companies:

† Visco-Lok is a trademark of GKN Viscodrive GmbH.
† QS3 is a trademark of Fox Factory, Inc.

FOREWORD
Dieses Handbuch ist möglicherweise in Ihrer Landessprache

Deutsch verfügbar. Bitte wenden Sie sich an Ihren Händler oder besuchen Sie:
www.operatorsguides.brp.com
This guide may be available in your language. Check with your dealer or
English
go to: www.operatorsguides.brp.com
Español Es posible que este manual esté disponible en su idioma. Consulte a su

distribuidor o visite: www.operatorsguides.brp.com
Ce guide peut être disponible dans votre langue. Vérifier avec votre
Français
concessionnaire ou aller à: www.operatorsguides.brp.com
Italiano Questa guida potrebbe essere disponibile nella propria lingua. Contattare
il concessionario o consultare: www.operatorsguide.brp.com
ᵜ᡻޼ਟ㜭ᴹᛘⲴ䈝⿽Ⲵ㘫䈁⡸ᵜǄ䈧ੁ㓿䬰୶䰞䈒ˈᡆ㘵ⲫᖅ
ѝ᮷
www.operatorsguides.brp.com ḕ䈒Ǆ
このガイドは、言語によって翻訳版が用意されています。.
日本語ディーラーに問い合わせるか、次のアドレスでご確認ください：
www.operatorsguides.brp.com
Deze handleiding kan beschikbaar zijn in uw taal. Vraag het aan uw dealer
Nederlands
of ga naar: www.operatorsguides.brp.com
Denne boken kan finnes tilgjengelig på ditt eget språk. Kontakt din
Norsk
forhandler eller gå til: www.operatorsguides.brp.com
Português Este manual pode estar disponível em seu idioma. Fale com sua
concessionária ou visite o site: www.operatorsguides.brp.com
Воспользуйтесь руководством на вашем языке. Узнайте
Русский о его наличии у дилера или на странице по адресу
www.operatorsguide.brp.com
Käyttöohjekirja voi olla saatavissa omalla kielelläsi. Tarkista jälleenmyyjältä
Suomi
tai käy osoitteessa: www.operatorsguides.brp.com
Denna bok kan finnas tillgänglig på ditt språk. Kontakta din återförsäljare
Svenska
eller gå till: www.operatorsguides.brp.com
Congratulations on your purchase of At delivery, you were informed of the

a new Can-Am® side-by-side vehicle. warranty coverage and signed the
It's backed by the BRP limited warranty PREDELIVERY CHECK LIST to ensure
and a network of authorized Can-Am your new vehicle was prepared to your
dealers ready to provide the parts, ac- entire satisfaction.
cessories or service you may require. Your dealer is committed to your satis-
faction. If you need more information,
please ask your dealer.
_______________ 1
FOREWORD
Know Before you Go hicle controls, maintenance and safe

To learn how to reduce the risk of ac- operating instructions. It is indispens-
cident for you or bystanders, read this able for the proper use of the product.
Operator's Guide before you operate Keep this Operator's Guide in the vehi-
the vehicle. cle as you can refer to it for things such
Also, read all safety labels on your ve- as maintenance, troubleshooting and
hicle and watch the SAFETY VIDEO instructing others.
located at https://can-am.brp.com/off- Note that this guide is available in sev-
road/safety. eral languages. In the event of any dis-
crepancy, the English version shall pre-
vail.
If you want to view and/or print an
extra copy of your Operator's Guide,
simply visit the following website
www.operatorsguides.brp.com.
Failure to follow the warnings con- The information contained in this doc-
tained in this Operator's Guide can ument is correct at the time of publi-
result in SERIOUS INJURY or DEATH. cation. BRP, however, maintains a pol-
icy of continuous improvement of its
Safety Messages products without imposing upon itself
any obligation to install them on prod-
The types of safety messages, what ucts previously manufactured. Due
they look like and how they are used in to late changes, some differences be-
this guide are explained as follows: tween the manufactured product and
the descriptions and/or specifications
The safety alert symbol indicates in this guide may occur. BRP reserves
a potential injury hazard. the right at any time to discontinue or
change specifications, designs, fea-
WARNING tures, models or equipment without
incurring any obligation upon itself.
Indicates a potential hazard which,
if not avoided, could result in seri- This Operator's Guide should remain
ous injury or death. with the vehicle when it is sold.
CAUTION Indicates a haz-

ardous situation which, if not
avoided, could result in minor or
moderate injury.
NOTICE Indicates an instruction
which, if not followed, could result
in severely damaged vehicle com-
ponents or other property.
About this Operator's

Guide
This Operator's Guide has been pre-
pared to acquaint the owner/operator
of a new vehicle with the various ve-
2 _______________
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Know Before you Go . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
About this Operator's Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY INFORMATION
GENERAL PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Avoid Carbon Monoxide Poisoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Avoid Gasoline Fires and Other Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Avoid Burns from Hot Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accessories and Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SAFE OPERATION - RESPONSIBILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Owner - Be Responsible. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operator - Be Qualified and Responsible. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Riding Carefully. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Occupant Restraint System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Terrain Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRE-RIDE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pre-Ride Inspection Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PREPARE TO RIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Before you Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Riding Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
AVOID ACCIDENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Avoid Rollovers and Tipovers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Avoid Collisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RIDING YOUR VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Practice Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Off-Road Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General Riding Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
MOVING LOADS AND DOING WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Working with your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Carrying Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
IMPORTANT ON-PRODUCT LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hang Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Compliance Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Technical Information Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
VEHICLE INFORMATION
PRIMARY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1) Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2) Accelerator Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
_______________ 3
TABLE OF CONTENTS
PRIMARY CONTROLS (cont’d)

3) Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4) Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SECONDARY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1) RF D.E.S.S Key and RF D.E.S.S. Post. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2) Engine Start/Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3) Headlight Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4) 2WD/4WD/Front Diff Lock (If equipped) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5) Front Differential Mode Switch (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6) Sport/ECO Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7) Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8) DPS Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9) Winch Switch (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
MULTIFUNCTION GAUGE (LCD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Multifunction Gauge Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Multifunction Gauge Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Navigating in the LCD Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Gauge Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
MULTIFUNCTION GAUGE (ANALOG/DIGITAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Multifunction Gauge Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Gauge Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1) Tilt Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2) Cup Holders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3) Passenger Handholds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4) Glove Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5) Tool Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6) Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7) Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8) Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9) Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10) Fuel Reservoir Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
11) Cargo Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
12) Recovery Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
13) Wheel Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
14) 12-Volt Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
15) Central Rearview Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
16) Rock Sliders and Suspension Arm Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
17) Winch (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
TUNE YOUR RIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Suspension Adjustment Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Suspension Factory Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Suspension Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
DPS Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4 _______________
TABLE OF CONTENTS
FUEL (cont’d)
Vehicle Fueling Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Operation During Break-In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
BASIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Waking Up the Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Operating the Shift Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Choosing the Correct Range (Low or High) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Stopping the Engine and Parking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Tips for Maximizing Drive Belt Durability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
What to do if Water Entered the CVT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
What to do if Battery is Drained out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
What to do if Vehicle Rolled Over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
What to do if Vehicle is Submerged. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
TRANSPORTING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
LIFTING AND SUPPORTING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Front of Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
MAINTENANCE
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
SEVERE DUSTY OR SNOWY CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
MAINTENANCE SCHEDULE LEGEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Front Grille Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
CVT Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Evaporative Emission System Pre-Filter (If Equipped) . . . . . . . . . . . . . . . . . . . . . 100
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Muffler Spark Arresters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Front Differential Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
CVT Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Drive and Driven Pulleys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
_______________ 5
TABLE OF CONTENTS
MAINTENANCE PROCEDURES (cont’d)

Drive Shaft Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Wheel Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Suspensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
VEHICLE CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Post-Operation Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Vehicle Cleaning and Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
STORAGE AND PRESEASON PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
TECHNICAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Vehicle Identification Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Engine Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Compliance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Radio Frequency Digitally Encoded Security System (RF D.E.S.S. key) . . 128
EVAPORATIVE EMISSION CONTROL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
NOISE EMISSION CONTROL SYSTEM REGULATION . . . . . . . . . . . . . . . . . . . . . . 131
EC-DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
TROUBLESHOOTING
TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

MESSAGES IN MULTIFUNCTION GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
WARRANTY
BRP LIMITED WARRANTY USA AND CANADA: 2019 CAN-AM® SSV. . . . 150
US EPA EMISSION-RELATED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
CALIFORNIA EVAPORATIVE EMISSIONS CONTROL WARRANTY
STATEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
BRP INTERNATIONAL LIMITED WARRANTY: 2019 CAN-AM® SSV. . . . . . . 159
BRP LIMITED WARRANTY FOR THE EUROPEAN ECONOMIC AREA, THE
COMMONWEALTH OF THE INDEPENDANT STATES AND TURKEY: 2019
CAN-AM® SSV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
CUSTOMER INFORMATION
PRIVACY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
6 _______________
TABLE OF CONTENTS
CONTACT US. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Oceania . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
South America. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Asia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
CHANGE OF ADDRESS/OWNERSHIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
_______________ 7
TABLE OF CONTENTS
8 _______________
SAFETY
INFORMATION
________ SAFETY INFORMATION ________ 9

GENERAL PRECAUTIONS
Avoid Carbon Monoxide – Never carry gasoline container(s) or
Poisoning any dangerous liquids on the cargo
rack.
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing car- – Strictly adhere to instructions in VE-
bon monoxide can cause headaches, HICLE FUELING PROCEDURE.
dizziness, drowsiness, nausea, confu- – Never start or operate the engine if
sion and eventually death. the fuel cap is not properly installed.
Carbon monoxide is a colorless, odor- Gasoline is poisonous and can cause
less, tasteless gas that may be present injury or death.
even if you do not see or smell any en- – Never siphon gasoline by mouth.
gine exhaust. Deadly levels of carbon – If you swallow gasoline, get any in
monoxide can collect rapidly, and you your eye(s), or inhale gasoline vapor,
can quickly be overcome and unable see a doctor immediately.
to save yourself. Also, deadly levels of
carbon monoxide can linger for hours If gasoline spills on you, wash with
or days in enclosed or poorly ventilated soap and water and change your
areas. If you experience any symp- clothes.
toms of carbon monoxide poisoning,
leave the area immediately, get fresh Avoid Burns from Hot Parts
air and seek medical treatment. Certain components become hot dur-
To prevent serious injury or death from ing operation. Avoid contact with
carbon monoxide: those parts during and shortly after
– Never run the vehicle in poorly ven- operation to avoid burns.
tilated or partially enclosed areas
such as garages, carports or barns. Accessories and
Even if you try to ventilate engine Modifications
exhaust with fans or open windows Any modifications or addition of acces-
and doors, carbon monoxide can sories may affect the handling of your
rapidly reach dangerous levels. vehicle. It is important to take the time
– Never run the vehicle outdoors to get familiar with the vehicle once
where engine exhaust can be drawn modifications are made to understand
into a building through openings how to adapt your driving behavior ac-
such as windows and doors. cordingly.
Do not temper with unauthorized mod-
Avoid Gasoline Fires and ifications or install equipment not
Other Hazards specifically certified by BRP for the
Gasoline is extremely flammable and vehicle. These modifications have not
highly explosive. Fuel vapors can been tested by BRP and they may in-
spread and be ignited by a spark or crease the risk of injury or loss of con-
flame many feet away from the en- trol, or render the vehicle illegal to ride.
gine. To reduce the risk of fire or explo- As an example, tempering with tire
sion, follow these instructions: specifications may affect the behavior
– Use only an approved gasoline con- of the vehicle and increase the risk of a
tainer to store fuel. loss of control.
– Never fill the gasoline container on Ask your authorized BRP dealer for
the vehicle - an electrical static dis- suitable available accessories for your
charge may ignite the fuel. vehicle.
10 _______ SAFETY INFORMATION ________

SAFE OPERATION - RESPONSIBILITIES
This is a high performance off-road cle. Each visit to your authorized BRP
vehicle. Operators must be respon- dealer is a great opportunity for your
sible and use care to avoid rollovers, dealer to verify if your vehicle is in-
tipovers, collisions, and other acci- cluded in any safety campaign. We
dents. Even with vehicle safety fea- also urge you to visit your authorized
tures (such as protective structure, BRP dealer in a timely manner if you
seat belts, doors) and protective gear become aware of any safety related
(such as a helmet), there is always a campaigns.
risk of injury or death in these acci-
dents. To reduce the risk of serious Operator - Be Qualified and
injury or death, follow the rules in this Responsible
section.
Read this Operator's Guide and watch
Owner - Be Responsible the SAFETY VIDEO. Refer to the link at
the beginning of the Operator's Guide.
Read this Operator's Guide and watch
the SAFETY VIDEO. Refer to the link at Become completely familiar with the
the beginning of the Operator's Guide. operational controls and the general
operation of the vehicle.
Always inspect and confirm the safe
operating condition of your vehicle Get familiar with this Off-Highway Ve-
prior to ride. Always follow the main- hicle (OHV); it may exceed the perfor-
tenance schedule described in this mance of other OHV you may have
Operator's Guide. ridden. This is a high performance ve-
hicle. Inexperienced riders may over-
Never allow anyone to operate your ve- look risks and be surprised by the spe-
hicle unless they are responsible and cific behavior of this vehicle in any ter-
can be trusted with a high performance rain condition.
vehicle. Consider supervising new or
young operators and setting rules and Take a training course if available (con-
limits (e.g., whether they can carry a tact an authorized Can-Am dealer to
passenger, what they may do with the find out about training course avail-
vehicle, where they may ride, etc.) for ability as well as on the internet at
anyone using your vehicle. http://www.rohva.org/), and perform
the practice exercises in PRACTICE
Select the appropriate key (see RF EXERCISES. Practice driving in a suit-
D.E.S.S KEY AND RF D.E.S.S. POST) able area free of hazards and feel the
based on the operator's experience, response of each control. Drive at low
vehicle use and environment. speeds. Higher speeds require greater
Discuss the safety information with experience, knowledge and suitable
anyone who will be using the vehicle. riding conditions.
Be sure that all operators and passen- Be at least 16 years of age.
gers meet the qualifications below and
agree to follow the safety information. Be tall enough to be properly seated:
Help users become familiar with the back against the backrest with the
vehicle. seat belt fastened, to hold the steer-
ing wheel with both hands and still be
We encourage you to have an An- able to reach the full stroke of brake
nual Safety Inspection of your vehi- and accelerator pedals with the right
cle. Please contact an authorized BRP foot and to firmly plant left foot on the
dealer for further details. Though not footrest.
required, it is recommended that an
authorized BRP dealer performs the Have a proper driver's license in accor-
preseason preparation of your vehi- dance with local laws.

Never use this vehicle with drugs or al- – Never attempt skidding or sliding.
cohol, or if tired or ill. These slow reac- If vehicle starts to skid or slide,
tion time and impair judgment. counter steer in the direction of
skidding or sliding. On extremely
Carrying Passenger slippery surfaces, such as ice, go
Only carry one passenger. The pas- slowly and be very cautious in order
senger must be properly seated in the to reduce the chance of skidding out
cockpit. of control.
– Always be sure there are no obsta-
The passenger must be tall enough cles or people behind the vehicle
to always be properly seated: back when you operate in reverse. Pay
against the backrest with seat belt fas- attention to blind spots. When it
tened, holding both handholds, and is safe to proceed in reverse, go
feet firmly planted on the footrests. slowly.
Never carry a passenger who has used – Never exceed the stated load limits
drugs or alcohol, or is tired or ill. These for this vehicle. Reduce speed, al-
slow reaction time and impair judg- low for greater braking distance and
ment. follow other instructions in MOV-
Instruct the passenger to read the vehi- ING LOADS AND DOING WORK.
cle’s safety labels. – Always remember that this vehicle
Never carry a passenger if you judge is heavy! Its pure weight alone may
his ability or judgement insufficient to entrap you should it tip or rollover.
concentrate on the terrain conditions
and adapt accordingly. More specifi- Occupant Restraint
cally for side-by-side vehicles, the pas- System
senger must also pay constant atten- – This vehicle is designed to carry
tion to the terrain ahead and be able to one driver and one passenger, both
brace for bumps. wearing proper protective gear. Re-
fer to RIDING GEAR in this section.
Riding Carefully – The driver and passenger must latch
– This vehicle handles differently the doors and wear the seat belts at
from other vehicles. A collision or all times when riding.
rollover can occur quickly, during
abrupt maneuvers such as doing Terrain Condition
sharp turns, acceleration or decel- – This vehicle is not designed to ride
eration and driving on hills or over on paved surfaces; if you must
obstacles, if you fail to take proper shortly use the vehicle on such sur-
precautions. faces, avoid abrupt inputs to steer-
– Never operate at excessive speeds. ing wheel, accelerator and brake
Always go at a speed that is proper pedals.
for the terrain, visibility, and operat- – Always go slowly and be extra care-
ing conditions, and your experience. ful when operating on unfamiliar
– Never attempt jumps, side slides, terrain. Always be alert to changing
donuts or any other stunts. terrain conditions when operating
– Never attempt rapid acceleration this vehicle. Take the time to learn
or deceleration when performing a how the vehicle performs in differ-
sharp turn. This may result in a roll ent environments.
over.

– Never operate on excessively – Always ensure to properly park the

rough, slippery or loose terrain un- vehicle on the flattest terrain section
til you have learned and practiced available. Put shift lever in PARK,
the skills necessary to control this stop engine and remove key before
vehicle on such terrain. Always be leaving the vehicle.
especially cautious on these kinds – Never assume that the vehicle will
of terrain. go everywhere safely. Sudden
– Never operate this vehicle on hills changes in terrain caused by holes,
too steep for the vehicle or your abil- depressions, banks, softer or harder
ities. Practice on small inclines. “ground” or other irregularities may
– Always follow proper procedures cause the vehicle to topple or be-
for climbing or going down hills as come unstable. To avoid this, slow
described in RIDING YOUR VEHI- down and always observe the ter-
CLE. Check the terrain carefully be- rain ahead. If the vehicle does begin
fore you start up or down any hill. to topple or rollover, the best advice
Never climb or descend hills with is to immediately steer in the direc-
excessively slippery or loose sur- tion of the rollover! Never attempt
faces. Never go over the top of any to prevent a rollover with your arms
hill at high speed. or legs. You should keep your limbs
– Never attempt steep hills or side inside the cage.
hilling when pulling a trailer (if
equipped with hitch).
– Always check for obstacles before
operating in a new area. Always
follow proper procedures when op-
erating over obstacles as described
in RIDING YOUR VEHICLE.
– Never operate this vehicle in fast
flowing water or in water deeper
than specified in RIDING YOUR VE-
HICLE. Remember that wet brakes
may have reduced stopping ability.
Test your brakes after leaving wa-
ter. If necessary, apply them sev-
eral times to let friction dry out the
brakes.

PRE-RIDE INSPECTION
Always inspect and confirm the safe operating condition of your vehicle prior to
ride. Always follow the maintenance schedule described in this Operator's Guide.
WARNING
Perform a pre-ride inspection before each ride to detect any potential prob-
lem that could occur during operation. The pre-ride inspection can help you
monitor component wear and deterioration before they become a problem.
Correct any problem that you discover to reduce the risk of a breakdown or
crash.
Before using this vehicle, the operator should always perform the following
pre-ride inspection check list.
Refer to MAINTENANCE PROCEDURES for details.
Pre-Ride Inspection Check List

What to Do Before Starting the Engine (Key OFF)
ITEMS TO BE
INSPECTION TO PERFORM ✔
INSPECTED
Check tire pressure and condition. Refer to SPECIFICATIONS
Tires
and adjust according to load.
Check wheels for damage and for abnormal play. Make
sure that lug nuts and beadlocks screws (if equipped) are
Wheels
tightened. Refer to WHEELS AND TIRES in MAINTENANCE
PROCEDURES for torque specification.
Radiator Check radiator for cleanliness.
Front grille Inspect front grille kit for cleanliness.
Engine oil Check engine oil level.
Coolant Check coolant level.
Brake fluid Check brake fluid level.
Engine air filter Inspect engine air filter, replace if needed.
Engine air filter Inspect engine air filter housing and clean if necessary (when
housing riding in dusty conditions or sand).
Inspect and clean the CVT air filter (when riding in dusty
CVT air filter
conditions).
Drive shaft boots Check drive shaft boots condition.

PRE-RIDE INSPECTION
ITEMS TO BE
INSPECTED
Cargo Load: If you transport a cargo, respect the maximum
cargo rack capacity. Refer to SPECIFICATIONS. Ensure the
weight of the operator, passengers, cargo, trailer tongue and
added accessories does not exceed the vehicle total load
allowed. Refer to SPECIFICATIONS.
If you are pulling a trailer or another equipment (if equipped
Cargo and load
with a hitch):
– Check hitch and trailer ball condition.
– Respect the tongue capacity and
towing capacity as indicated on
the label affixed to the hitch or refer to SPECIFICATIONS.
– Ensure trailer is properly secured to hitch.
Rear cargo rack Check if the cargo on rack is properly secured.
Check underneath vehicle for any debris on chassis or
Chassis and
suspension components (upper and lower arms, wheels,
suspension
shock absorber, springs) and clean them properly.
What to Do Before Starting the Engine (Key ON)

ITEMS TO BE
INSPECTED
Check operation of indicator lamps in gauge (With the
Gauge D.E.S.S. key ON, briefly push the Start / Stop button).
Check for messages in gauge.
Check operation and cleanliness of headlights and taillight.
Lights Check operation of high and low beam.
Check operation of brake light.
Check seat adjustment and make sure locking device is
properly engaged before riding.
Check doors for any damage. Have the
doors replaced if any damage is found.
Seats, doors and Close both doors and confirm that they latch
seat belts securely.
Check seat belts for any damage (including retractors,
buckles and semi-cinching tabs). Fasten seat belts and
ensure that they remain securely fastened and tightened
against the body

PRE-RIDE INSPECTION
ITEMS TO BE
INSPECTED
Press on the accelerator pedal a few times to ensure it
Accelerator pedal operates freely and it returns to the rest position when
released.
Press down on the brake pedal and make sure you feel
Brake pedal firm resistance and that it fully returns to position when
released.
Fuel level Check the fuel level.
What to Do After the Engine is Started

ITEMS TO BE
INSPECTED
Check if steering operates freely by completely turning it
Steering
from side to side.
Check if D.E.S.S. post is working properly by pulling the
RF D.E.S.S. post
D.E.S.S. key from D.E.S.S. post.
Shift lever Check operation of shift lever (P, R, N, H and L).
2WD/4WD/Front
Check operation of 2WD/4WD/Front Diff Lock (If equipped)
Diff Lock (If
selector.
equipped) selector
Drive forward slowly a few feet and apply brakes. The
brake pedal must feel firm when applied. The pedal must
Brakes
return to rest position when released. The brakes must
respond adequately to the driver's input.

PREPARE TO RIDE
Before you Ride Weather conditions should help you
Perform pre-ride inspection to confirm decide how to dress. To maximize
the safe operating condition of your comfort and avoid frostbites in win-
vehicle. Refer to PRE-RIDE INSPEC- ter, dress for the coldest weather ex-
TION. pected. Thermal underwear next to
the skin also provides good insulation.
Driver and passenger must:
Never wear any loose clothing that
– Be properly seated. may get entangled in the vehicle or on
– Close both doors and fasten seat tree branches and shrubs.
belts.
– Wear appropriate riding gear. (Refer Helmets and Eye Protection
to RIDING GEAR below.) Helmets protect the head and brain
from injury. Even with the vehicle's
Riding Gear cage and doors, objects can enter the
It is important that the operator and cockpit and strike the head, or the head
passenger always wears appropriate can strike the cage itself or objects out-
protective clothing and apparel, includ- side the vehicle. Even the best helmet
ing: is no guarantee against injury, but sta-
– An approved helmet tistics indicate that helmet use signif-
icantly reduces the risk of brain injury.
– Eye protection So, be safe and always wear a helmet
– Boots while riding.
– Gloves
– A long sleeved shirt or jacket Choosing a Helmet
– Long pants. Helmets should be manufactured to
meet the appropriate standard in your
Depending on conditions, anti-fogging state, province or country and should
goggles may be required. fit properly.
A helmet with face protection is a bet-
1 ter choice as it protects also against
2 frontal impacts. It can also protect
against debris, stones, insects, the el-
ements, etc.
3 An open-face helmet does not offer the
4 same protection for the face and chin.
If you wear an open-face helmet, you
5 should use a snap-on face shield and/or
a pair of goggles. Ordinary glasses or
sunglasses are not sufficient eye pro-
6 tection for riders. They can shatter
rmo2008-001-019_a
or fly off, and they allow wind and air-
borne objects to reach the eyes.
RIDING GEAR
1. Approved helmet For winter riding conditions, a stock-
2. Eye and face protection ing type cap, balaclava and face mask
3. Long sleeves shirt or jacket should always be carried or worn.
4. Gloves
5. Long pants
6. Boots (over-the-ankle footwear)

PREPARE TO RIDE
Use tinted face shields or goggles in crash, good quality protective gear
the daytime only; do not use them at made of sturdy material may prevent
night or in poor illumination. Do not or reduce injury.
use them if they impair your ability to In cool-weather riding, protect your-
discern color. self against hypothermia. Hypother-
mia, a condition of low body tempera-
Other Riding Gear ture, can cause loss of concentration,
Footwear slowed reactions and loss of smooth,
precise muscle movement. In cool
Always wear closed toe footwear. conditions, proper protective gear like
Sturdy over-the-ankle boots with a windproof jacket and insulated layers
non-slip soles offer more protection of clothing are essential. Even while
and allow you to plant your foot prop- riding at moderate temperatures, you
erly on footrest. can feel very cold due to the wind.
Avoid long shoelaces that can be tan- Protective gear that is appropriate for
gled in the accelerator or brake pedals. cold-weather riding may be too hot
For winter riding conditions, rubber when stopped. Dress in layers so that
soled boots with either a nylon or clothing can be removed as desired.
leather uppers, with removable felt Topping the protective gear with a
liners are best suited. windproof outer layer can prevent cold
air from reaching the skin.
Avoid rubber boots. Rubber boots may
get trapped behind or between pedals, Rain Gear
impairing the proper operation of brake
and accelerator pedals. If you must ride in wet weather, a rain
suit or a waterproof riding suit is rec-
Gloves ommended. On long rides, it is a good
idea to carry rain gear. A dry rider will
Full-fingered gloves protect hands be much more comfortable and alert.
from the wind, sun, heat, cold and fly-
ing objects. Gloves that fit snugly will Hearing Protection
improve grip on the steering wheel and
help reduce hand fatigue. Sturdy, rein- Long-term exposure to wind and en-
forced motorcycle or ATV gloves help gine noise when riding can cause per-
protect hands better in the event of an manent hearing loss. Properly worn
accident or a rollover. If gloves are too hearing protective devices such as
bulky, it may be difficult to operate the earplugs can help prevent hearing loss.
controls. Check local laws before using any hear-
ing protective devices.
For winter riding conditions, hands
should be protected by a pair of snow-
mobile gloves which have sufficient
insulation and allow use of thumbs and
fingers for operation of controls.
Jackets, Pants and Riding Suits
Wear a jacket or a long sleeved shirt
and long pants, or a full riding suit.
Quality ATV-type protective gear will
provide comfort, and it can help you
avoid being distracted by adverse en-
vironmental elements. In case of a

AVOID ACCIDENTS
Avoid Rollovers and – Never attempt donuts, skids, slides,
Tipovers fishtails, jumps, or other stunts. If
vehicle starts to skid or slide, steer
Side-by-side vehicles handle differ- in the direction of the skid or slide.
ently from other vehicles. Side-by-side Never slam the brakes and lock the
vehicles are designed to handle wheels.
off-road terrain (for example, their
wheel base and track width, ground – Avoid paved surfaces. This vehi-
clearance, suspension, drivetrain, cle is not designed to operate on
tires, etc.), and, as a result, can over- paved surfaces and is more likely to
turn in situations where vehicles de- roll over. If you must drive on pave-
signed for use primarily on paved or ment, turn gradually, go slowly, and
smooth terrain may not. avoid abrupt acceleration and brak-
ing.
A rollover or other accident can oc-
cur quickly during abrupt maneuvers This vehicle can roll over sideways
such as sharp turns or hard accelera- or tip over forward or backwards on
tion or deceleration when turning, or slopes or uneven terrain.
when driving on hills or over obsta- – Avoid side hilling (driving along the
cles. Abrupt maneuvers or aggressive slope rather than up or down a hill).
driving can cause rollovers or loss of When possible, drive straight up and
control even in flat open areas. If the down inclines rather than across
vehicle rolls over, any part of your body them. If you must side hill, use ex-
(such as arms, legs, or head) outside of treme caution and avoid slippery
the cockpit can be crushed and trapped surfaces, objects, or depressions. If
by the cage or other parts of the vehi- you feel the vehicle start to rollover
cle. You can also be injured by impact or slide sideways, steer downhill if
with the ground, cockpit or other ob- possible.
jects. – Avoid steep hills and follow proce-
To reduce the risk of rollovers: dures in this guide for climbing and
descending hills.
– Use care when turning.
– Sudden changes in terrain such as
• Do not turn the steering wheel holes, depressions, banks, softer or
too far or too fast for your speed harder ground or other irregularities
and environment. Adjust steer- may cause the vehicle to tip or be-
ing inputs according to your come unstable. Observe the terrain
speed and environment. ahead and slow down in areas of un-
• Slow down before entering a even terrain.
turn. Avoid hard braking during
a turn. This vehicle will handle differently
when carrying or pulling a load.
• Avoid sudden or hard accelera-
tion when turning, even from a – Reduce speed and follow instruc-
stop or low speed. tions in this manual for carrying
cargo or pulling a trailer.
– Avoid hills and rough terrain.
– Allow more distance to stop.
Be Prepared in Case of Rollover
– Close both doors and fasten seat
belt to help you avoid sticking out
arms or legs.

AVOID ACCIDENTS
– Never grab the cage while riding.

Hands can be crushed between the
cage and the ground in a rollover.
Keep hands on the steering wheel
or handholds.
– Never try to stop a rollover using
your arms or legs. If you think that
the vehicle may tip or roll, the driver
should keep both hands on the
steering wheel and the left foot
firmly planted on the footrest. The
passenger should keep both hands
on the handholds and both feet
firmly planted on the floor.
Avoid Collisions
This vehicle can reach high speeds. At
higher speeds, there is an increased
risk of losing control, particularly in
challenging off-road conditions, and
the risk of injury in a collision is greater.
Never operate at excessive speeds.
Always go at a speed that is proper for
the terrain, visibility, and operating con-
ditions, and your experience. Consider
reserving use of the performance key
for situations in which full speed and
acceleration capability are appropriate.
Never operate this vehicle on any pub-
lic street, road or highway, even dirt
or gravel ones. Riding your vehicle on
roads or highways could result in a colli-
sion with another vehicle. This vehicle
is not designed for operation on roads.
For example, it does not meet motor
vehicle safety standards that apply to
automobiles. In many jurisdictions it
is not legal to operate this vehicle on
public roads.
This vehicle does not have the same
kind of protection for collisions as a
car; for example, there are no air bags,
the cockpit is not fully enclosed, and
it is not designed for collisions with
other vehicles. Therefore, it is particu-
larly important to fasten seat belts and
close doors and wear an approved hel-
met.

RIDING YOUR VEHICLE
Practice Exercises U Turn Exercises
Before you go out for a ride, it is very Practice doing U turns.
important to familiarize yourself with – Accelerate slowly and while remain-
the handling of your vehicle by prac- ing at low speed, then gradually turn
ticing in a controlled environment. If the steering wheel to the right until
possible, it is also a very good idea to you have completed the U turn.
take a more formal training course to – Repeat U turn exercise with differ-
sharpen your skills and increase your ent steering inputs and always at a
knowledge of the vehicle. very low speed.
Find a suitable area to practice and – Repeat U turn exercise on the other
perform the following exercises. It side.
should be at least 45 m (150 ft) by 45 m As mentioned before in this guide, do
(150 ft) free of obstacles like trees and not ride on paved surfaces as the ve-
rocks. Once you’ve selected a suitable hicle behavior will not be the same,
permitted location, proceed with the increasing the risk of rollover.
following exercises.
Braking Exercises
Turning Exercises
Practice braking to get familiar with the
Turning is one of the most frequent brake response.
causes of accidents. It is easier for the – Do it at low speed first, then in-
vehicle to lose traction or rollover if you crease the speed.
turn too sharply, or go too fast. Slow
down when you approach a turn. – Practice braking in straight line at dif-
ferent speeds and different braking
– First learn how to perform slight force.
right turns at very low speeds. Re-
lease the throttle before turning and – Practice emergency braking; opti-
slowly reapply the throttle when mal braking is obtained in straight
turning. line, with high force applied, with-
out locking the wheels.
– Repeat turning exercise but this Remember, braking distance depends
time maintain the throttle at the on vehicle speed, load and the type of
level while turning. surface. Also, the tires and brakes con-
– Finally, repeat turning exercise ditions play a major role.
while accelerating slowly.
– Practice exercises turning on the Reverse Exercises
other side. The next step involves using the re-
Note how your vehicle reacts in these verse.
different exercises. We recommend
releasing the throttle before entering a – Install 1 cone marker on both sides
turn to help initiate directional change. of the vehicle beside each rear
You will feel the lateral force increasing wheel. Move the vehicle forward
with the speed and with your steer- until you can see the cone markers,
ing input. The lateral force should be then stop the vehicle. Acknowl-
maintained as low as possible to make edge the distance required to see
sure it does not cause the vehicle to obstacles behind you.
roll over. – Learn how the vehicle handles itself
in reverse and reacts with steering
inputs.

RIDING YOUR VEHICLE
– Always perform this reverse exer- Whenever there is the slightest doubt
cise at slow speeds. that the vehicle can safely negotiate an
– Become familiar with the usage of obstacle or a particular piece of terrain,
the override function. Do not steer always choose an alternate route.
while using the override as it in- In off-road operation, power and trac-
creases the risks of rollover. tion, not speed, are important. Never
drive faster than visibility and your own
Emergency Engine Stopping ability to select a safe route permit.
Exercise Always go slowly and be extra careful
Learn how to stop your engine quickly when operating on unfamiliar terrain.
in an emergency situation. Always be alert to changing terrain con-
– While running at low speed, simply ditions when operating this vehicle.
remove the RF D.E.S.S. key from Be especially cautious on excessively
the D.E.S.S. post. rough, slippery, icy or loose terrain.
This is to familiarize you with the ve- Constantly watch the terrain ahead
hicle’s reaction when the engine is for sudden changes in slopes or ob-
turned off while driving and to develop stacles, such as rocks or stumps, that
this reflex. may cause loss of stability, resulting in
tip over or rollover.
Off-Road Operation Never operate the vehicle if the con-
The very nature of off-road operation trols do not function normally. See an
is dangerous. Any terrain, which has authorized Can-Am dealer.
not been specially prepared to carry To maintain proper control it is strongly
vehicles, presents an inherent danger advised that you keep your hands on
where terrain substance, shape and the steering wheel and within easy
steepness are unpredictable. The ter- reach of all controls. The same holds
rain itself presents a continual element true for your feet. To minimize the pos-
of danger, which must be knowingly sibility of any leg or foot injury, keep
accepted by anyone venturing over it. your left foot on the footrest and right
An operator who takes a vehicle foot on the floor at all times. Staying
off-road should always exercise the ut- completely within the cockpit will also
most care in selecting the safest path help keep you from striking objects
and keeping close watch on the ter- outside the vehicle.
rain ahead of him. The vehicle should Watch for and avoid branches and
never be operated by anyone who is other foreign objects that could en-
not completely familiar with the driving ter the passenger compartment and
instructions applicable to the vehicle, strike you or your passenger.
nor should it be operated on steep or
treacherous terrain. Operating in Reverse
When operating in reverse, check that
General Riding Techniques the path behind the vehicle is free of
people or obstacles. Pay attention to
General Driving Tips blind spots. When it is safe to proceed
Care, caution, experience and driving in reverse, go slowly and avoid sharp
skill are the best precautions against turns.
the hazards of vehicle operation.
WARNING
Steering inputs in reverse opera-
tion increase the risk of rollover.

RIDING YOUR VEHICLE
NOTE: In reverse operation, the en- ilarly so, be watchful of hazards such
gine RPM is limited thus limiting the as rocks, logs, etc., partially covered by
vehicle reverse speed. vegetation.
WARNING Riding on Snow or Ice

When driving downhill in reverse, When performing pre-ride inspection,
gravity can increase the vehicle pay special attention to locations on
speed above the set limited re- the vehicle where snow and/or ice ac-
verse speed. cumulations may obstruct visibility of
the tail lamp, clog ventilation openings,
block the radiator and fan, and interfere
Crossing Roads with the movement of controls. Be-
If you have to cross a road, ensure to fore starting with your vehicle, check
have complete visibility on both sides the steering, accelerator and brake
for incoming traffic and decide on exit pedals for interference free operation.
point on other side of road. Drive in Whenever this vehicle is ridden on a
a straight line toward that point. Do snow covered drive path, the tire grip
not make sharp direction changes or is generally reduced causing the ve-
abrupt accelerations as it may result hicle to react differently to control in-
in a rollover situation. Do not travel on puts from the operator. On low grip
sidewalks or bicycle trails as they are surfaces, the steering responses are
designated specifically for those uses. not as crisp and precise, stopping dis-
tances are lengthened and accelera-
Riding on Paved Surfaces tion is also affected. Slow down and
Avoid paved surfaces. This vehicle is do not "gun" the accelerator. This will
not designed to operate on paved sur- only result in spinning of the tires and
faces and is more likely to roll over. possibly in an over steering slide of the
If you must drive on pavement, turn vehicle. Avoid hard braking. This will
gradually, go slowly, and avoid abrupt possibly result in a straight line slide of
acceleration and braking. the vehicle. Again, the best advice is to
safely reduce speed in anticipation of
Shallow Water Crossing a maneuver to give yourself time and
Water can be a unique hazard. If it is distance in order to keep control of the
too deep the vehicle may “float” and vehicle.
topple. Check the water depth and cur- As you drive your vehicle over a loose
rent before you attempt to cross any snow covered surface, snow dust will
water. Water depth should not exceed be picked up in the wake turbulence
30 cm (12 in) for vehicle to safely cross of the moving vehicle and transported
the obstacle. Beware of slippery sur- to contact and accumulate or melt on
faces such as rocks, grass, logs, etc., some exposed components including
both in the water and on its banks. A rotating parts like brake discs. Water,
loss of traction may occur. Do not at- snow or ice may affect the response
tempt to enter the water at high speed. time of the brake system of your vehi-
Water will affect the braking ability of cle. Even when not required to reduce
your vehicle. Make sure you dry the vehicle speed apply brakes frequently
brakes by applying them several times to prevent ice or snow accumulation
after the vehicle leaves the water. and to dry brake pads and discs. While
doing so in low risk driving situations
Mud or marsh lands may be encoun- you will test for grip level and keep
tered near water. Be prepared for sud- yourself alerted to how the vehicle re-
den “holes” or changes in depth. Sim- acts to your control inputs. Always

RIDING YOUR VEHICLE
keep brake and accelerator pedals and Riding on Gravel, Loose Stones or
floor boards free of snow and ice. Fre- Other Slippery Surfaces
quently wipe snow off seat, steering Riding on loose stones or gravel is very
wheel, headlights and tail lamps. similar to riding on ice. They will affect
The depth of the snow cover may hide the steering of vehicle, possibly caus-
rocks, tree stumps or other objects and ing it to slide and tip over especially at
if it is wet may totally impede the driv- high speeds. In addition, braking dis-
ability as the vehicle becomes bogged tance may be affected. Remember
down or completely looses traction in that “gunning” the throttle or sliding
slushy snow. Look far ahead and al- may cause loose stones to be ejected
ways be watchful of any visible clues rearwards into the path of another
that might indicate the presence of rider's way. Never do it deliberately.
such obstacles. In doubt steer clear. If you do get into a slide or skid, it may
Avoid driving on any frozen waterways help to turn the steering wheel into the
before checking that the ice will safely direction of the skid until you regain
support the vehicle, its riders and its control. Never jam the brakes and lock
load of cargo. the wheels.
At the end of each ride it is a good prac-
tice to clean the vehicle and all moving Crossing Obstacles
components (brakes, steering com- Use the low range (L) for crossing ob-
ponents, drivelines, controls, radiator stacles.
fan etc.) from any snow or ice accu-
mulations. Wet snow will turn to ice Obstacles on the “trail” should be tra-
during the shut down period and be- versed with caution. This includes
come more difficult to remove at the rocks, fallen trees, and depressions.
next pre-ride inspection. You should avoid them whenever pos-
sible. Remember that some obstacles
Riding on Sand are too large or dangerous to cross
and should be avoided. As a guideline,
Sand and riding on sand dunes is an- never attempt to cross an obstacle
other unique experience but there are higher than the ground clearance of
some basic precautions that should the vehicle. Small rocks or small fallen
be observed. Wet, deep or fine sand trees may be safely crossed - approach
may create a loss of traction and cause obstacle at low speed and as much as
the vehicle to slide, drop off or become possible at a right angle. Adjust speed
“bogged” down. If this occurs look for without losing momentum and do not
a firmer base. Again, the best advice accelerate abruptly. Passenger must
is to slow down and be watchful of the grasp both handholds firmly and brace
conditions. feet on the footrests. Hold steering
When riding in sand dunes it is advis- firmly without closing your fists around
able to equip the vehicle with an an- it and proceed. Be aware that the ob-
tenna type safety flag. This will help stacle may be slippery or may move
make your location more visible to oth- while crossing.
ers over the next sand dune. Proceed
carefully should you see another safety Hill Driving Conditions
flag ahead. When driving on hills or slopes, two
things are highly important: be pre-
pared for slippery surfaces or terrain
variations and obstacles and brace
yourself properly inside vehicle. If you
climb or descend a hill that is too slip-

RIDING YOUR VEHICLE
pery or has too loose a surface, you Side Hilling

can lose control. If you go over the Whenever possible, sidehilling (driv-
top of a hill at high speed, you may not ing across a slope rather than up or
have time to prepare for the terrain down it) should be avoided. If neces-
on the other side. Avoid parking on sary, do so with extreme caution. Side
a slope. Always put the shift lever in hilling on steep inclines could result in
PARK when stopped or parked, espe- rollover. In addition, slippery or unfirm
cially on an incline, to avoid rolling. If surfaces could result in uncontrollable
you must park on a steep incline, block side sliding. Avoid all objects or de-
the wheels using rocks or bricks. pressions that will intensify the raising
Uphill Driving of one side of the vehicle higher than
the other, thus causing rollover. If you
Use the low range (L) for uphill driving. feel the vehicle start to rollover or slide
Due to its configuration, this vehicle sideways, steer downhill if possible.
has very good traction even while
climbing, so much so that tip over is WARNING
possible before traction is lost. For Be careful when loading and trans-
example, it is common to encounter porting liquid reservoirs. They can
terrain situations where the top of the affect vehicle stability when side
hill has eroded to a point that the hill hilling by pulling downhill and in-
peak rises very sharply. This vehicle is creasing the risk of a roll over.
not designed to negotiate such a con-
dition. Take an alternate route.
Drop-Offs
It is also wise to know the terrain con-
dition on the other side of the hill or This vehicle is not designed to negoti-
bank. All too often there exists a sharp ate drop-offs. It will “bottom-out” and
drop-off that is impossible to negotiate usually stop if either the front or rear
or descend. wheels are driven over a drop-off. If
the drop is sharp or deep, the vehicle
If you feel that the slope is getting too will nose dive and tip over.
steep to climb, apply brakes to immo-
bilize vehicle. Put shift lever in reverse Avoid negotiating drop-offs. Reverse
(R), and back down the hill, barely re- and select an alternate route.
leasing brakes to remain at low speed.
Do not attempt to turn around. Never Recreational, Group and Distance
coast down hill while vehicle is in neu- Riding
tral. Do not perform hard braking as it Respect the rights and limitations of
increases the risk of tipover. others. Stay away from areas des-
ignated for other types of off road
Downhill Driving use. This includes snowmobile trails,
This vehicle can climb steeper slopes equestrian trails, cross country ski
than it can descend safely. Therefore, trails, mountain bike trails, etc. Never
it is essential to assure that a safe route assume there are no other users on
exists to descend a slope before you the trail. Always stay to the right of the
climb it. trail and do not zig zag to one side of
the trail then the other. Be prepared
Decelerating while negotiating a slip- to stop or pull off to the side if another
pery downhill slope could “toboggan” trail user appears in front of you.
the vehicle, causing it to slide. Main-
tain steady speed and/or accelerate Join a local side-by-side vehicle club. It
slightly to regain control. Never slam will provide you with a map and advice
brakes and lock the wheels. or inform you where you can ride. If a

RIDING YOUR VEHICLE
club does not exist in your area, help hicle. If you encounter animals on the
to start one. Group riding and club ac- trail, stop and observe quietly and with
tivities provide a pleasurable, social caution. It will be one of the better
experience. Never use with drugs or memories of your life.
alcohol, or tired or ill. Observe the rule... “what you take in,
Always keep a safe distance from carry out”. Do not litter. Do not start
other riders. Your judgment of speed, campfires unless you have permission
terrain conditions, weather, mechan- to do so, and then only away from dry
ical condition of your vehicle and the areas. The hazards you may create on
“trust in judgment” you have in others the trail may cause injury to others or
around you will help you make a better yourself, even at a later date.
choice of appropriate safe distance. Respect farm lands. Always obtain the
This vehicle, like any other motorized permission of the landowner before
vehicle, cannot stop “on a dime”. riding on private land. Respect crops,
Before you ride, tell someone where farm animals and property lines.
you are planning to travel and your ex- Finally, do not pollute streams, lakes or
pected time of return. rivers and do not modify the engine or
Depending on the length of your ride, exhaust system, or remove any of its
carry additional tools or emergency components as it will alter the vehicle
equipment. Find out where you can emissions.
get additional gasoline. Be prepared
for the possible conditions you may
encounter. An emergency first aid kit
should always be a consideration.
Environment
One of the benefits of this vehicle is
that it can take you off the beaten path
away from most communities. How-
ever, you should always respect na-
ture and the rights of others to enjoy
it. Do not ride in environmentally sen-
sitive areas. Do not drive over forest
crops or shrubs, nor cut down trees
or take down fencing, nor spin your
wheels and destroy the terrain. “Tread
Lightly”.
This vehicle can cause OHV wildfires
if debris builds up near the exhaust
or other engine hot spots and ignites
then falls off into dry grass. Avoid rid-
ing in wet areas, through muskeg or
tall grass, where debris can build up.
Should you ride in those areas, inspect
and remove all debris from your en-
gine and hot spots. Refer to VEHICLE
CARE for details.
Chasing wildlife is in many areas il-
legal. Wildlife can die of exhaustion
after being chased by a motorized ve-

MOVING LOADS AND DOING WORK
Working with your Vehicle
Your vehicle can help you perform a number of different LIGHT tasks ranging
from snow removal to carrying cargo. A variety of accessories are available from
your authorized Can-Am dealer. To prevent possible injury, follow the instructions
and warnings that accompany the accessory. Always respect the load limits of
the vehicle. Overloading the vehicle can overstress the components and cause
failure. Avoid overexerting yourself if you lift or pull heavy loads or manually push
the vehicle.
Always be aware that the cargo may slide or fall off and cause an accident.
Carrying Loads
Any load carried on the vehicle will affect the handling, stability and braking
distance of the vehicle. Do not exceed the load limits of the vehicle, including
the weight of operator, passenger, cargo, accessories and trailer tongue weight.
Always be aware that the cargo may slide or fall off and cause an accident.
LOAD LIMIT OF THE VEHICLE
Includes occupants, cargo, added accessories,
286 kg (630 lb)
and tongue weight (if applicable)
The following is an example of suitable total vehicle load distribution:

EXAMPLE OF SUITABLE VEHICLE TOTAL LOADS (LOW RANGE)
OPERATOR TOTAL
TONGUE
AND CARGO LOAD ACCESSORIES VEHICLE
WEIGHT
PASSENGER LOAD
171 kg (377 lb) 31 kg (68 lb) 25 kg (55 lb) 59 kg (130 lb) 286 kg (630 lb)
NOTE: When the gearbox is in the high range, the combined weight on cargo rack
and tongue weight must not exceed the cargo rack capacity, refer to SPECIFICA-
TIONS.
To reduce the risk to lose control or the load carried, follow these recommenda-
tions.
Vehicle Settings When Carrying NOTE: When carrying heavy loads on

Load the cargo rack or pulling a loaded trailer
When the total load exceeds 195 kg operate with the shift lever in L (low
(430 lb), including weight of operator, range).
passenger, cargo, accessories and, if
applicable, trailer tongue weight, in- Loading the Cargo Rack
flate the tires to maximum pressure. NOTICE Do not exceed the maxi-
Refer to SPECIFICATIONS mum cargo rack capacity.
NOTE: When carrying a passenger or
heavy loads readjust suspension ac- For cargo rack capacity, refer to SPECI-
cordingly. FICATIONS.

Load cargo as low as possible – a Hauling a Load

higher load can raise the vehicle’s (if Equipped with Hitch)
center of gravity, which can reduce Never pull a load by attaching it to the
stability. Position cargo on the rack as cage or any other accessories; this can
evenly distributed as possible. cause the vehicle to tip over. Use only
Secure the load on the cargo rack. Do the trailer hitch (if installed) or winch (if
not secure cargo to the cage or other installed) to pull a load.
part of the vehicle. If it is not prop- In an emergency situation, use the re-
erly secured, a load may slide or fall covery hook to recover a stuck vehicle.
off, possibly striking occupants or by-
standers; or it may shift during riding, When pulling loads with a chain or ca-
affecting the handling of the vehicle. ble, ensure that there is no slack before
starting and maintain tension while
Objects that are high may affect visibil- pulling.
ity for the driver and may act as projec-
tiles in case of an accident. Loads that When pulling loads with a chain or ca-
protrude sideways can get snagged or ble, be sure to brake progressively.
caught in bush, branches or other ob- The inertia of the load could lead to an
stacles. Avoid covering and obstruct- impact.
ing the brake lights with the cargo. When hauling a load, respect the maxi-
Ensure no cargo protrudes outside the mum hauling capacity. See PULLING
cargo rack and that cargo will not inter- A TRAILER below.
fere with your visibility or control of the
vehicle. WARNING
Do not overload cargo rack. A slack in the chain or cable can
cause it to break and snap back.
WARNING
Never carry gasoline container(s) When pulling another vehicle, be sure
or any dangerous liquids on the that someone is controlling the pulled
cargo rack. vehicle. They must brake and steer to
prevent the vehicle from going out of
control.
WARNING
Before pulling loads with a winch, refer
Never overload, tow or carry cargo to the winch manufacturer’s instruc-
improperly. Safely reduce speed tions.
according to terrain conditions
when carrying cargo or pulling a Reduce your speed when hauling a
trailer, and avoid hills and rough load and turn gradually. Avoid hills and
terrain. Allow greater distance for rough terrain. Never attempt steep
braking. Always secure cargo as hills. Allow more distance for brak-
low as possible to reduce the ef- ing, especially on inclined surfaces
fect of a higher center of gravity. and when a passenger is on board. Be
Failure to follow the recommenda- careful not to skid or slide.
tions here could cause changes in
vehicle handling which could lead Pulling a Trailer
to an accident. (if Equipped with Hitch)
NOTICE A BRP approved rear
hitch must be properly installed on
the vehicle for hauling trailers.

Riding this vehicle with a trailer sub-

stantially increases the risk of toppling,
especially on inclined slopes. If a trailer
is used behind the vehicle make sure
that its hitch is compatible with the
one on the vehicle. Make sure the
trailer is horizontal with the vehicle. (In
some instances a special extension
may have to be installed on the vehicle
hitch). Use security chains or cables to
secure the trailer with the vehicle.
Reduce your speed when pulling a
trailer and turn gradually. Avoid hills
and rough terrain. Never attempt
steep hills. Allow more distance for
braking, especially on inclined surfaces
and when a passenger is on board. Be
careful not to skid or slide.
Improperly loading a trailer may cause
loss of control.
Always make sure load is evenly dis-
tributed and safely secured on the
trailer; an evenly balanced trailer is
easier to control.
Always put the shift lever to L (low
range) for hauling a trailer – in addition
to providing more torque, operating
in low range helps account for the in-
creased load on the rear tires.
When stopped or parked, block the ve-
hicle and trailer wheels from possible
movement.
Use caution when disconnecting a
loaded trailer; it or its load may topple
on you or others.
When hauling a trailer, respect the ma-
ximum tongue weight and towing ca-
pacity indicated on the label affixed to
the hitch.
Make sure there is at least some
weight on the tongue.

IMPORTANT ON-PRODUCT LABELS
Hang Tag
This vehicle comes with a hang tag and labels containing important safety informa-
tion.
Any person who rides this vehicle should read and understand this information be-
fore riding.
EN-704906754A-DEC

WARNING . Operating, servicing and

maintaining an off-road vehicle can expose
you to chemicals including engine exhaust,
carbon monoxide, phthalates, and lead,
which are known to the State of California
to cause cancer and birth defects or other
reproductive harm.
To minimize exposure, avoid breathing
exhaust, do not idle the engine except as
necessary, service your vehicle in a
well-ventilated area and wear gloves or wash
your hands frequently when servicing your
vehicle.
For more information go to

www.P65Warnings.ca.gov/products/
passenger-vehicle
704906872
EN-704906872-DEC
GET FAMILIAR WITH THIS OFF-HIGHWAY VEHICULE

(OHV); IT MAY EXCEED THE PERFORMANCE OF
OTHER OHV YOU MAY HAVE RIDDEN.
THIS IS A HIGH PERFORMANCE OHV.

704906437
INEXPERIENCED RIDERS MAY OVERLOOK

RISKS AND BE SURPRISED BY THE SPECIFIC
BEHAVIOR OF THIS OHV IN ANY
TERRAIN CONDITION.
EN-704906437-DEC
Safety Labels
Read and understand all the safety la-
bels on your vehicle.
These labels are affixed to the vehicle
for the safety of the operator, passen-
ger or bystanders.
The following labels are on your vehi-
cle, and they should be considered per-
manent parts of the vehicle. If missing
or damaged, they can be replaced free
of charge. See an authorized Can-Am
dealer.
NOTE: In the event of any discrep-
ancy between this guide and the ve-
hicle, the safety labels on the vehicle
have precedence over the labels in this
guide.

219001949-001_a

Drive Responsibly
Avoid loss of control and
rollovers:
• Avoid abrupt maneuvers,
sC a n sideways sliding, skidding or
hicle
ay Ve fishtailing, and never do donuts.
O ff - Highw th • Slow down before entering a turn.
se of r Dea Ahea
d • Avoid hard acceleration when turning,
per U jury o Plan ,
ImproSevere In a n d lf . even from a stop.
e tion r roll yours
e
Caus Atten may tip o race
• Plan for hills, rough terrain, ruts, and other
s Pay le and b ason. changes in traction and terrain. Avoid
u r e Riderel the vehic a n d holds for any re paved surfaces.
Be S ink or fe ry: l or h hicle
th ju whee the ve • Avoid side hilling (riding across slopes).
If you r risk of ine steeringutside of
u
e yo on th ody o
reduc firm grip of your b
pa art
• Kee put any p
o t Rollovers have caused severe
• Do n ed oors. gear. ot
lose d rotective st seat, fo injuries and death, even on flat,
epar and c
Be Prseat belts lmet and pback again ring open areas.
ten d h e it h ste e
• Fas approve le to sit w ands on hicle.
ar an e ab nd h e ve
• We er must b footrest, a inside th 704906372
h rid on tely
• Eac e floor or tay comple
n th .S
flat o andholds
l or h
whee
EN-704906372-DEC
LABEL 1

Improper Use of Off-Highway Vehicles

Can Cause Severe Injury or Death
Be prepared in case of rollover
• Hold the cage while riding.
• Try to stop a rollover using
your arm or leg.
• Fasten seat belts and close doors.
704907264
Require Proper Use of Your Vehicle
Do your part to prevent injuries:
•Make sure operators are 16 or older
with a valid driver's license.
• Do not let people drive or ride after using
alcohol or drugs.
• Do not allow operation on public roads
(unless designated for off-highway
vehicle access) – collisions with cars
and trucks can occur.
• Do not exceed seating capacity:
2 occupants.
Read and understand all
safety labels, locate and
read operator's guide.
Watch the safety
video using the QR
code link or visit
Can-am web
site before
operation.
EN-704907264-DEC
LABEL 2

PASSENGER
Improper Use of Off-Highway Vehicles
Can Cause Severe Injury or Death
9B
Be prepared in case of rollover
70490614
• Hold the cage while riding.
• Try to stop a rollover using your arm or leg.
Be Prepared
• Each rider must be able to sit with back agains
seat,foot flat on the floor or on footrest, and
hands on handholds. Stay completely inside the
vehicle.
Be sure riders pay attention and
plan ahead
If you think or feel the vehicle may tip or roll,
reduce your risk of injury:
• Keep a firm grip on handholds and
brace yourself.
• Do not put any part of your body
outside of the vehicle for any
reason.
Passenger qualifications
and responsibilities
• Do not ride after using
drugs or alcohol.
• Ask the operator to
slow down or stop
if you feel
uncomfortable
when riding.
EN-704906149-DEC
LABEL 3

Put the Shift Lever to PARK (P)

Put the Shift Lever to PARK
before exiting vehicle. The
(P) before exiting vehicle.
vehicle can roll if not in PARK.
The vehicle can roll if not
in PARK. Stop the vehicle and apply
the Brake before using the
Shift Lever and the 2WD/4WD
Switch.
Stop the vehicle and apply

the Brake before using the
Shift Lever and the Allow more room
2WD/4WD Switch. to turn.
704906152A 704907122
EN-704906152-DEC EN-704907122-DEC
LABEL 4 - MODELS WITHOUT SMART-LOK™ LABEL 4 - MODELS WITH SMART-LOK

DIFFERENTIAL DIFFERENTIAL
Loss of control can result in severe injury or death.

Improper tire pressure or • An underinflated tire can come off the rim.
overloading can cause loss of control. • Use Max pressure if total load exceeds 195 kg (430 lb).
2 OCCUPANTS
COLD TIRE 30”
3
TIRE SIZE 27” 28” 29”
33
PRESSURE
07
XRS / XMR XRC 64 XRC 72
49
179 (26) 152 (22) 131 (19) 117 (17) 124 (18) 131 (19)
70
Front:
Minimum
Rear : kPa (psi) 179 (26) 152 (22) 138 (20) 165 (24) 165 (24) 165 (24)
Maximum Front: 193 (28) 159 (23) 138 (20) 124 (18) 124 (18) 138 (20)
Rear : kPa (psi) 234 (34) 207 (30) 186 (27) 214 (31) 214 (31) 214 (31)
MAX LOAD CAPACITY: 286 (630)
EN-704907333-DEC
LABEL 5
DA ADVERSEL: FINN OG LES BRUKSANVISNINGEN. FØLG ALLE ANVISNINGER OG ADVARSLER.

DE WARNUNG: BETRIEBSANLEITUNG AUSFINDIG MACHEN UND LESEN. ALLE ANWEISUNGEN UND WARNHINWEISE BEFOLGEN.
EL ΠΡΟΕΙΔΟΠΟΙΗΣΗ: BPEITE ΚΑΙ ΔΙΑΒΆΣΕΙ ΤΟΝ ΟΔΗΓΌ ΧΕΙΡΙΣΤΉ. ΑΚΟΛΟΥΘΉΣΤΕ ΌΛΕΣ TIΣ ΟΔΗΓΊΕΣ ΚΑΙ ΤΙΣ ΠΡΟΕΙΔΟΠΟΙΉΣΕΙΣ.
ES ADVERTENCIA: UBICAR Y LEER LA GUÍA DEL OPERADOR. ATENERSE A TODAS LAS INSTRUCCIONES Y MENSAJES DE ADVERTENCIA.
FI VAROITUS: PAIKANNA JA LUE KÄYTTÄJÄN OPAS. NOUDATA KAIKKIA KÄYTTÖOHJEITA JA VAROITUKSIA.
FR AVERTISSEMENT : LOCALISER ET LIRE LE GUIDE DE L'OPÉRATEUR. SUIVRE TOUS LES CONSIGNES ET AVERTISSEMENTS.
IT AVVERTENZA: LEGERRE IL MANUALE DELL’OPERATORE. SEGUIRE TUTTE LE ISTRUZIONI AVVERTENZE.
704906153A
NL WAARSCHUWING: ZOEK DE GEBRUIKERSHANDLEIDING OP EN LEES HEM. HOUD U AAN ALLE AANWIJZINGEN EN WAARSCHUWINGEN.
PT ADVERTENCIA: LOCALIZAR E LER O GUIA DE OPERAÇÃO. OBSERVAR TODAS AS INSTRUÇÕES E MENSAGENS DE AVISO.
SV VARNING: TA REDE PÀ INSTRUKTIONSBOKEN OCH LÄS DEN. UPPMÄRKSAMMA ALLA ANVISNINGAR OCH VARNINGER.
EN-704906153-DEC
LABEL 6 - OUTSIDE NORTH AMERICA

Overloading can cause loss of control. Loss

of control can result in severe injury or death.
NEVER exceed REAR LOAD CAPACITY, evenly distributed, includes
....trailer tongue weight if applicable.
NEVER exceed the VEHICLE LOAD CAPACITY, including weight of operator,
....passenger(s), accessories and trailer tongue weight.
NEVER carry passenger on this carrier.
ALWAYS secure the load.
2 occupants 4 occupants
REAR LOAD CAPACITY: kg (lb) 90 (200) 68 (150)
VEHICULE LOAD CAPACITY: kg (lb) 286 (630) 399 (880)
704906932
EN-704906932-DEC
LABEL 7
NEVER place gasoline, flammable or dangerous

liquids container on carrier. This can lead to an
explosion.
NEVER attach to cargo area to pull a load. this can cause

the vehicle to tip over. use only the trailer hitch or recovery hook
to pull a load.
704906241B
EN-704906241-DEC
LABEL 8

Storage compartment
Maximum load: 5 kg (11 lb)
704906154B
WARNING
EN-704906154-DEC
LABEL 9
Get familiar with
this Off-Highway
Vehicule (OHV);
it may exceed
the performance
Unleaded fuel only of other OHV you
Recommended: may have ridden.
PREMIUM 91 (min (R+M)/2)
SUPER 95 (min RON) This is a high
performance OHV.
704906157A Inexperienced
EN-704906157-DEC
riders may
LABEL 10
overlook
risks and be
surprised by
the specific
behavior of this
OHV in any
terrain
condition.
vmo2010-010-100_a
LABEL 11
704906439
EN-704906439-DEC
LABEL 12
6160A
NEVER attach to the cage to pull a load. This can cause the vehicle
to tip over. Use only the trailer hitch or recovery hook to pull a load.
EN-704906160-DEC
LBEL 13

WARNING
This vehicle is an
off road vehicle
not intended for
use on public
roads.
704906373
AVERTISSEMENT
704906158B
Ce véhicule est
704906158-DEC conçu pour un
LABEL 14 usage hors route
et n'est pas
destiné aux voies
publiques.
EN-FR-704906373-DEC
LABEL 16
7408
NEVER attach here

to pull a load
EN-704907408-DEC
704906159B LABEL 17
704906159-DEC
LABEL 15

EMISSION CONTROL INFORMATION

THIS VEHICLE IS CERTIFIED TO OPERATE ON UNLEADED
GASOLINE AND CONFORMS TO U.S. EPA &
CALIFORNIA EMISSION / EVAP REGULATIONS FOR ATV AND
USE ONLY TO RECOVER OFF-ROAD SPORT VEHICLE.
STUCK VEHICLE. ENGINE FAMILY FAMILLE DE MOTEUR
NEVER USE TO PULL A LOAD

PERMEATION FAMILY FAMILLE DE PERMEATION
7410 PERMEATION LIMITE DE PERMEATION
STANDARD (FEL) DE LA FAMILLE
EN-704907410-DEC CERTIFICATION LIMITE DES ÉMISSIONS

STANDARD (FEL) DE LA FAMILLE
LABEL 18
ENGINE DISPLACEMENT CYLINDRÉE
SYSTÈME DE CONTRÔLE
Compliance Labels EXHAUST EMISSION
CONTROL SYSTEM DES ÉMISSIONS
RENSEIGNEMENTS SUR LE DISPOSITIF ANTIPOLLUTION

CE VÉHICULE EST CERTIFIÉ POUR FONCTIONNER À L'ESSENCE SANS PLOMB ET
IL EST CONFORME AUX NORMES DE L'EPA ET DE LA CALIFORNIE AU
NIVEAU DES RÉGLEMENTATIONS DE L’ÉCHAPPEMENT ET DE L’ÉVAPORATION
POUR LES VTT ET LES VÉHICULES HORS-ROUTE SPORTS.
704906314
SEE OPERATOR’S GUIDE FOR MAINTENANCE SCHEDULE
VOIR LE PROGRAMME D’ENTRETIEN DANS LE GUIDE DU CONDUCTEUR
BOMBARDIER RECREATIONAL PRODUCTS INC.
EN-FR-704906314-DEC
EN-704907080-DEC TYPICAL - BEHIND PASSENGER SEAT

BEHIND PASSENGER SEAT California models without evaporative emission
control system
EMISSION CONTROL INFORMATION

THIS VEHICLE IS CERTIFIED TO OPERATE ON UNLEADED
GASOLINE AND CONFORMS TO U.S. EPA EMISSION VEHICULE EMISSIONS CONTROL INFORMATION
/ EVAP REGULATIONS FOR ATV. CERTIFIED FOR SALE IN BOMBARDIER RECREATIONAL PRODUCTS INC.
ALL U.S. STATES EXCEPT CALIFORNIA. THIS VEHICULE IS CERTIFIED TO OPERATE ON UNLEADED
GASOLINE AND CONFORMS TO U.S. EPA & CALIFORNIA
EMISSIONS REGULATIONS FOR ATV AND OFF-ROAD SPORT VEHICLE.
ENGINE FAMILY FAMILLE DE MOTEUR RENSEIGNEMENT SUR LE DISPOSITIF ANTIPOLLUTION
CE VÉHICULE EST CERTIFIÉ POUR FONCTIONNER À L’ESSENCE SANS
PERMEATION FAMILY FAMILLE DE PERMEATION PLOMB ET EST CONFORME AUX NORMES DE L’EPA POUR LES VTT.
CERTIFICATION LIMITE DES ÉMISSIONS ENGINE FAMILY / FAMILLE DE MOTEUR
STANDARD (FEL) DE LA FAMILLE PERMEATION FAMILY / FAMILLE DE PERMÉATION
ENGINE DISPLACEMENT CYLINDRÉE CERTIFICATION STANDARDS (FEL)

NORMES DE CERTIFICATION (LEF)
EXHAUST EMISSION SYSTÈME DE CONTRÔLE
704906801
CONTROL SYSTEM DES ÉMISSIONS
RENSEIGNEMENTS SUR LE DISPOSITIF ANTIPOLLUTION DISPLACEMENT / CYLINDRÉE

CE VÉHICULE EST CERTIFIÉ POUR FONCTIONNER À L'ESSENCE SANS PLOMB ET
EMISSION CONTROL SYSTEM
IL EST CONFORME AUX NORMES DE L'EPA AU NIVEAU DES
SYSTÈME DE CONTRÔLE DES ÉMISSIONS
RÉGLEMENTATIONS DE L’ÉCHAPPEMENT ET DE L’ÉVAPORATION POUR LES VTT.
THIS VEHICULE CONFORMS TO CALIFORNIA EVAPORATIVE EMISSIONS
REGULATIONS APPLICABLE TO NEW OFF-ROAD SPORT VEHICLES
AND IS CERTIFIED TO 1.0 TOG GRAM PER DAY EVAPORATIVE.
EVAP. FAMILY MODEL
704905926
SEE OPERATOR’S GUIDE FOR MAINTENANCE SCHEDULE EVAP. EMISSION CONTROL SYSTEM: LPFL, LPFT, PURGE CANISTER.
VOIR LE PROGRAMME D’ENTRETIEN DANS LE GUIDE DU CONDUCTEUR SEE OPERATOR’S GUIDE FOR MAINTENANCE SCHEDULE AND FUEL,
OIL AND SPARK PLUG SPECIFICATIONS. VOIR LE CALENDRIER
BOMBARDIER RECREATIONAL PRODUCTS INC. D’ENTRETIEN ET LES SPÉCIFICATIONS D’ESSENCE, D’HUILE ET DE
BOUGIE D’ALLUMAGE DANS LE GUIDE DE L’OPÉRATEUR.
EN-FR-704905926-Dec
EN-FR-704906801-DEC
TYPICAL - BEHIND PASSENGER SEAT
Models outside California, compliant to the US TYPICAL - BEHIND PASSENGER SEAT
EPA standards, or equivalent models California models with evaporative emission
control system

BRP certifies that this ROV complies with the American National Standard for
Recreational Off-Highway Vehicles, ANSI / ROHVA 1 - 2016 Standard.
BRP certifie que ce véhicule récréatif hors-route est conforme à la norme
"American National Standard for Recreational Off-Highway Vehicles", ANSI /
ROHVA 1 - 2016.
This roll over protective structure meets the performance requirements of ISO
3471: 2008 .
Cette structure de protection contre le retournement respecte les requis de
performance de la norme ISO 3471: 2008 .
704906982
EN-704906982-DEC
ON LH SIDE OF CAGE
704907278-DEC
LOCATED NEAR GAS CAP
Technical Information
Labels
707800373
ON ENGINE AIR FILTER HOUSING
Unleaded fuel only

Recommended:
PREMIUM 91 (min (R+M)/2)
SUPER 95 (min RON)
704906157A
EN-704906157-DEC
INSIDE FUEL TANK CAP COVER

This page is
intentionally blank

VEHICLE
INFORMATION
_______________ 43
PRIMARY CONTROLS
It is important to know the location and operation of all controls, and to develop and
practice smooth and coordinated use of them.
NOTE: Some vehicle safety labels are not shown on illustrations. For information
on vehicle safety labels, refer to IMPORTANT ON-PRODUCT LABELS.
219001761-006_a
TYPICAL - PARTS REMOVED FOR CLARITY
1) Steering Wheel
The steering wheel is located in front of
the driver's seat.
The steering wheel steers the vehicle
to the left or right.
Turn the steering wheel in the direction
you want to go.
219001761-007_a
1. Steering wheel
Grip the steering wheel with both

hands, without having thumbs rolled
around the steering wheel.
44 ______________
PRIMARY CONTROLS
CAUTION Under rough trail

conditions or when crossing an ob-
stacle, the steering wheel could sud-
denly jerk on one side, causing hand
or wrist injuries if the thumbs are
rolled around the steering wheel.
The DPS (Dynamic Power Steering)
reduces the effort to turn the steering
wheel.
219001949-004_a
2) Accelerator Pedal X RC MODELS

1. Brake pedal
The accelerator pedal is located on the 2. Accelerator pedal
right side of the brake pedal.
The accelerator pedal controls the en-
gine speed.
219001761-008_a
ALL OTHER MODELS

1. Brake pedal
2. Accelerator pedal
219001761-008_a
TYPICAL To decrease vehicle speed or to stop

1. Brake pedal vehicle, press down the brake pedal
2. Accelerator pedal
with your right foot.
To increase or maintain vehicle speed, The brake pedal is spring loaded and
press on the accelerator pedal with should return to rest position when not
your right foot. pressed.
To decrease vehicle speed, release the
accelerator pedal. 4) Shift Lever
The accelerator pedal is spring loaded The shift lever is located on the lower
and should return to rest position (idle) console.
when not pressed. The shift lever is used to change the
NOTE: The accelerator pedal should gearbox position.
never be disassembled.
3) Brake Pedal
The brake pedal is located on the left
side of the accelerator pedal.
The brake pedal function is to slow
down or stop the vehicle.
_______________ 45
PRIMARY CONTROLS
Neutral
The neutral position disengages the
gearbox.
High Range (Forward)

This position selects the high speed
range of the gearbox. It is the normal
driving speed range. It allows the vehi-
cle to reach its maximum speed.
219001761-009_a
1. Shift lever Low Range (Forward)

2. Park
3. Reverse This position selects the low speed
4. Neutral range of the gearbox. It allows the ve-
5. High range (forward) hicle to move slowly with maximum
6. Low range (forward) torque at the wheels.
The vehicle must be stopped and NOTICE Use the low speed range
brakes applied prior to selecting any to pull a trailer (if equipped with
gear. hitch), carry heavy cargo, go over
NOTICE This gearbox is not de- obstacles or drive uphill and down-
hill.
signed to shift while vehicle is mov-
ing.
Park
The park position locks the gearbox to
help prevent vehicle movement.
WARNING
Always use the PARK (P) position
when the vehicle is not in oper-
ation. The vehicle can roll if the
shift lever is not set to P (PARK).
Reverse
The reverse position allows the vehicle
to go backwards.
NOTE: In reverse operation, the en-
gine's RPM is limited, thus limiting the
vehicle reverse speed.
WARNING
When driving downhill in reverse,
gravity can increase the vehicle
speed above the set limited re-
verse speed.
46 ______________
SECONDARY CONTROLS
on vehicle safety labels, refer to IMPORTANT ON-PRODUCT LABELS.
219001834-003_a
1) RF D.E.S.S Key and RF RF D.E.S.S Key

D.E.S.S. Post
Digitally Encoded Security System
RF D.E.S.S. Post (D.E.S.S.)
The D.E.S.S. post is located on the up- The D.E.S.S. key contains an electronic
per console. circuit that gives it a unique electronic
serial number.
The D.E.S.S. system reads the key
code and allows engine starting for
keys it recognizes.
Types of Keys
This vehicle can be operated using 2
different types of ignition keys:
– Normal key (green)
– Performance key (grey).
The key type is differentiated by its
219001761-076_b color.
TYPICAL
1. D.E.S.S. post
_______________ 47
SECONDARY CONTROLS
WARNING NOTE: The RF D.E.S.S. key must be

installed on the RF D.E.S.S. post to al-
Rollovers, tipovers, collisions and low engine start.
loss of control resulting in serious
injury or death are possible with a To power up the electrical system with-
performance or normal key. Using out starting the engine, refer to WAK-
the normal key is not a substitute ING UP THE ELECTRICAL SYSTEM
for the operator being prepared,
qualified, and operating with care.
Normal Key
The vehicle is delivered with a normal
key.
The normal key limits engine torque. It
also limits the vehicle speed to 70 km/h
(43 MPH).
WARNING 219001761-076_a
On steep downhills, the engine 1. Engine start / stop button

speed limiter may not prevent the
vehicle from accelerating beyond 3) Headlight Dimmer
this speed. Switch
The headlight dimmer switch is lo-
This key may be useful for riders who cated on the LH side of dashboard.
prefer more gradual acceleration, or
for riding in environments where full
speed and high acceleration are not
desirable. For example, in narrow,
winding trails, operators may prefer
the normal key.
Performance Key
The vehicle is delivered with a perfor-
mance key, which allows the user to
access the full torque of the engine as
well as the top speed of the vehicle. 219001761-011_a
This may be useful for riders who pre- TYPICAL
fer greater acceleration, and for envi- 1. Headlight dimmer switch
ronments where higher speeds and
greater acceleration are appropriate. This switch is used to select either the
For example, in wide-open, straight headlights low or high beams.
trails, operators may prefer the perfor-
mance key.
2) Engine Start/Stop
Button
The engine start / stop button is located
on the upper console. When pressed
and held, it starts the engine.
48 ______________
SECONDARY CONTROLS
4) 2WD/4WD/Front Diff When the front differential is locked,

Lock (If equipped) Switch the effort to turn the steering wheel
might be higher and the response
The 2WD/4WD/Front Diff Lock switch might be slower.
is located on the upper console.
WARNING
Abruptly changing direction can
cause loss of control or injury.
Never engage Front Diff Lock be-
fore entering a turn or when turn-
ing.
The 4WD mode is engaged when the

switch is in the middle position.
The 2WD mode is engaged when the
219001761-076_e switch is pushed downwards. The ve-
TYPICAL hicle is then rear wheel drive only.
1. 2WD/4WD/Front Diff Lock switch
5) Front Differential Mode
This switch selects 2 wheel drive or 4
wheel drive mode when the vehicle is Switch (If equipped)
stopped and the engine is running. The Front Differential Mode switch is
The front diff. lock can be activated on located on the console.
the fly, no need to stop the vehicle to
engage. To deactivate, push again on
the switch. When the vehicle is turned
off, the front diff lock will be deacti-
vated.
NOTICE Never go from 4X4 with
the front diff locked to 2X4. Always
unlock the front differential before
putting the vehicle in 2X4 mode.
NOTICE The vehicle must be
stopped to engage or disengage 219001834-004_a
2WD/4WD switch. Mechanical dam- 1. Front Differential Mode switch

age may occur if switch is engaged
or disengaged while driving. X rc models
The Front Differential Mode switch is
The front differential is fully locked used to choose between the TRAIL
when the switch is pushed upward. mode or ROCK mode.
It's a momentary position. When the
front diff is locked, the switch light Use TRAIL mode for all normal riding.
will illuminate and a message will ap- The front differential will automati-
pear in the cluster for 2 seconds to cally synchronize the front wheels as
say "DIFFLOCK". The light will turn off needed.
when the differential is unlocked and a Use ROCK mode when riding in rocky
message in the cluster will appear and conditions to optimize traction and
show "SMARTLOK", meaning that you maneuverability. The front differen-
are back in the automatic mode. tial will prevent the wheels to slip by
_______________ 49
SECONDARY CONTROLS
pre-charging the clutches. It will not

wait to detect a slip. Based on the
driver's demand (engine torque), the
module will adjust the clutches to op-
timize traction while maintaining the
ease of manoeuvrability. This func-
tion is active up to 20 km/h (12 MPH).
Above 20 km/h (12 MPH), it will moni-
tor for wheel slippage and synchronize
as needed.
219001761-076_d
X ds and X rs models
TYPICAL
The Front Differential Mode switch is 1. Sport/ECO switch
used to choose between the TRAIL
mode or TRAIL ACTIV mode. The sport mode provides a crisper
throttle response.
Use TRAIL mode for all normal riding.
The front differential will automati- NOTE: The sport mode can be acti-
cally synchronize the front wheels as vated with all key types and provides
needed. the maximum power with the used
key.
Use TRAIL ACTIV mode to increase
traction on the front drive train. This The ECO (fuel economy mode) setting
mode will optimize traction while go- reduces fuel consumption by limit-
ing out of a corner and/or while doing throttle response and maximum
ing hard acceleration by the detection throttle opening to maintain an optimal
of the engine torque required by the cruising setting.
driver. High speed traction is also im- NOTE: Use ECO mode on bumpy
prove by a determined precharge on trails to provide smoother ride con-
the clutches maintained. ditions.
TRAIL ACTIVE Mode might require ad-
justments on your driving style as the 7) Override Switch
front drive train is going to pull more The override switch is located on the
than usually. lower console.
WARNING
The fully locked option of the front
differential reduces the maneuver-
ability of the vehicle in certain con-
ditions.
6) Sport/ECO Mode Switch

The sport/ECO switch is located on the
upper console.
It is used to select the sport or ECO 219001761-076_c
mode in high range.
1. Override switch
50 ______________
SECONDARY CONTROLS
The override switch is used to: 8) DPS Switch

– Bypass the engine speed limiter in The DPS switch is used to change the
reverse by allowing maximum en- DPS (Dynamic Power Steering) mode.
gine torque. Refer to ENTERING
THE OVERRIDE MODE. To change mode, DPS switch needs to
be held for at least 2 seconds. If held
– Temporarily deactivate the elec- for less than 2 seconds, it will display
tronic drive belt protection (if avail- the selected mode in the multifunction
able and activated on your model). gauge.
– Erase the MAINTENANCE RE-
QUIRED message, refer to MULTI-
FUNCTION GAUGE (ANALOG/DIG-
ITAL).
– Allow the vehicle to be driven in the
eventuality of an accelerator pedal
failure. Refer to ENTERING THE
MANUAL LIMP HOME MODE.
Entering the Override Mode
Press and hold the override switch to
enter the bypass mode.
219001830-014_a
1. DPS switch
WARNING
Use the "override" mode only if the 9) Winch Switch (If
vehicle is caught in mud or other Equipped)
soft terrain and the "low range" is
not enough. Make sure the area is The winch can be controlled from in-
secure before using the "override" side and outside the vehicle with the
mode. Do not use the "override" winch control switch located in the up-
mode when driving normally in per console.
reverse, this would result in exces-
sive speed.
Release the override switch to exit the

bypass mode.
Entering the Manual Limp Home

Mode
If one or both the pedal position sen-
sor(s) is (are) defective, the accelerator
pedal will not respond.
219001834-010_a
Depending on the type of failure, 1. Winch switch
pressing and holding the Override
Switch, will temporarily restore the Refer to your winch GUIDE included
response of the pedal OR temporarily with your vehicle for proper winch op-
increase the engine speed to be able eration.
to drive the vehicle.
Releasing the Override Switch will re-
lease the throttle and let the engine re-
turn to idle speed.
_______________ 51
MULTIFUNCTION GAUGE (LCD)
The multifunction gauge (LCD) is lo-
cated on the steering column.
WARNING
Do not adjust the display while rid-
ing . You could lose control.
Multifunction Gauge tmo2011-001-702_d

Description 1. Gearbox position
DISPLAY FUNCTION
P Park
R Reverse
N Neutral
H High range
L Low range
tmo2013-001-100_c
1. Selector button - Indicated in-between

2. Gearbox position display gear
3. Main screen
4. Fuel level display
5. 4WD indicator lamp 3) Main Screen
6. Low fuel level indicator lamp
7. Check engine indicator lamp The main screen is used to display nu-
8. High beam indicator lamp merous functions of the multifunction
9. MPH and KM/H indicator lamp gauge.
10. Seat belt indicator lamp
Refer to MULTIFUNCTION GAUGE
1) Selector Button MODES for the different available
modes:
The selector button is used to navigate
or change settings in the multifunction 4) Fuel Level Display
gauge.
Bar gauge continuously indicates the
2) Gearbox Position Display level of fuel in the fuel tank while riding.
This display will show gearbox posi-
tion.
tmo2013-001-100_b
1. Fuel level display
52 ______________
5) 4WD Indicator Lamp 10) Seat Belt Indicator Lamp
When this indicator is ON, it indicates

the 4WD system is activated. When this indicator is ON, the driver's
seat belt is not buckled.
6) Low Fuel Level Indicator Lamp
Multifunction Gauge
Modes
Speed Mode
When this indicator is ON, it indi-
cates that there is approximately 8.5 L In this mode, the main screen shows
(2.2 U.S. gal.)of fuel left in fuel tank. the speed of the vehicle either in km/h
or in MPH.
7) Check Engine Indicator Lamp

an engine fault code, look for a mes-
sage at the LCD display.
When this indicator blinks, it indicates vdd2008-001-084
that the LIMP HOME mode is acti-

vated. RPM Mode
Refer to TROUBLESHOOTING section In this mode, the main screen shows
for more details. the engine RPM.
8) High Beam Indicator Lamp

that high beam is selected on the
headlights.
vdd2008-001-089
9) KM/H or MPH Indicator Lamp
Combined Mode
In this mode, the main screen shows
the speed of the vehicle and the engine
The proper lamp turns on to indicate RPM.
the unit the speedometer uses.
_______________ 53
vdd2008-001-085_a
vsi2009-018-031
1. Vehicle speed
2. Engine RPM It can be used to establish a fuel tank
range or distance between 2 way
Odometer (OD) points.
Odometer records the total distance Press and HOLD the selector button
travelled either in miles or kilometers. for 2 seconds to reset the trip meter.
Trip Hour Meter (TH)

The trip hour meter records vehicle
running time when the electrical sys-
tem is activated. It can be used to es-
tablish traveling time between 2 way
points .
vsi2009-018-030
Clock
Shows current time.
vsi2009-018-032
Press and HOLD the selector button

for 2 seconds to reset the hour meter.
Engine Hour Meter (EH)

vmo2011-008-001 The engine hour meter records engine
running time.
Refer to GAUGE SETUP to set current
time.
Trip Meter (TP)

The trip meter records the travelled
distance since it has been reset. Dis-
tance travelled is displayed either in
kilometers or miles.
vsi2009-018-033
54 ______________
Message Display Mode

Important messages can be displayed in the main screen. Refer to table below.
If an abnormal engine condition occurs, a message may scroll across the main
screen in conjunction with a pilot lamp. Refer to TROUBLESHOOTING section
for details.
MESSAGE
(NORMAL DESCRIPTION
OPERATION)
Message displayed when the brakes are applied continuously
BRAKE for 15 seconds. (Speed needs to be higher than 5 km/h
(3 MPH))
NORMAL KEY Displayed at power up when the normal key is used.
WORK KEY Displayed at power up when the work key is used.
When the driver seat belt is not buckled and the vehicle speed
SEAT BELT is less than 10 km/h (6 MPH), the message is displayed and
the pilot lamp will be lit. No engine torque limitation engaged.
When the driver seat belt is not buckled and the vehicle
ENGINE LIMITATION speed is above 10 km/h (6 MPH), the message is displayed
ENGAGED FASTEN and the pilot lamp stays on. The engine management will
SEAT BELT engage a torque limitation that will limit the vehicle speed to
approximately 20 km/h (12 MPH).
SPORT MODE ACTIVE Displayed when sport mode is activated
ECO MODE ACTIVE Displayed when ECO mode is activated.
MAINTENANCE
Displayed in gauge when vehicle is due for a maintenance.
REQUIRED (1)
Displayed when belt protection is active in high gear. (If
LOW GEAR
available and activated on your model)
(1) To erase the MAINTENANCE RE- NOTE: Steps 4 and 5 must be com-
QUIRED message, proceed as fol- pleted within 5 seconds.
lows: NOTE: Do not turn ignition switch to
1. Select PARK. ON before the multifunction gauge
2. Turn ignition switch to ON. Do NOT turns off.
start engine.
Fault Code Mode
3. Set the cluster to odometer display.
At the engine hour menu, press and
4. Press SET button on the multifunc- hold MODE button while switching
tion gauge and keep it pressed until high and low beam (three cycles) to
step 6. access diagnostic fault codes.
5. Switch the high beam On-Off three
times rapidly.
6. Turn ignition switch to OFF.
_______________ 55
Navigating in the LCD Press and release selector button to

Gauge change the default display mode to the
temporary mode.
Default Display Mode
After vehicle startup, the default dis-
play mode is either:
– Vehicle speed
– Engine revolutions per minute
(RPM)
– Both parameters simultaneously
(combined mode).
To change from one display to the
other, proceed as follows. tmo2011-001-702_c
1. Turn key to ON to power-up the sys- 1. Selector button

tem up. The gauge will display the selected
2. Wait until the “greeting message” mode for 10 seconds then will return
has been displayed. to the normal display mode.
3. Press and release selector button While in a resettable mode, push and
once to display OD (odometer). HOLD selector button for 2 seconds to
4. Press the selector button again, this reset it.
time for 2 seconds.
This will change the Mode to either
Gauge Setup
Speed, RPM or Combined. Clock Setting
Once clock display has been selected,
use the display selector button to set
clock as follows:
vdd2008-001-083
5. To select another mode, repeat

steps 3 and 4 until the desired mode
is displayed.
Temporary Display Mode vmo2011-008-001_a
In the temporary display mode, the fol- 1. Selector button

2. Time
lowing functions are available:
– Odometer 1. Press and HOLD button (Display will
– Clock flash).
– Trip meter (resettable) 2. Choose the 12-hour (12H) or
– Trip Hour meter (resettable) 24-hour (24H) format by pressing
– Engine hour meter. button.
56 ______________
3. If the 12-hour format was selected,

choose Am ("A") or Pm ("P") by press-
ing button.
4. Press and HOLD button.
5. Choose hour first digit by pressing
button.
7. Choose hour second digit by press-
ing button.
9. Choose minutes first digit by press-
ing button.
11. Choose minutes second digit by
pressing button.
12. Press button to enter settings
(CLOCK will appear on display).
NOTE: The gauge will display the cur-
rent time for 10 seconds then will re-
turn to the normal display mode.
Unit Selection (km/h vs MPH)

The speedometer, odometer and trip
meter are factory preset in miles but
it is possible to change them to kilo-
meter reading. Contact an authorized
Can-Am dealer.
Language Selection
The gauge display language can be
changed. Refer to an authorized
Can-Am dealer for language availability
and setup the gauge to your prefer-
ence.
_______________ 57
MULTIFUNCTION GAUGE (ANALOG/DIGITAL)
Multifunction Gauge Description
The multifunction gauge (analog/digital) is located on the steering column.
It is comprised of a digital gauge and two analog gauges (speedometer and
tachometer).
The engine temperature and fuel level bar graphs are comprised in the digital
gauge.
The indicators lamps are comprised in both analog gauges.
1 11 2 6 3 7 4
M S
M S
5 10 12 13 9 8 5
tmo2014-001-010_a
WARNING
Do not adjust the display while riding. You could lose control.
58 ______________
1) Analog Speedometer
Measures vehicle speed in km/h or mph.
2) MODE (M) Button

Pressing the MODE (M) button will scroll through the functions of the main digital
display.
FUNCTION SEQUENCE OPTIONS
Press SET (S) to scroll and select desired
Numerical Display is flashing
function and press MODE (M) to confirm
Press SET (S) to scroll and select desired
Multifunction display is flashing
function and press MODE (M) to confirm
3) SET (S) Button

Pressing the SET (S) button will scroll through the functions of the secondary digi-
tal display.
FUNCTION SEQUENCE INFORMATION DISPLAYED
XX:XX (24:00 time base)
Clock
XX:XX A or P (12:00 AM/PM time base)
Cumulative distance odometer XXXXX.X km or mi
Trip distance — odometer A (TRIP A) XXXXX.X km or mi
Trip distance — odometer B (TRIP B) XXXXX.X km or mi
Engine time chronometer (Hr) XXXXX.X
Trip time chronometer (HrTRIP) XXXXX.X
To reset any trip functions, push and hold the SET (S) button for three seconds.
4) Analog Tachometer (RPM)

Measures engine revolutions per minute (RPM). Multiply by 1000 to obtain actual
revolutions.
_______________ 59
5) Indicator Lamps
Indicator lamps will inform you of various conditions or problems.
An indicator lamp can flash alone or in combination with another lamp.
INDICATOR LAMP(S) DESCRIPTION
All indicator lamps are activated when D.E.S.S. key
All indicator lamps On
is installed and the engine is not started
On Low fuel
On Check engine
On High engine temperature
On Headlights in the HIGH beam position
Brake pedal is depressed for more than 15

On
seconds
Operator seat belt is not properly latched.

Engine output will be limited, reducing
On
the speed and operability of the vehicle.
Main digital display: FASTEN SEAT BELT
SPORT On Sport mode activated

MODE
On ECO mode activated
6) Main Digital Display

Displays useful real-time information to the rider.
7) Multifunction Display
The vehicle speed or the engine revolutions (RPM) can be displayed. See MODE
(M) BUTTON in this section.
Important messages can also be displayed. Refer to table below.
If an abnormal engine condition occurs, a message can be combined with a pilot
lamp. Refer to TROUBLESHOOTING for details.
60 ______________
MESSAGE DESCRIPTION
Message displayed when the brakes are applied continuously for
BRAKE
15 seconds. (Speed needs to be higher than 5 km/h (3 MPH))
PERFORMANCE
Displayed at power up when the performance key is used.
KEY
NORMAL KEY Displayed at power up when the normal key is used.
Override is displayed when the override switch is pressed and
OVERRIDE
the shift lever is set to reverse gear.
When the driver seat belt is not buckled and the vehicle speed
SEAT BELT is less than 10 km/h (6 MPH), the message is displayed and the
pilot lamp will be lit. No engine torque limitation engaged.
When the driver seat belt is not buckled and the vehicle speed is
ENGINE
above 10 km/h (6 MPH), the message is displayed and the pilot
LIMITATION
lamp stays on. The engine management will engage a torque
ENGAGED FASTEN
limitation that will limit the vehicle speed to approximately
SEAT BELT
20 km/h (12 MPH).
SPORT MODE
Displayed when the sport mode is activated.
ACTIVE
ECO MODE ACTIVE Displayed when ECO mode is activated.
MAINTENANCE
Displayed in gauge when vehicle is due for a maintenance.
REQUIRED(1)
Displayed when belt protection is active in high gear. (If available
LOW GEAR
and activated on your model)
DIFFLOCK Displayed for 2 seconds when front differential lock is activated.
Displayed for 2 seconds when automatic mode (Trail or Mud) is
SMARTLOK
activated.
(1) To erase the MAINTENANCE RE- NOTE: Do not turn ignition switch to
QUIRED message, proceed as fol- ON before the multifunction gauge
lows: turns off.
1. Select PARK.
8) Fuel Level Indicator
2. Turn ignition switch to ON. Do NOT
start engine. Bar graph that continuously indicates
the level of fuel left in the fuel tank.
3. Set the cluster to odometer display.
4. Press SET button on the multifunc- 9) Gearbox Position Indicator
tion gauge and keep it pressed until Displays the selected gearbox posi-
step 6. tion.
5. Switch the high beam On-Off three
times rapidly. 10) Engine Temperature Indicator
6. Turn ignition switch to OFF. Bar graph that continuously indicates
the engine coolant temperature.
NOTE: Steps 4 and 5 must be com-
pleted within 5 seconds.
_______________ 61
11) Numerical Display

The vehicle speed or the engine revo-
lutions (RPM) can be displayed. See
MODE (M) BUTTON in this section.
12) 2WD/4WD Indicator
When this indicator is ON, the 4WD
system is activated.
13) Secondary Digital Display

Displays useful real time information to
the rider. For display function informa-
tions, refer to SET (S) BUTTON.
Gauge Setup
Setting Metric/Imperial Units
See a Can-Am dealer for setting.
Setting Clock
1. Press SET (S) button to select clock
display.
2. Push and hold SET (S) button for
three seconds.
3. Press SET (S) button to select 12:00
AM PM or 24:00 time base.
4. If 12:00 AM PM time base is se-
lected, A or P flashes. Press MODE
(M) button to select A (AM) or P
(PM).
5. Press SET (S) button to change
hours.
6. Press SET (S) button to switch to
minutes (minutes flash).
7. Press SET (S) button to change min-
utes.
8. Press SET (S) button.
Setting Language
The gauge display language can be
changed. Refer to an authorized
Can-Am dealer for language availability
and setup the gauge to your prefer-
ence.
62 ______________
EQUIPMENT
on vehicle safety labels, refer to VEHICLE SAFETY LABELS.
219001834-012_a
TYPICAL
_______________ 63
EQUIPMENT
219001834-009_a
TYPICAL
1) Tilt Steering
The steering wheel height is ad-
justable.
Adjust the steering wheel height to
face your chest, not your head.
To adjust steering wheel height:
1. Unlock steering by pulling the tilt
lever toward you.
219001761-017_a
2. Move steering wheel to the desired
position. 1. Tilt lever
3. Release tilt lever to lock steering WARNING

wheel in position.
Never adjust the steering wheel
height while riding. You may lose
control.
2) Cup Holders
Two cup holders are located at the rear
of the lower console.
64 ______________
EQUIPMENT
4) Glove Box
The vehicle is equipped with a closed
glove box intended to carry light ob-
jects.
219001761-018_a
TYPICAL
1. Cup holders
NOTE: Do not use cup holders while

riding in rough conditions.
219001761-067_a
3) Passenger Handholds 1. Glove box
There is one passenger handhold on
the console and one in the RH door. GLOVE BOX CAPACITY
MAXIMUM
5 kg (11 lb)
LOAD
5) Tool Kit
A tool kit with basic tools is provided. It
is located in the glove box.
219001761-201_a
1. Door handhold
2. Console handhold
Adjust the seat position in order to get

a solid and comfortable grip on the
handholds. Refer to SEATS for adjust-
ment procedure. 219001761-021_a
Holding the handholds helps the pas- 1. Tool kit

senger brace against the movement of
the vehicle and helps keep hands and 6) Footrests
body inside the cockpit in the event of The vehicle is equipped with driver and
a rollover. passenger footrests to allow firmly
planting feet on vehicle floor, which
WARNING helps to maintain proper body position
Never use any part of vehicle cage while riding.
as handholds. Hands can be struck
by objects outside the cockpit or
crushed in a rollover.
_______________ 65
EQUIPMENT
219001830-001_a
The footrests help minimize the risk of 219001761-023_a
leg or foot injury. 1. Latch strap

Always wear appropriate footwear.
See RIDING GEAR. 8) Seat Belts
This vehicle is equipped with seat belts
7) Doors to help protect the driver and passen-
The vehicle is equipped with doors to ger in the event of a collision, rollover,
help occupants keep their body and or tip-over. The seat belts can help
limbs inside the vehicle, reducing the keep occupants stay in the passenger
risk of injury. compartment.
The doors can also prevent the intru-
sion of branches and other foreign ob- WARNING
jects into the passenger compartment. Wear seat belts properly at all
times. Make sure it remains se-
WARNING curely fastened and tightened
against the body. Seat belts re-
Never operate vehicle unless both duce the risk of injury in a crash
doors are closed and secured. and help keep limbs inside the
cockpit in a rollover or any acci-
dents.
If driver's seat belt is not fastened

when:
– The start button is pressed, the seat
belt indicator lamp will flash.
– The engine is started and shift
lever is moved out of PARK, vehicle
speed will be limited to a maximum
of approximately 20 km/h (12 MPH)
on flat ground.
219001761-022_a
1. Door closed and locked in place

WARNING
To unlock doors, pull on the strap to re- The vehicle may reach higher or
lease the latch. lower speed depending on in-
clines.
To remind you to fasten the seat belt,

the multifunction gauge will display the
following message: ENGINE LIMITA-
TION ENGAGED FASTEN SEAT BELT.
66 ______________
EQUIPMENT
WARNING To fasten the seat belt, insert the latch

plate into the buckle, then pull the belt
There is no indicator light or mes- to ensure it is properly fastened.
sage for the passenger seat belts.
The driver is responsible for the Adjust the seat belt tightly against your
safety of the passenger and should body by pulling the shoulder belt up-
ensure that the passenger buckles wards.
the seat belt.
3 Points Seat Belts
219001761-210_a
TYPICAL
219001761-024_a
To detach the seat belt, push on the red
TYPICAL button on the buckle.
1. Seat belt
4 Points Seat Belts
WARNING
Wear seat belt properly. Make sure
it remains securely fastened and
tightened against the body. Make
sure it is not twisted or defective.
The seat belt is equipped with a semi-

cinching tab.
This device locks the seat belt in the ad-
justed position.
219001830-005_a
TYPICAL - PARTS REMOVED FOR CLARITY

1. Seat belt
WARNING
Wear seat belt properly. Make sure
it remains securely fastened and
tightened against the body. Make
sure it is not twisted or defective.
To fasten the seat belt, insert the latch

tmr2014-037-005_a plate into the buckle, then pull the belt
TYPICAL - LOCKED POSITION to ensure it is properly fastened.
1. Semi-cinching tab
_______________ 67
EQUIPMENT
9) Seats
Seat Forward and Rearward
Adjustment
The seats can be adjusted forward or
backward.
Slide the adjustment lever, place the
seat at the desired position, then re-
lease the lever.
219001830-002_a
Try to move the seat forward and back-
ward to make sure it is properly locked
On both sides, adjust the seat belt in place.
tightly against your body by pulling the
excess of the lap belt towards the in-
side. The buckle must be centered at
the waistline (as low as possible).
219001799-012_a
1. Adjustment lever
WARNING
219001830-003_a
Never adjust the seat position
while the vehicle is moving.
To loosen the seat belt, hold the lap
belt with one hand and pull the red Seat Cushion Removal and
strap outwards. Installation
Unclip the cushion retaining tab.
219001830-004_a
To detach the seat belt, push on the red

button on the buckle.
68 ______________
EQUIPMENT
219001799-011_a

1. Front anchor point
219001834-018_a 2. Rear anchor point
Pull up the rear of the cushion, then To install, reverse the removal installa-
free the cushion from the seat frame tion, however pay attention to the fol-
by pulling it off towards the rear. lowing.
Install seat using NEW nuts. Tighten to
specification.
WARNING
Use new nuts when installing seat
anchor points.
TIGHTENING TORQUE
Rear anchor 105 N•m ± 15 N•m
tmr2017-049-004_a point (77 lbf•ft ± 11 lbf•ft)
To install, reverse the removal proce- Front anchor 24.5 N•m ± 3.5 N•m
dure. point (18 lbf•ft ± 3 lbf•ft)
Seat Removal and Installation Seat Height Adjustment

Remove the seat cushion. Seat height can be adjusted using the
Remove all four anchor points. anchor points. See SEAT REMOVAL
AND INSTALLATION.
Setup in HIGH Position
Remove the seat cushion.
Remove both nuts securing the rear
anchor points.
Remove both nuts securing the front
anchor points.
Assemble both rear anchor points as
shown. Use NEW nuts.
_______________ 69
EQUIPMENT
Setup in LOW Position

Remove the seat cushion.
Remove both nuts securing the rear
anchor points.
Remove both nuts securing the front
anchor points.
Assemble both rear anchor points as
219001761-033_a
REAR ANCHOR POINT IN HIGH POSITION

1. Retaining nut
2. Seat frame
3. Sleeve
4. Vehicle frame
Install both front anchor points as

219001761-031_a
REAR ANCHOR POINT IN HIGH POSITION

1. Retaining nut
2. Sleeve
3. Seat frame
4. Vehicle frame
Install both front anchor points as

219001761-034_a
FRONT ANCHOR POINTS IN HIGH POSITION

1. Retaining bolt
2. Seat support
WARNING
anchor points. Ensure both an-
chor points at the front and both
anchor points at the rear are set to
the same position (HIGH or LOW)
before riding the vehicle. 219001761-035_a
FRONT ADJUSTMENT MECHANISM IN

POSITION LOW
Tighten nuts to specification. 1. Retaining bolt
2. Bracket support
TIGHTENING TORQUE
point (77 lbf•ft ± 11 lbf•ft)
Front anchor 24.5 N•m ± 3.5 N•m
point (18 lbf•ft ± 3 lbf•ft)
70 ______________
EQUIPMENT
WARNING Refer to FUEL for information on fuel-

ing procedure and fuel requirements.
anchor points. Ensure both an-
chor points at the front and both 11) Cargo Rack
anchor points at the rear are set to Cargo rack is convenient for carrying
the same position (HIGH or LOW) equipment and various other cargo. It
before riding the vehicle. must never be used to carry a passen-
ger.
Tighten nuts to specification.
TIGHTENING TORQUE
points (77 lbf•ft ± 11 lbf•ft)
Front anchor 24.5 N•m ± 3.5 N•m
points (18 lbf•ft ± 3 lbf•ft)
10) Fuel Reservoir Cap

Open fuel reservoir cap cover. 219001761-027_a
CARGO RACK
WARNING
– Never carry a passenger on a
cargo rack.
– Cargo must never interfere with
the drivers line of sight or affect
his ability to properly steer the
vehicle.
– Do not overload the vehicle.
219001761-025_a – Always ensure all cargo is prop-
1. Fuel reservoir cap cover erly secured and does not ex-
tend out passed the rack.
The fuel reservoir cap is located at front – Never carry gasoline con-
on the right hand side of the vehicle. tainer(s) or any dangerous liq-
uids on the cargo rack.
Refer to SPECIFICATIONS for cargo

weight recommendations.
12) Recovery Hook

Convenient hook that can be use to re-
cover a stuck vehicle.
219001761-026_a
1. Fuel reservoir cap
_______________ 71
EQUIPMENT
219001761-120_a
ALL MODELS EXCEPT X rc

1. Front recovery hook
219001834-016_a
X rc MODELS
1. Front recovery hook
NOTICE Recovery hooks are de-

signed to recover a stuck vehicle,
they should not be used to carry a
load, to attach a pulley or other me-
chanical devices that can overload
the attachment point. Failure to do
so can cause damages to the vehicle
frame.
219001834-015_a
13) Wheel Scraper
X rc MODELS Located inside the rear wheels to
1. Front recovery hook reduce accumulation of mud in the
wheels that can damage parts inside
the wheels.
219001761-125_a
1. Rear recovery hook

219001761-028_a
1. Wheel scraper
Check wheel scraper condition. Re-

place when wear exceeds wear limit at
any location.
72 ______________
EQUIPMENT
219001799-014_a
219001761-029_a BEHIND THE MIRROR

1. Wear limit 1. Knob
14) 12-Volt Power Outlet 16) Rock Sliders and

Convenient for handheld spotlight or
Suspension Arm
other portable equipment. Protectors
UHMW rock sliders for additional
lower body protection.
219001761-014_a
1. 12 V power outlet
Remove protective cap to use. Always

reinstall it after use to protect against
weather.
219001887-001_a
15) Central Rearview 1. Rock sliders
Mirror 2. Trailing arm protector
This vehicle comes equipped with a
central rearview mirror.
Be aware that objects in mirror are
closer than they appear.
The mirror can be adjusted to suit
driver's preference.
To adjust mirror; loosen knob located
behind mirror and tighten it to secure
mirror in position.
_______________ 73
EQUIPMENT
It is recommended to let the vehicle

run while winching. Do not stop vehi-
cle immediately after winching to let
battery recharge.
Also, when winching for more than
30 seconds, it is recommended to in-
crease engine RPM in the range of
3000 RPM to increase charging power
to the battery.
NOTE: Make sure vehicle is in NEU-
TRAL (N) before increasing engine
RPM.
Refer to your winch GUIDE included
219001834-014_a with your vehicle for proper winch op-
1. A- arm Protector eration.
Intensive use of the winch may cause
17) Winch (If Equipped) the built-in circuit breakers to momen-
The winch can be actuated inside the tarily turn OFF. In such a case, wait a
vehicle using the winch control switch moment, then continue winching. the
on the upper console. breakers automatically turn ON once
they cooled down.
219001834-019_a
1. Winch
NOTE: Using the winch intensively

over a long period of time may dis-
charge the battery.
The following tips will help to reduce
the risk of discharging the battery:
Always unreel manually: Unlock the
cable using the handle then pull on the
hook strap to unreel.
74 ______________
TUNE YOUR RIDE
Suspension Adjustment Adjustment Location
Guidelines
Your vehicle handling and comfort de-
pend upon suspension adjustments.
WARNING
Suspension adjustment could af-
fect vehicle handling. Always take
time to familiarize yourself with
the vehicle's behavior after any
suspension adjustment has been
made. 219001761-040_a
TYPICAL - MAVERICK TURBO AND X RC

Choice of suspension adjustments TURBO MODELS - FRONT SUSPENSION
vary with vehicle load, personal pref- 1. Compression damping
erence, riding speed and terrain condi- 2. Preload
3. Spring Crossover
tion.
The best way to set up the suspension,
is to start from factory settings, then
customize each adjustment one at a
time.
Front and rear adjustments are interre-
lated. It may be necessary to readjust
the rear shock absorbers after adjust-
ing front shock absorbers for instance.
Test run the vehicle under the same
conditions; trail, speed, load, etc.
Change one adjustment and retest. 219001761-116_a
Proceed methodically until you are sat- TYPICAL - MAVERICK TURBO AND X RC
isfied. TURBO MODELS - REAR SUSPENSION
1. Compression damping
Following are guidelines to fine-tune 2. Preload
suspension. 3. Spring Crossover
_______________ 75
TUNE YOUR RIDE
219001761-040_b 219001761-041_a
TYPICAL - MAVERICK X DS, X RS AND XRC TYPICAL - MAVERICK X RSAND XRC TURBO
TURBO R MODELS - FRONT SUSPENSION R MODELS - REAR SUSPENSION
1. Compression damping (high speed and low 1. Compression damping (high speed and low
speed) speed)
2. Preload 2. Preload
3. Spring Crossover 3. Spring Crossover
4. Rebound damping 4. Rebound damping
Suspension Factory
Settings
For adjustment procedures, refer to
SUSPENSION ADJUSTMENTS in this
section.
To adjust compression and rebound to
factory settings, proceed as follows:
1. Turn adjuster clockwise until it
stops.
219001761-039_a
2. Turn adjuster counterclockwise by
TYPICAL - MAVERICK X DS MODELS - REAR the specified amount, see table be-
SUSPENSION
1. Compression damping (high speed and low low.
speed)
2. Preload
3. Spring Crossover
4. Rebound damping
76 ______________
TUNE YOUR RIDE
FRONT SUSPENSION FACTORY SETTINGS

ADJUSTMENT MODEL FACTORY SETTING
MaverickTurbo 36.8 mm (1.45 in)
Maverick X ds 38.5 mm (1.52 in)
Spring preload Maverick X rc TURBO 38.8 mm (1.53 in)
Maverick X rs
53 mm (2.09 in)
Maverick X rc TURBO R
MaverickTurbo
Maverick X rc TURBO
Maverick X ds
Compression damping
Maverick X rs 2 Turns
(low speed)
MaverickX ds 2 Turns
Compression damping
(high speed) Maverick X rs
3 Turns
Maverick X ds
Rebound damping Maverick X rs Position 12
Maverick X ds 120 mm (4.72 in)
Crossover ring position Maverick X rs
71 mm (2.8 in)
Maverick X rc TURBO 101 mm (3.98 in)

MaverickTurbo 89 mm (3.5 in)
Spring preload Maverick X rs
105.8 mm (4.17 in)
Maverick X rc TURBO 89.1 mm (3.51 in)
Maverick
Maverick X rc TURBO
Maverick X ds 3 Turns
Compression damping
(low speed) MaverickX rs
2 Turns
_______________ 77
TUNE YOUR RIDE

Maverick X ds 2 Turns
Compression damping
(high speed) Maverick X rs
3 Turns
MaverickX rc TURBO R
Maverick X ds Position 15
Rebound damping MaverickX rs
Position 12
MaverickX rc TURBO R
Crossover rings
position Maverick X rs
154.6 mm (6.09 in)
Maverick X rc TURBO 119.56 mm (4.71 in)
Suspension Adjustments NOTE: Factory settings are suitable

for almost all conditions. Take into con-
Spring Preload Adjustment sideration that an increase in ground
Shorten the spring for a firmer ride and clearance can affect the handling of
rough riding condition or when pulling a the vehicle.
trailer (if equipped with hitch).
Lengthen the spring for a softer ride
and smooth riding condition.
WARNING
The left and right shock adjust-
ment on front or rear suspension
must always be set to the same
position. Never adjust one shock
only. Uneven adjustment can
cause poor handling and loss of 219001761-072_a
stability, which could lead to an ac- TYPICAL

cident. Step 1: Loosen top locking ring
Step 2: Turn adjusting ring accordingly
Step 3: Tighten top locking ring
Lift the vehicle. Spring length should
be measured without load on the Shock Damping Adjustments
wheels. (Maverick Turbo and Maverick X rc
Spring length should be equal on both TURBO)
sides. Compression damping controls how
Adjust by loosening lock ring and turn- the shock absorber reacts when riding.
ing adjuster ring as desired. Use tool
from vehicle tool kit.
78 ______________
TUNE YOUR RIDE
RESULT ON ACTION RESULT

POSITION SETTING
BIG BUMPS
Increasing Firmer
Softer compression compression
1 Soft compression damping force damping
damping
Decreasing Softer
Medium compression compression
Medium
2 compression damping force damping
(Factory)
damping
Firmer WARNING
3 Hard compression Make sure compression damping
damping setting is the same on both sides.
Low Speed Compression Damping

(Maverick X ds, Maverick X rs and
Maverick X rc TURBO R)
Low speed compression damping con-
trols how the shock absorber reacts to
a low suspension velocity (slow com-
pression strokes, in most cases when
riding at lower speeds).
219001682-007_a
RESULT ON BIG
1. Position 1 ACTION
BUMPS
2. Position 2
3. Position 3 Increasing Firmer
low speed compression
compression damping (slow
damping force compression)
Decreasing Softer
low speed compression
compression damping (slow
219001727-010_a
COMPRESSION DAMPING
Turn adjuster clockwise to increase

shock damping action (stiffer).
Turn adjuster counterclockwise to de-
crease shock damping action (softer). 219001761-133_a
LOW SPEED COMPRESSION DAMPING

(USE A SCREWDRIVER)
1. Adjustment screw
2. Increases compression damping (stiffer)
3. Decreases compression damping (softer)
_______________ 79
TUNE YOUR RIDE
Turning it clockwise (H) increases

shock damping action (stiffer).
Turning it counterclockwise (S) de-
creases shock damping action (softer).
High Speed Compression Damping

(Maverick X ds, Maverick X rs and
Maverick X rc TURBO R)
High speed compression damping
controls how the shock absorber re-
acts to a high suspension velocity
(quick compression strokes, in most
cases when riding at higher speeds). tbl2013-009-049_a
1. Rebound adjuster
RESULT ON 2. Increases rebound (stiffer)
ACTION 3. Decreases rebound (softer)
SMALL BUMPS
Increasing Firmer Adjusting Spring Crossover
high speed compression
compression damping (fast Dual compression rate crossover
damping force compression) point can be modified by adjusting the
crossover rings position. See an au-
Decreasing Softer thorized Can-Am dealer.
high speed compression
compression damping (fast
tmo2015-017-308_a
TYPICAL - CROSSOVER ADJUSTMENT -

REAR SHOCK
A. Spring preload
B. Crossover ring position
219001799-020_a
HIGH SPEED COMPRESSION DAMPING DPS Function

(USE A 17 MM WRENCH)
1. Adjustment screw The Tri-Mode Dynamic Power Steering
2. Increases compression damping (stiffer) (DPS) offers easy steering assistance
3. Decreases compression damping (softer)
to the rider. The level of assistance
Rebound Damping (Maverick X ds, will automatically adapt according to
Maverick X rs and Maverick X rc the vehicle's speed and rider’s de-
TURBO R) mand, in order to provide maximum
steering power at lower speed where
Use a flat screwdriver to adjust it. the demand is normally higher. As
speed increases, the assistance is pro-
gressively reduced to keep maximum
steering feel and precision to the rider.
80 ______________
TUNE YOUR RIDE
It is possible to choose between three

modes of assistance: Minimum,
Medium and Maximum. Each mode
will continue to automatically adapt
to the vehicle’s speed and rider’s de-
mand, so it does not require to be
changed when riding. These modes
are used to set the level of assistance
to match each rider's preferences.
The following DPS modes are preset in ANALOG/DIGITAL GAUGE
the vehicle.
1. DPS mode display
DPS MODE
DPS To change the DPS mode, proceed as
Maximum steering assist follows:
MAX.
1. Press and hold DPS switch for 2
DPS
Medium steering assist seconds to go to the next setting.
MED.
2. Release DPS switch.
DPS
Minimum steering assist 3. Repeat until desired setting is se-
MIN.
lected.
To show the active DPS mode, pro- NOTE: The DPS adjustment will not
ceed as follows: be possible if the gearbox is set to RE-
1. Press and release DPS switch. VERSE.
219001830-014_a
1. DPS switch
2. Check the multifunction gauge to

confirm the active DPS mode.
_______________ 81
FUEL
Fuel Requirements NOTICE Never experiment with
other fuels. Engine or fuel system
NOTICE Always use fresh gaso- damages may occur with the use of
line. Gasoline will oxidize; the re- an inadequate fuel.
sult is loss of octane, volatile com-
pounds, and the production of gum NOTICE Do NOT use fuel from fuel
and varnish deposits which can pumps labeled E85.
damage the fuel system.
Use of fuel labeled E15 is prohibited by
Alcohol fuel blending varies by coun- U.S. EPA Regulations.
try and region. Your vehicle has been
designed to operate using the recom- Vehicle Fueling Procedure
mended fuels, however, be aware of
the following:
– Use of fuel containing alcohol above
WARNING
the percentage specified by gov- – Fuel is flammable and explosive
ernment regulations is not recom- under certain conditions.
mended and can result in the fol- – Never use an open flame to
lowing problems in the fuel system check fuel level.
components: – Never smoke or allow flame or
• Starting and operating difficul- spark in vicinity.
ties. – Always work in a well-ventilated
• Deterioration of rubber or plastic area.
parts. – Vehicle must be on a level sur-
• Corrosion of metal parts. face to perform fueling.
• Damage to internal engine parts.
– Inspect frequently for the presence 1. Place vehicle on a level surface.
of fuel leaks or other fuel system
abnormalities if you suspect the 2. Stop engine.
presence of alcohol in gasoline ex-
ceeds the current government reg- WARNING
ulations. Always stop engine before refuel-
– Alcohol blended fuels attract and ing.
hold moisture which may lead to
fuel phase separation and can result 3. Have driver and passenger get out
in engine performance problems or of vehicle.
engine damage.
Recommended Fuel WARNING

Use unleaded gasoline containing MA- Do not allow anyone to remain in
XIMUM 10% ethanol. the vehicle while fueling. If there is
a fire or explosion during fueling, a
Use premium unleaded gasoline with vehicle occupant could be unable
an AKI (R+M)/2 octane rating of 91, or to quickly leave the area.
an RON octane rating of 95.
4. Open the fuel reservoir cap cover.
82 ______________
FUEL
WARNING
Never top up the fuel tank before
placing the vehicle in a warm area.
As temperature increases, fuel ex-
pands and may overflow.
9. Fully tighten fuel reservoir cap clock-

wise until you hear a clicking noise.
219001761-025_a
1. Fuel reservoir cap cover

WARNING
Always wipe off any fuel spillage
5. Slowly unscrew the fuel reservoir from the vehicle.
cap counterclockwise to remove it.
219001761-026_a
1. Fuel reservoir cap
WARNING
If a differential pressure condition
is noticed (whistling sound heard
when loosening fuel reservoir cap)
have vehicle inspected and/or re-
paired before further operation.
6. Insert the spout into the filler neck.

7. Pour fuel slowly so that air can es-
cape from the tank and prevent fuel
flow back. Be careful not to spill
fuel.
8. Stop filling when the fuel reaches
the bottom of filler neck. Do not
overfill.
_______________ 83
BREAK-IN PERIOD
Operation During Break-In
A break-in period of 10 operating hours
or 300 km (200 mi) is required for the
vehicle.
Engine
During the break-in period:
– Avoid full throttle operation.
– Avoid pressing accelerator pedal
more than 3/4 of the stroke.
– Avoid sustained accelerations.
– Avoid prolonged cruising speeds.
However, brief accelerations and
speed variations contribute to a good
break-in.
Brakes
WARNING
New brakes will not operate at
their maximum efficiency until
their break-in is completed. Brak-
ing performance may be reduced,
so use extra caution.
Drive Belt
A new belt requires a break in period of
50 km (30 mi).
During the break-in period:
– Avoid strong acceleration and decel-
eration.
– Avoid pulling a load.
– Avoid high speed cruising.
84 ______________
BASIC PROCEDURES
Starting the Engine Release brakes.
Install D.E.S.S. key on D.E.S.S. post. NOTICE When changing gear se-
Press the brake pedal. lection, always completely stop the
NOTE: If shift lever is not set to PARK vehicle and apply the brakes prior
(P), the brake pedal must be pressed to to shifting. Damage to the gearbox
allow engine starting. may occur.
Press the engine start button and hold Choosing the Correct
until the engine starts.
Range (Low or High)
NOTE: Do not press the accelera-
tor pedal. If the accelerator pedal is It is important to limit situations known
pressed at least 20%, the engine will to make the drive belt slip excessively.
not start. The main reason the drive belt will slip
is if the gearbox is in high range when it
Release the engine start button imme- should be in low range.
diately when the engine has started.
Pay attention to the following:
NOTICE If engine does not start
after a few seconds, do not hold the Low range
engine start button more than 10 Low range should be used whenever:
seconds. Refer to TROUBLESHOOT- – Pulling
ING.
– Pushing
Wait approximately 10 seconds to let – Hauling a load
engine oil flow through engine and – 4x4 applications
turbo. – Mud holes
– Water holes
Waking Up the Electrical
– Crossing obstacles
System
– Climbing onto trailer
Press and release the START button for – Hill climbing
less than half a second and the electri-
cal system will turn ON: It is also recommended to use low
– For 20 seconds, without powering range if driving for prolonged periods
any equipment, if the D.E.S.S. key is at speeds under 24 km/h (15 MPH)
NOT installed on the D.E.S.S. post. Please refer to BREAK-IN PERIOD in
– For 10 minutes, powering equip- this guide for information in regards to
ment, if the D.E.S.S. key is installed belt break-in period.
on the D.E.S.S. post. The electrical
system will shutdown after 20 sec- High range
onds if the D.E.S.S. key is removed. High is the default riding range.
NOTICE Waking up the electrical
Electronic Drive Belt Protection
system repeatedly or using elec- (if available and activated on your
trical equipment will discharge the model)
battery and you may not be able to
start the engine. Some vehicles have the electronic
drive belt protection function acti-
Operating the Shift Lever vated.
Apply brakes and select the desired Refer to your authorized Can-Am
shift lever position. dealer for availability and possible acti-
vation.
_______________ 85
BASIC PROCEDURES
This function is activated when riding Stopping the Engine and

at too slow speed for the high range, Parking the Vehicle
such as in the following situations:
– Pulling WARNING
– Pushing
Avoid parking on steep slope as
– Hauling a load the vehicle may roll away.
– 4x4 applications
– Mud holes
– Water holes
WARNING
– Crossing obstacles Always put the vehicle in PARK
when stopped or parked to pre-
– Climbing onto trailer vent rolling.
– Hill climbing
In the above mentioned situations the
electronic drive belt protection will WARNING
help protect the CVT drive belt from Avoid parking in places where hot
being damaged by activating the en- parts can start a fire.
gine torque limiter. The gauge will also
scroll a LOW GEAR message, sug- When stopped or parked always bring
gesting the operator to immobilize the shift lever to park position. This is es-
vehicle and set to LOW GEAR. pecially important when parking on
Whenever the electronic drive belt a slope. On very steep inclines or
protection is activated, you MUST if the vehicle is carrying a cargo, the
shift in LOW range. Refer to OPER- wheels should be blocked using rocks
ATING THE SHIFT LEVER. or bricks.
If the situation does not allow you to Select the flattest terrain available for
shift in LOW range, it is possible to parking.
temporarily deactivate the electronic Release accelerator pedal and use
drive belt protection by pressing on the brakes to completely stop the vehi-
override switch. Refer to OVERRIDE cle.
SWITCH.
Set shift lever in PARK position.
WARNING Press the start / stop button to stop the
DO NOT USE THE OVERRIDE engine.
SWITCH if the slope is too steep Remove D.E.S.S key from its post.
and that there might be a risk of If you must park on a steep incline or if
tipover. Apply brakes to immobi- the vehicle is carrying cargo, block the
lize vehicle. Put shift lever in re- wheels using rocks or bricks.
verse (R), and back down the hill,
barely releasing brakes to remain Before stopping the engine and park-
at low speed. Do not attempt to ing the vehicle following a more in-
turn around. Never coast down tense ride, let vehicle run idle for a
hill while vehicle is in neutral. Do period of 20 to 30 seconds to allow for
not perform hard braking as it in- cooling of the turbo system.
creases the risk of tipover.
86 ______________
BASIC PROCEDURES
Tips for Maximizing Drive

Belt Durability
Riding style and conditions have a di-
rect impact on drive belt durability.
Your vehicle features a CVT system de-
sign that is optimized to offer the best
performance. The CVT and drive belt
have successfully endured thousands
of miles of durability tests. However,
to maximize drive belt durability and
to prevent premature failures, it is im-
portant that the operator understands
the limits of a belt driven CVT system
and adapts their riding style and speed
accordingly.
If riding in any of the conditions listed
below, BRP highly recommends not to
constantly hold the throttle wide open
(WOT) for more than five (5) minutes.
– High ambient temperatures (above
30°C (86°F)
– Heavy loads: Passengers / Heavy
cargo
– Heavy drag: Soft sand / Hill climbing
/ Mud / Using a track kit.
After a few minutes at WOT, partially
release the accelerator and allow the
CVT to cool down.
For more tips for maximizing the drive
belt durability, refer to CHOOSING
THE CORRECT RANGE (LOW OR
HIGH).
_______________ 87
SPECIAL PROCEDURES
What to do if Water Entered To access the battery, move the pas-
the CVT senger seat completely forward. Re-
fer to SEATS in EQUIPMENT.
If water is present in the CVT, the en-
gine will accelerate but the vehicle will NOTICE Do not connect any elec-
remain still. trical source to the steering column.
NOTICE Stop the engine and drain
the water to avoid damage to the What to do if Vehicle Rolled
CVT. Over
Abrupt maneuvers, sharp turns, side
hilling or accident may cause vehicle to
rollover.
Should the vehicle be rolled over, it will
be necessary to have it transported
to an authorized Can-Am dealer for in-
spection as soon as possible. NEVER
START THE ENGINE!
Points to be verified, including but not
limited to:
219001761-050_a – All fluid levels
1. CVT drain – Seat belts, including retractors,
buckles and semi-cinching tabs
The CVT drain is accessible from under – Cage
the rear of vehicle on the LH side. – Steering system
– Suspension
What to do if Vehicle is
Submerged
Should the vehicle become immersed,
it will be necessary to have it trans-
ported to an authorized Can-Am dealer
as soon as possible.
NOTICE Never start the engine as
219001761-078_a immersion of the vehicle can cause
1. CVT drain serious damage to the engine if the
correct restart procedure is not fol-
See an authorized Can-Am dealer to lowed.
have the CVT inspected and cleaned.
What to do if Battery is
Drained out
The vehicle can be jump started by us-
ing the red (+) cable to the battery pos-
itive pole and the black (-) cable to the
vehicle chassis.
88 ______________
TRANSPORTING THE VEHICLE
If your vehicle needs to be transported, 3.2 Attach the straps to the winch
it should be carried on a flatbed trailer cable of the towing vehicle.
of the proper size and capacity. 3.3 Pull the vehicle on the flatbed
NOTICE Do not tow this vehicle — with the winch.
towing can seriously damage the ve- 4. Remove the key from the D.E.S.S.
hicle's drive system. post.
When contacting a towing or trans- 5. At rear, secure the vehicle on both
porting service, be sure to ask if they sides using a strap around the cen-
have a flatbed trailer, loading ramp or tral suspension arm as close to the
power ramp to safely lift the vehicle wheel as possible.
and tie-down straps. Ensure the vehi-
cle is properly transported as specified
in this section.
NOTICE Avoid using chains to tie
the vehicle — they may damage
the surface finish or plastic com-
ponents.
WARNING
If the vehicle is equipped with a 219001761-122_a
windshield, transport it facing for-
ward to avoid damaging the wind- 1. Rear central suspension arm
shield. 6. At front, secure the vehicle on both
sides using a strap around the lower
To load the vehicle on a platform for suspension arm as close to the
transport, proceed as follow: wheel as possible.
1. Place shift lever to NEUTRAL (N).
2. If the vehicle is equipped with a
winch, use the winch to roll the ve-
hicle on the platform.
3. If the vehicle is not equipped with a
winch, proceed as follows:
3.1 Put a strap around the front re-
covery hook.
219001761-124_a
1. Front lower suspension arm
7. Strap the rear tires by using tire tow-

ing straps.
8. Firmly attach the rear suspension
219001761-120_a tie-down straps to both sides of the
1. Front recovery hook rear of the trailer with ratchets.
_______________ 89
TRANSPORTING THE VEHICLE
9. Ensure that both the front and rear

wheels are firmly attached to the
trailer.
WARNING
Make sure no loose objects are
present inside vehicle during vehi-
cle transportation.
90 ______________
LIFTING AND SUPPORTING THE VEHICLE
Front of Vehicle Rear of Vehicle
Place vehicle on a flat non slippery Place vehicle on a flat non slippery
ground. ground.
Engage the 4WD mode. Activate 4WD mode.
Ensure vehicle shift lever is set to Ensure vehicle shift lever is set to
PARK. PARK.
Install an hydraulic jack under the round Install an hydraulic jack under the vehi-
tube. cle.
219001761-079_a 219001761-080_a
FRONT OF VEHICLE REAR OF VEHICLE

1. Hydraulic jack position 1. Hydraulic jack position
Lift front of vehicle and install a jack Lift rear of vehicle and install a jack
stand on each side under frame as stand on each side under frame as
shown below: shown below:
219001761-129_b 219001761-129_a
JACK STAND POSITIONS - FRONT OF JACK STAND POSITIONS - REAR OF

VEHICLE VEHICLE
Lower hydraulic lift and ensure vehi- Lower hydraulic lift and ensure vehi-
cle is supported safely onto both jack cle is supported safely onto both jack
stands. stands.
_______________ 91
LIFTING AND SUPPORTING THE VEHICLE
This page is
intentionally blank
92 ______________
MAINTENANCE
_______________ 93
Maintenance is very important for keeping your vehicle in safe operating condition.
Proper maintenance is the owner's responsibility. The vehicle should be serviced
as per the maintenance schedule.
A repair shop or person of the owner's choosing may maintain, replace, or repair
emission control devices and systems. These instructions do not require compo-
nents or service by BRP or authorized Can-Am dealers. Although an authorized
Can-Am dealer has an in-depth technical knowledge and tools to service the
Can-Am SSV, the emission-related warranty is not conditioned on the use of
an authorized Can-Am dealer or any other establishment with which BRP has a
commercial relationship. For emission-related warranty claims, BRP is limiting
the diagnosis and repair of emission-related parts to the authorized Can-Am
dealers. For more information, please refer to the US EPA EMISSION-RELATED
WARRANTY contained herein. Proper maintenance is the owner’s responsibility.
A warranty claim may be denied if, among other things, the owner or operator
caused the problem through improper maintenance or use.
You must follow the instructions for fuel requirements in FUEL. Even if gasoline
containing greater than ten volume percent ethanol is readily available, the US
EPA issued a prohibition against the use of gasoline containing greater than 10
vol% ethanol that applies to this vehicle. The use of gasoline containing greater
than 10 vol% ethanol with this engine may harm the emission control system.
The following message appears in the gauge after every 100 hours of operation, to
remind you of maintenance requirements: MAINTENANCE REQUIRED. To erase
message, refer to MULTIFUNCTION DISPLAY in MULTIFUNCTION GAUGE (ANA-
LOG/DIGITAL).
The maintenance schedule does not exempt the pre-ride inspection.
WARNING
Failure to properly maintain the vehicle according to the maintenance
schedule and procedures can make it unsafe to operate.
SEVERE DUSTY OR SNOWY CONDITIONS

Air Filter Maintenance Guideline
Air filter maintenance should be adjusted according to riding conditions.
Air filter maintenance must be increased in frequency in the following dusty condi-
tions:
– Riding on snow covered surfaces
– Riding on dry gravel roads or similar conditions.
Riding in a group in these conditions would increase even more the air filter main-
tenance.
NOTE: An accessory pre-filter should be used to avoid snow accumulation when
the vehicle is used in such conditions. Contact an authorized Can-Am dealer for de-
tails.
94 ______________
MAINTENANCE SCHEDULE LEGEND

Operation in trail riding conditions
Operation in severe riding conditions (dusty or muddy) or carrying heavy loads condition
Make sure to perform proper maintenance at recommended intervals as indicated
in the tables. Some items of the maintenance schedule must be performed in
function of the calendar, regardless of the distance or time of operation.
Check fault codes
Replace engine oil and filter
Check gearbox oil level and look for contamination
Inspect and clean engine air filter. Replace if needed
Inspect steering system for abnormal play and damages (column, rack and pinion,
bellows)
Inspect the tie rod ends and ball joints for play and inspect boots condition
Inspect wheel bearings for abnormal play
Inspect suspension arm bushing and wear plates. Replace if needed
Verify the transverse suspension arm nuts tightening torque
Inspect front and rear shock absorber spherical bearing O-rings (if damaged, clean,
lubricate and reinstall O-rings)
Lubricate suspension arms and stabilizer bar bushings (Front / Rear)
Inspect CV joints and rubber boots condition (check for abnormal play in the joints and
for cuts in the rubber boots)
Inspect and clean the brake system (fluid level, pads, discs, lines, calipers)
Check front differential oil level and look for contamination and overall condition (vents,
mount bolt torque, seals)
Inspect battery condition and connections
Inspect propeller shaft U-joints for abnormal play
Clean exhaust pipes and muffler area
Clean muffler spark arrester
Replace fuel vent breather filter
_______________ 95
Inspect CVT drive belt and clean CVT pulleys
Inspect and lubricate drive pulley hub needle bearing
Inspect centrifugal levers and rollers of drive pulley
Inspect input and output shaft seals (engine, gearbox, differential)
Inspect beadlock screws (if equipped)
Inspect rear wheel scrapers wear plates
Tighten cage fasteners (if equipped with a replacement cage)
Inspect, clean and validate operation of seat belts retractors, buckles and semi-cinching
(if applicable)
Verify coolant level and adjust if needed
PERFORM AT THE FIRST 3 000 KM (2,000 MI)AND AT 6 000 KM (4,000 MI)

THEN FOLLOW THE REGULAR SCHEDULE
PERFORM AT THE FIRST 1 500 KM (1,000 MI) AND AT 3 000 KM (2,000 MI)
THEN FOLLOW THE REGULAR SCHEDULE
Replace gearbox oil
EVERY TWO YEARS OR 6 000 KM (4,000 MI) OR 200 HOURS

(whichever comes first)
EVERY TWO YEARS OR 3 000 KM (2,000 MI) OR 100 HOURS
(whichever comes first)
Check fault codes
Replace front differential oil
Replace gearbox oil.
Replace brake fluid (must be performed every 2 years)
Test engine coolant strength + level
Verify fuel system for leaks (including evaporative emission system components if
equipped)
Verify fuel pump pressure (idle and wide open throttle)
Replace spark plugs
Clean vehicle speed sensor
Replace canister vent pre-filter (evaporative emission system) if equipped
96 ______________
EVERY 5 YEARS OR 12 000 KM (8,000 MI) (whichever comes first)

EVERY 5 YEARS OR 6 000 KM (4,000 MI) (whichever comes first)
Replace engine coolant
_______________ 97
MAINTENANCE PROCEDURES
This section includes instructions for – Riding on dry dirt covered surfaces.
basic maintenance procedures. – Riding on dry gravel trails or similar
Due to the complexity of some of the conditions.
maintenance procedures, good me- – Riding in areas with high concentra-
chanical skills are required. If you are tion of seeds or crop husks.
not comfortable with these proce- – Riding in severe snow conditions.
dures, do not hesitate to contact an
authorized Can-Am off-road dealer, re- NOTICE When riding in dusty con-
pair shop or person of your own choos- ditions or sand, the air filter housing
ing. needs to be cleaned before every
NOTE: Maintenance message can ride.
be removed by alternately pressing NOTE: Riding in a group under these
the override switch and brake pedal conditions would increase even more
3 times at power up. the air filter replacement frequency.
WARNING Engine Air Filter Removal
Unless otherwise indicated, al-
ways remove D.E.S.S. key from
the D.E.S.S. post before perform-
ing any maintenance and remove
key.
WARNING
Should removal of a locking de-
vice be required (e.g. lock tab,
self-locking fastener, etc.) , always
replace it with a new one. 219001830-011_a
LH REAR OF VEHICLE
1. Air filter housing
Engine Air Filter
Remove the air filter cover by releasing
NOTICE Never modify the air in- the retaining clamps.
take system. Otherwise, engine per-
formance degradation or damage
can occur. The engine is calibrated
to operate specifically with these
components.
Engine Air Filter Replacement

Guideline
Engine Air filter replacement fre-
quency should be adjusted according
to riding conditions as it is critical to en-
sure proper engine performance and
life span.
Engine Air filter replacement fre-
quency must be increased for the fol-
lowing severe riding conditions: 219001830-012_a
– Riding on dry sand.
98 ______________
Remove the filter cartridge. – Riding on dry gravel trails or similar

conditions.
Engine Air Filter Housing Cleaning – Riding in muddy conditions.
Inspect air filter housing for cleanli- – Riding in areas with high concentra-
ness. tion of seeds or crop husks.
– Riding in severe snow conditions.
NOTICE If sand or other particles
are found in air filter housing, clean NOTE: Riding in a group in these con-
it using a vacuum cleaner. ditions would increase even more the
air filter replacement requirement.
Engine Air Filter Cleaning
CVT Air Filter Removal
Clean engine air filter by tapping out
heavy dust from paper element, this Open the air box cover.
will allow dirt and dust to get out of the
paper filter.
NOTICE It is not recommended to
blow compressed air on the paper
element; this could damage the pa-
per fibers and reduce its filtration
ability when used in dusty environ-
ments. If engine air filter is too dirty
and cannot be cleaned following the
recommended procedure, it should
be replaced. 219001761-203_a
Engine Air Filter Installation Remove CVT filter from vehicle.

Install air filter cartridge.
Install filter cover with the "TOP" mark
upwards (duckbill valve downwards).
Secure cover using the retaining
clamps.
Front Grille Kit

1. Remove debris from front grille.
2. Clean front grille with water.
219001761-204_a
CVT Air Filters 1. CVT air filter
CVT air filter inspection and cleaning Step 1: Unlatch
frequency should be adjusted accord- Step 2: Lift the rear part
Step 3: Pull off
ing to riding conditions as it is critical
to ensure proper engine performance
and life span. CVT Air Filter Inspection and
Cleaning
CVT Air filter inspection and cleaning
frequency must be increased for the Inspect filter and replace if necessary.
following severe riding conditions: Remove CVT filter. Refer to CVT FIL-
– Riding on dry sand. TER REMOVAL and clean it using soft
– Riding on dry dirt covered surfaces. soap and water then rinse with water.
_______________ 99
Gently shake off excess water and al-

low filter to dry at room temperature.
CVT Air Filter Installation

Reinstall filter:
– Insert the three tabs at front of the
filter in the corresponding slots
– Securely latch the filter.
Reinstall the air box cover. Make sure it 219001830-007_c
is properly secured. 1. Filter
2. Retaining screw
Evaporative Emission
System Pre-Filter (If 5. Install a new pre-filter assembly.
Secure the hoses using clamps.
Equipped)
TIGHTENING TORQUE
Evaporative Emission System
Pre-Filter Replacement Pre-filter
2.5 N•m ± 0.5 N•m
retaining
1. Remove the protective plate. (22 lbf•in ± 4 lbf•in)
screw
6. Reinstall the protective plate.

TIGHTENING TORQUE
Protective
6.5 N•m ± 0.5 N•m
plate retaining
screw
Engine Oil
219001830-006_b Engine Oil Level Verification
1. Protective plate
NOTICE Operating the engine
2. Remove the hose clamps. with an improper level may severely
damage engine.
With the engine at normal operating
temperature, place vehicle on a level
surface and check the oil level as fol-
lows:
1. Start engine and let it idle for at least
20 seconds.
2. Stop engine.
3. Unscrew dipstick then remove it
219001830-007_b
and wipe clean.
1. Hose clamps
3. Remove the retaining screw.

100 ______________
Recommended Engine Oil

RECOMMENDED ENGINE OIL
(GENERAL PURPOSE)
4T 5W40 SYNTHETIC
Scandinavia BLEND OIL (EUR)
(P/N 779290)
All other
4T 5W40 SYNTHETIC
countries
BLEND OIL
219001761-085_a
(P/N 779133)
LH REAR OF VEHICLE
1. Dipstick
4. Reinstall dipstick, screw it in com- (WARM TEMPERATURE)
pletely.
4T 10W50
5. Remove dipstick and check oil level. Scandinavia SYNTHETIC OIL (EUR)
It should be near or equal to the up- (P/N 779240)
per mark.
All other 4T 10W50 SYNTHETIC
countries OIL (P/N 779234)

(COLD TEMPERATURE)
4T 0W40 SYNTHETIC
tmo2011-001-076_a
Scandinavia OIL (EUR)
TYPICAL (P/N 779286)
1. MIN
2. MAX
3. Operating range
All other 4T 0W40 SYNTHETIC
countries OIL (P/N 779139)
To add oil, remove the dipstick. Place a
funnel into the dipstick tube. NOTE: The XPS oil is specially formu-
Add a small amount of recommended lated to meet the lubrication require-
oil and recheck oil level. ments of this engine. BRP recom-
mends the use of its XPS oil. If XPS en-
Repeat the above procedures until gine oil is not available, use a 4-stroke
oil level reaches the dipstick's upper SAE 5W 40 or 10W50 engine oil that
mark. meets or exceeds the requirements
NOTE: Do not overfill. Wipe off any for API service classification SJ, SL,
spillage. SM or SN. Always check the API ser-
vice label certification on the oil con-
Properly tighten dipstick. tainer it must contain at least one of
the above standards.
NOTICE Damages caused by the
use of oil not suitable for this engine
may not be covered by the BRP lim-
ited warranty.
______________ 101
Engine Oil Change
CAUTION The engine oil can

be very hot. Wait until engine oil is
warm.
NOTICE Engine oil and oil filter
must be replaced at the same time.
Bring engine to its normal operating
temperature. tmr2017-014-020_a

Place vehicle on a level surface. 2. Gasket ring
Remove dipstick. 3. Secondary drain plug
4. Gasket ring
Place a drain pan under the engine
drain plug area. Allow oil to drain completely from the
crankcase.
Clean the magnetic drain plug from
metal shavings and residue. Presence
of debris gives an indication of internal
engine damage.
Install a NEW gasket ring on the drain
plug.
NOTICE Never use the gasket ring
a second time. Always replace by a
219001761-208_a
new one.
UNDERNEATH REAR OF VEHICLE Install and tighten drain plug to the rec-
2. Secondary drain plug ommended specification.
Clean the drain plugs area. TIGHTENING TORQUE

NOTE: A funnel can be used between Secondary 15 N•m ± 2 N•m
the drain holes and the skid plate to drain plug (133 lbf•in ± 18 lbf•in)
avoid spillage.
Magnetic 30 N•m ± 3 N•m
Unscrew drain plugs and discard the drain plug (22 lbf•ft ± 2 lbf•ft)
gasket rings.
Replace oil filter. Refer to OIL FILTER.
Refill engine with recommended en-
gine oil.
Check oil level, refer to ENGINE OIL
LEVEL VERIFICATION.
ENGINE OIL CAPACITY
Engine oil and
3.5 L
engine oil filter
(3.7 qt (U.S. liq.))
replacement
102 ______________
Oil Filter
Oil Filter Access
Access the oil filter by the RH rear of
the vehicle.
219001761-091_a
1. Outlet to the engine oil providing system

2. Inlet from the oil pump to the oil filter
Install a NEW O-ring on oil filter cover.

Install the new filter into the cover.
219001761-205_a
Apply engine oil on O-ring and filter
1. Oil filter cover seal.
Oil Filter Removal
Clean oil filter area.
Remove oil filter cover.
Remove oil filter.
vmr2006-008-001_a
1. Slightly oil
2. Slightly oil
NOTICE Pay attention to avoid

pinching the O-ring during filter and
219001761-206 cover installation.
Oil Filter Installation Install the cover on the engine.
Check and clean the oil filter inlet and Tighten oil filter cover screws to rec-
outlet area for dirt and other contami- ommended specification.
nations.
TIGHTENING TORQUE
Oil filter cover 10 N•m ± 1 N•m
______________ 103
Radiator Engine Coolant

Radiator Inspection and Cleaning Engine Coolant Level Verification
To access the radiator, remove the
front service cover. WARNING
Check coolant level with engine
CAUTION Wait for the radiator cold.
to cool down before proceeding.
1. Place vehicle on a level surface.
2. Remove service cover by unlatching
the rear lifting it upwards.
219001761-092_a
FASCIA COVER
NOTICE Do not attempt to remove

219001761-060_a
the lower grilles
LIFTING REAR OF SERVICE COVER
Inspect radiator and hoses for leaks or
any damage.
Inspect radiating fins. They must be
clean, free of mud, dirt, leaves and any
other deposit that would prevent the
radiator to cool properly.
If available, use a garden hose to rinse
the radiating fins.
CAUTION Never clean radiator

with your hands when it is hot. Let 219001761-059_a
the radiator cool down before clean- 1. Service cover

ing.
3. Remove pressure cap.
NOTICE Be careful not to damage
the radiating fins when cleaning. Do WARNING
not use any object/tool that could
damage the fins. When hosing, use In order to avoid potential burns,
low pressure only. Never use a HIGH do not remove the pressure cap if
PRESSURE washer. the engine is hot.
Reinstall the fascia cover and grille.
104 ______________
Recommended Engine Coolant

RECOMMENDED
COUNTRIES
COOLANT
EXTENDED LIFE
Scandinavia
PRE-MIXED
COOLANT (EUR)
(P/N 779223)
EXTENDED LIFE
219001761-095_a
All other countries
PRE-MIXED
1. Pressure cap COOLANT
(P/N 779150)
4. Ensure cooling system is full up to
the MAX line. Distilled water
and antifreeze
Alternative, or if
solution (50%
not available
distilled water,
50% antifreeze)
NOTICE Always use ethylene-gly-

col antifreeze containing corrosion
inhibitors specifically for internal
combustion aluminum engines.
Engine Coolant Replacement

219001761-094_a
Cooling System Draining
5. Add coolant in system as neces-
sary. Use a funnel to avoid spillage. WARNING
Do not overfill.
In order to avoid potential burns,
6. Reinstall pressure cap on cooling do not remove the pressure cap or
tank. loosen the coolant drain plug if the
NOTE: Coolant level can be checked engine is hot.
by looking at the side of the coolant
reservoir. Lift the rear of the vehicle approxi-
mately 30 cm (12 in).
219001761-135_a
A. 30 cm (12 in)
______________ 105
Place a drain pan under the lower hose Fill cooling system with coolant, re-
of the radiator. fer to COOLING SYSTEM REFILLING
AND BLEEDING procedure.
Cooling System Refilling and
Bleeding
1. Remove the pressure cap.
219001834-013_a
1. Lower hose 219001761-095_a
1. Pressure cap
Install a large hose pincher on the
lower hose of the radiator. 2. Fill the cooling system until level
Slowly detach hose from radiator. reaches the MAX line on the coolant
reservoir.
Remove coolant reservoir pressure
cap.
219001761-094_a
219001761-095_a 3. Install pressure cap.

1. Pressure cap 4. Run engine at idle with the pressure
cap on until the cooling fan cycles 2
Wait until the coolant flow stops or de- times.
creases.
5. Depress throttle pedal two or three
Remove the hose pincher to drain the times.
rest of the coolant.
6. Stop engine and let it cool down.
Install radiator hose clamp.
Add coolant if necessary.
TIGHTENING TORQUE
Radiator hose 2.5 N•m to 3.5 N•m
clamp (22 lbf•in to 31 lbf•in)
106 ______________
WARNING Inspect spark arrester chamber in muf-

fler. Remove any debris as needed.
In order to avoid potential burns,
do not remove the pressure cap if Reinstall the spark arrester in the
the engine is hot. reverse of the removal procedure.
Tighten retaining screws to specifi-
cation.
7. After the next ride following this pro-
cedure, check coolant level. Add TIGHTENING TORQUE
coolant as required. Refer to EN-
GINE COOLANT LEVEL VERIFICA- Muffler cover 10 N•m ± 2 N•m
TION. screws (89 lbf•in ± 18 lbf•in)
Muffler Spark Arresters Front Differential Oil

Muffler Spark Arrester Cleaning Front Differential Oil Level
The mufflers must be periodically Verification
purged of accumulated carbon. Clean filler plug prior to check oil level.
CAUTION Never perform this

operation immediately after the en-
gine has been running because ex-
haust system is very hot.
Remove retaining screws securing
muffler cover in place and remove muf-
fler cover.
Pull out spark arrester and remove car-
bon deposits using a brush.
219001799-018_a
MODELS EQUIPPED WITH VISCO-LOK

FRONT DIFFERENTIAL
1. Filler plug
219001761-048_a
1. Retaining screws
2. Muffler cover
3. Spark arrester
NOTICE Use a soft brush and be

careful to avoid damaging spark ar-
rester mesh.
Inspect mesh of spark arrester for any
damage. Replace as needed.
______________ 107
ALTERNATE OIL REQUIREMENT

75W 90 (API GL-5) synthetic gear oil
NOTICE Do not use another type

of oil when servicing.
Front Differential Oil Change

Place vehicle on a level surface. Set
the gearbox to PARK.
From underneath of vehicle, clean
drain plug area.
219001834-001_a
MODELS EQUIPPED WITH SMART-LOK

FRONT DIFFERENTIAL
1. Filler plug
With vehicle on a level surface, check

oil level by removing filler plug. Oil
level must reach the lower edge.
TIGHTENING TORQUE
16.25 N•m ± 2.75 N•m
Filler plug
(144 lbf•in ± 24 lbf•in) 219001799-019_b
UNDERNEATH THE VEHICLE

1. Drain plug
Recommended Front Differential 2. Access hole
Oil
Place a drain pan under the front differ-
RECOMMENDED FRONT ential.
DIFFERENTIAL OIL
Access the drain plug through the hole
75W90 in the skid plate.
Scandinavia
SYNTHETIC Remove drain plug.
GEAR OIL (EUR)
(P/N 779212) Unscrew filler plug.
75W90
All other countries
SYNTHETIC
GEAR OIL
(P/N 779158)
NOTE: The XPS oil is specially formu-

lated to meet the lubrication require-
ments of this gearbox. BRP strongly
recommends the use of its XPS oil.
However, if the XPS synthetic gear oil
is not available, use the following lubri-
cant: 219001799-018_a
MODELS WITH VISCO-LOK FRONT

DIFFERENTIAL
1. Filler plug
108 ______________
219001761-064_a
1. Gearbox oil level plug
Reinstall the plug, screw it in com-

219001834-001_a
pletely.
MODELS WITH SMART-LOK FRONT Remove plug again and check oil level
DIFFERENTIAL on the dipstick. It should be near or
1. Filler plug equal to the upper mark.
Install drain plug.
TIGHTENING TORQUE
2.75 N•m ± .25 N•m
Drain plug
Refill front differential with recom-

mended oil.
TIGHTENING TORQUE
16.25 N•m ± 2.75 N•m
Filler plug
(144 lbf•in ± 24 lbf•in) tmr2016-106-005_a
1. MIN.
2. MAX.
Gearbox Oil 3. Operating range
Gearbox Oil Level Verification To add oil, place a funnel into the oil
level plug hole.
Place the vehicle on a level surface.
Select PARK position. Add a small amount of recommended
oil and recheck oil level.
Check the gearbox oil level by remov-
ing the gearbox oil level plug located at Repeat the above procedures until
the rear of vehicle, on the RH side. oil level reaches the dipstick's upper
mark.
NOTICE Pay attention not to loose NOTE: Do not overfill. Wipe off any
the oil level plug O-ring. spillage.
NOTICE Operating the gearbox
with an improper oil level may se-
verely damage gearbox.
Properly tighten the plug.
______________ 109
TIGHTENING TORQUE Remove the magnetic gearbox drain

plug and discard sealing ring.
Gearbox oil level 5 N•m ± 0.6 N•m
plug (44 lbf•in ± 5 lbf•in)
Recommended Gearbox Oil

RECOMMENDED GEARBOX OIL
75W140
Scandinavia
SYNTHETIC
GEAR OIL (EUR)
(P/N 779215)
75W140 219001761-065_a
All other countries

SYNTHETIC 1. Gearbox drain plug
GEAR OIL 2. Engine oil drain plug
(P/N 779160)
NOTE: The XPS oil is specially formu-

lated to meet the lubrication require-
ments of this gearbox. BRP strongly
recommends the use of its XPS oil.
However, if the XPS synthetic gear oil
is not available, use the following lubri-
cant:
ALTERNATE OIL REQUIREMENT
75W 140 API GL-5 synthetic gear oil tmr2016-106-006_a

NOTICE Do not use another type 2. Sealing ring (discard)
of oil when servicing. 3. Gearbox oil level plug (dipstick)
4. O-ring
Gearbox Oil Change Let oil completely drain from gearbox.
Oil change should be done with a warm Install the drain plug.
engine.
NOTE: Clean drain plug from any
metallic particles prior to installation.
CAUTION The gearbox oil can
be very hot. Reinstall magnetic drain plug.
Place the vehicle on a level surface. Always install a NEW sealing ring.
Clean drain plug area. TIGHTENING TORQUE
Clean the oil level plug area. Magnetic drain 30 N•m ± 3 N•m
Under the vehicle, place a drain pan unplug (22 lbf•ft ± 2 lbf•ft)
derneath the magnetic drain plug area.
Remove the gearbox oil level plug (dip- Refill gearbox.
stick). NOTICE Use ONLY the recom-
NOTICE Pay attention not to loose mended type of oil.
O-ring on plug.
110 ______________
Check oil level, refer to GEARBOX OIL

LEVEL VERIFICATION.
Dispose gearbox oil as per your local
environmental regulations.
Spark Plugs
Access to Spark Plugs (Models
without Intercooler)
tmr2017-034-001
Remove the air inlet cover and the
grille. Remove the protective plate front re-
taining screws.
219001830-010_a
1. Air inlet cover

2. Grille 219001830-008_a
Remove the protective plate rear re- Remove the protective plate.
taining screws.
Access to Spark Plugs (Models with
Intercooler)
Remove the air inlet cover and the
grille.
219001830-009_a
Remove the service cover. 219001830-010_a
1. Service cover
2. Grille
Remove the intercooler rear retaining

screws.
______________ 111
Lift intercooler assembly.

Disconnect the intercooler fan connec-
tor.
Move intercooler assembly aside
tmr2017-034-007
Remove the service cover.
tmr2017-034-004_a
1. Intercooler assembly
2. Intercooler fan connector
Spark Plug Removal (All Models)

1. Disconnect CAPS (camshaft posi-
tion sensor).
tmr2017-034-001
Remove the intercooler front retaining

screws.
tmr2017-019-001_a
219001830-008_a
2. Remove:
– Ignition coil retaining screws
Disconnect intercooler hose. – Ground connector.
3. Disconnect ignition coil connectors.
tmr2017-034-006
112 ______________
TIGHTENING TORQUE
Spark plug 11 N•m (97 lbf•in)
Install the ignition coil on the spark

plug.
Align the retaining screw hole of the ig-
nition coil with the threaded hole on the
valve cover.
tmr2017-019-002_a
Push the ignition coil all the way down
until it rests on the valve cover.
1. Retaining screws
2. Ground connectors Install and tighten retaining screw.
3. Ignition coil connectors
TIGHTENING TORQUE
NOTICE Do not pry on ignition coil
with a tool. Ignition coil
9 N•m ± 1 N•m
retaining
4. Remove ignition coils with gaskets screw
from spark plug by rotating coil side
to side as you pull up. Reinstall all other removed parts using
5. Clean spark plug and cylinder head the reverse of removal procedure.
with pressurized air. NOTE: Make sure to reconnect the in-
tercooler fan connector (if equipped).
CAUTION Always wear safety TIGHTENING TORQUE
goggles when using pressurized air.
Protective
6. Unscrew the spark plugs com-
plate retaining
pletely using a spark plug socket.
screws
7. Use ignition coil as a puller. (models
without 8 N•m ± 1 N•m
Spark Plug Installation intercooler) (71 lbf•in ± 9 lbf•in)
Prior to installation make sure that con- Intercooler
tact surface of cylinder head and spark retaining
plug is free of grime. screws (if
Using a feeler gauge, set the spark plug equipped)
gap.
SPARK PLUG GAP CVT Cover
0.8 mm (.031 in) NOTE: For a better understanding,
some illustrations are taken with en-
Apply HEAT-SINK PASTE P12 (P/N 420 gine out of vehicle. To perform the
897 186) on the spark plug threads. following instructions, it is not neces-
sary to remove engine.
Screw spark plug into cylinder heads
by hand and tighten to specification This CVT is lubrication free except for
using a torque wrench. the drive pulley bearing.
CAUTION Do not overtighten

spark plugs. engine damage can oc-
cur.
______________ 113
WARNING NOTICE Do not use an impact tool

to remove CVT cover screws.
Never touch CVT while engine is
running. Never drive vehicle when Remove the CVT cover and its gasket.
CVT cover is removed.
CAUTION Let engine cool

down before removing the CVT
cover.
Place the vehicle on a level surface.
Select PARK position.
CVT Cover Access

CVT cover can be accessed from the
LH side at the rear of vehicle. 219001761-138_a
1. CVT cover screws

2. CVT cover
3. Gasket
Check inside front and rear CVT outlet

hoses to make sure there are no de-
bris.
CVT Cover Installation

Install the center top screw first.
Tighten the CVT cover screws as per
219001761-114_a
following sequence.
1. CVT cover
CVT Cover Removal

Loosen CVT inlet hose clamp(s).
219001761-113_a
TIGHTENING TORQUE
CVT Cover 7 N•m ± 0.8 N•m
219001761-051_a
1. Clamp
Remove all CVT cover retaining

screws.
Remove the center top screw last to
support the cover during removal.
114 ______________
Drive Belt
Drive Belt Removal
NOTICE In case of a drive belt fail-
ure, the CVT, cover and air outlets
must be cleaned.
Please refer to TIPS FOR MAXIMIZING
DRIVE BELT DURABILITY for some
IMPORTANT information.
Remove CVT COVER. tmr2017-021-006_a
Open driven pulley.

Drive Belt Installation
REQUIRED TOOLS For installation, reverse the removal
procedure. Pay attention to following
PULLER/LOCKING details.
TOOL (P/N 529
000 088) The maximum drive belt life span is
obtained when the drive belt has the
DRIVEN PULLEY proper rotation direction. Install it
ADAPTER (P/N 708 so that the arrow printed on belt is
200 720) pointing towards front of the vehicle,
viewed from top.
Insert the pulley adaptor in the driven
pulley threaded hole, then screw it in.
Insert the puller/locking tool in the pul-
ley adaptor threaded hole, then screw
it in to open the pulley.
vmr2007-051-006_a
1. Arrow printed on belt

2. Drive pulley (front)
3. Driven pulley (rear)
4. Rotation direction
Turn the driven pulley until the low-

219001761-052_a
est portion of the cogs on the external
1. Fixed sheave of driven pulley surface of drive belt is even with the
2. Adaptor (in glove box) driven pulley edge.
3. Puller/locking tool (in tool kit)
4. Wrench (in tool kit)
To remove belt, slip the belt over the

top edge of fixed sheave, as shown.
______________ 115
Battery Access
To access the battery, move the pas-
senger seat completely forward, refer
to SEAT in EQUIPMENT.
Battery Removal
Disconnect BLACK (-) cable first then
RED (+) cable.
219001761-053_a
NOTICE Always respect this order
1. Lowest portion of cogs even with external for disassembly; disconnect BLACK
surface of drive belt (-) cable first.
Remove battery holder retaining
Drive and Driven Pulleys screws.
Drive and Driven Pulleys Inspection
This inspection must be performed by
an authorized Can-Am dealer, repair
shop, or person of your own choosing
for maintenance, repair, or replace-
ment.
Drive Pulley
Inspect the bushings of the sliding
sheave of the drive pulley, replace
worn parts. 219001761-054_a
Driven Pulley 1. Battery holder retaining screws

2. Battery
Inspect the bushings of the cam and of 3. Battery holder
the sliding sheave of the driven pulley,
replace worn parts. Remove battery holder.
Remove battery.
Battery
Battery Cleaning
Battery Maintenance Clean battery, battery casing and bat-
NOTICE Never charge a battery tery posts using a solution of baking
soda and water.
while installed in vehicle.
Remove corrosion from battery cable
These vehicles are equipped with a terminals and battery posts using a
VRLA battery (Valve Regulated Lead firm wire brush. Battery casing should
Acid). It is a maintenance-free type be cleaned by soft brush and baking
battery, there is no need to add water soda solution.
to adjust electrolyte level.
Battery Installation
NOTICE Never remove the battery
sealing cap. Battery installation is the reverse of
the removal procedure, however, pay
attention to the following.
NOTICE Reversed battery polarity
will damage the voltage regulator.
116 ______________
CAUTION Always connect Rear Fuse Box

RED (+) cable first then BLACK (-) To access the rear fuse box, remove
cable. the driver seat. Refer to SEATS in
EQUIPMENT.
Fuses
Fuse Replacement
If a fuse is burnt, replace it by one of the
same rating.
NOTICE Do not use a higher rated
fuse as this can cause severe dam-
age.
Fuses and Fusible Links Location

219001949-002_a
Front Fuse Box and Dynamic Power 1. Driver seat
Steering (DPS) Fuse
To access the front fuse box or the DPS
fuse, remove the front service cover.
219001949-003_a
1. Rear fuse box
219001761-207_a
Fusible Links
1. Front service cover The fusible links are on the starter sole-
noid harness.
In the event that a fusible link blows,
see a Can-Am SSV dealer, a repair shop
or the person of your choosing.
Fuse Box Description

DPS FUSE HOLDER
NO DESCRIPTION RATING
- Dynamic power
40 A
219001950-001_a steering (DPS)
1. Front fuse box
2. DPS fuse
______________ 117
FUSIBLE LINKS NOTE: Fuses are identified on the

fuse box cover.
1 Main 16 AWG Lights
Always check light operation after re-
2 Accessories 16 AWG placement.
FRONT FUSE BOX The headlights and taillights are LEDs
(Light Emitting Diode). This technol-
NO DESCRIPTION RATING ogy has proven itself on the reliability.
F7 4WD actuator 10 A In the unlikely event they do not work,
have them checked by an authorized
F11 Lights 10 A Can-Am SSV dealer, repair shop or per-
son of your choosing.
DC Outlet
F12 20 A
Connector DC3
Drive Shaft Boot
F14 Accessories 30 A
Drive Shaft Boot Inspection
F16 Taillights 10 A
Visually inspect drive shaft boots con-
F23 Smart-Lok 20 A ditions.
Accessories Check boots for cracks, tears, leaking
R3 Engine Control - grease, etc.
Module (ECM) Repair or replace damaged parts as
-
necessary.
R8 Brake Relay
REAR FUSE BOX

Gauge
F4 10 A
relay
Ignition
F5 Fuel injectors 10 A
Fuel pump
Engine Control 219001761-103_a
F6 10 A
Module (ECM) FRONT OF VEHICLE
D.E.S.S. (key switch
F8 10 A
- clock)
F9 Cooling fan 25 A
F17 Intercooler fan 25 A
F18 EVAP/Oxygen Sensor 10 A
R1 Cooling fan -
R2 Main -
R10 Intercooler fan -
118 ______________
See an authorized Can-Am dealer, a re-

pair shop or person of your choosing if
there is abnormal play.
219001761-104_a
FRONT OF VEHICLE
219001761-107_a
TYPICAL
Wheels and Tires

Wheel Removal
Loosen nuts then lift and support vehi-
cle. Refer to LIFTING AND SUPPORT-
ING VEHICLE.
219001761-105_a
Remove lug nuts then remove wheel.
REAR OF VEHICLE (COMPONENTS
REMOVED FOR CLARITY)
1. Inner drive shaft boot Wheel Installation
If tires are unidirectional, their rotation
must be kept in a specific direction.
Unidirectional tires have inscriptions
on the sidewall.
219001761-106_a
REAR OF VEHICLE
Wheel Bearing tmr2011-033-002_a
TYPICAL
Wheel Bearing Inspection 1. Direction of rotation
Lift and support vehicle. Refer to LIFT- Tighten wheel lug nuts to the specified
ING AND SUPPORTING THE VEHI- torque using the illustrated sequence.
CLE.
Push and pull the wheels from the up-
per edge to feel the play.
______________ 119
TIGHTENING TORQUE Tire Inspection

120 N•m ± 5 N•m Check tire for damage and wear. Re-
Wheel lug nuts place if necessary.
WARNING
Do not rotate tires. The front and
rear tires have a different size. The
left and right tires have different
unidirectional tread patterns.
Tire Replacement
Tires replacement should be per-
formed by an authorized Can-Am
dealer, repair shop or person of your
219001761-127_a
own choosing.
NOTICE Always use the recom- WARNING

mended wheel nuts for the type of
wheel. Using a different nut could – Replace tires only with the same
cause damages to the rim or studs. type and size as original tires.
– For unidirectional tread pat-
Tire Pressure tern, ensure that the tires are
installed in the correct direction
WARNING of rotation.
– Tires should be replaced, by an
Tire pressure greatly affects vehi-
experienced person, in accor-
cle handling and stability. Insuf-
dance with tire industry stan-
ficient pressure may cause tire to
dards and tools.
deflate and rotate on wheel. Over-
pressure may burst the tire. Al-
ways follow recommended pres- Tire Mounting on Beadlock Wheels
sure. NEVER set tire pressure be- 1. Mount the tire on wheel.
low minimum. It could cause the
tire to dislodge from the rim. 1.1 On the opposite side of bead-
lock, apply tire mounting lube
on inner bead of tire and wheel
Check pressure when tires are cold to ensure proper seat when in-
before using the vehicle. Tire pres- flating. Mount the inner bead
sure changes with temperature and over the wheel.
altitude. Recheck pressure if one of
these conditions has changed. NOTICE Mount tire from
Refer to SPECIFICATIONS or the label beadlock side only.
on your vehicle for applicable pressure. 1.2 Seat tire outer bead in the
For your convenience, a pressure shoulder of the beadlock in-
gauge is supplied in tool kit. ner ring and center the tire.
NOTE: Although the tires are specif-
ically designed for off-road use, a flat
may still occur. Therefore, it is rec-
ommended to carry a tire pump and a
repair kit.
120 ______________
tmo2015-017-301_a
TYPICAL
tmo2015-017-303_b
1. Tire outer bead
2. Beadlock inner ring shoulder TYPICAL - TIGHTENING SEQUENCE
2. Install all beadlock screws. To avoid 4. At this time check if the tire is still
cross threading, start all screws by centered on wheel. Reposition it if
hand. necessary.
NOTICE Do not use an impact 5. Tighten beadlock screws as per the
wrench for installing beadlock second torque using the same se-
screws. The risk of screw breaking quence.
or screw stripping is high when us- TIGHTENING TORQUE
ing an impact wrench.
Beadlock
screws 25 N•m ± 1 N•m
(SECOND (18 lbf•ft ± 1 lbf•ft)
TORQUE)
tmo2015-017-303_a
1. Beadlock to be manually tightened
3. Tighten beadlock screws as per fol-

lowing specification and sequence. tmo2015-017-303_b
NOTE: To ensure even pressure TYPICAL - TIGHTENING SEQUENCE
on the beadlock clamp ring, tighten
screws a few turns at a time. NOTE: The beadlock clamp ring
should be in contact with the bead-
TIGHTENING TORQUE lock inner ring. The beadlock clamp
Beadlock ring can flex slightly to match the tire
14 N•m ± 1 N•m bead. IT IS NORMAL.
screws (FIRST
TORQUE) 6. Verify the gap between tire and
beadlock clamp ring, it should be
practically equal all around the ring.
______________ 121
WARNING
Never exceed tire's recommended
maximum pressure for seating
beads.
Suspensions
Front Suspension Lubrication
tmo2015-017-302_a SUSPENSION GREASE
1. Tire
2. Beadlock clamp ring edge SYNTHETIC
A. Gap equal all around beadlock clamp ring GREASE
Scandinavia SUSPENSION
If the gap is not acceptable, (EUR)
– Loosen all screws. (P/N 779226)
– Check tire position on wheel and SYNTHETIC
reposition it if necessary. All other GREASE
– Restart the torquing sequence as countries SUSPENSION
detailed. (P/N 779163)
7. Torque beadlock screws a final time
following the indicated sequence. Lubricate upper and lower suspension
arms.
TIGHTENING TORQUE
There are 2 grease fittings on each sus-
Beadlock pension arm.
25 N•m ± 1 N•m
screws (FINAL
TORQUE)
219001761-108_a

1. Grease fittings
tmo2015-017-303_c
TYPICAL - FINAL TIGHTENING SEQUENCE
8. Inflate tire to seat the inner bead on

wheel. Always use safe practices,
such as a tire safety cage.
122 ______________
219001761-109_a 219001761-112_a
TYPICAL - FRONT SUSPENSION TYPICAL - REAR STABILIZER BAR

1. Grease fittings 1. Grease fitting
Stabilizer Bar Lubrication Suspension Inspection

SUSPENSION GREASE See an authorized Can-Am dealer, a re-
pair shop or person of your choosing if
SYNTHETIC any problem is detected.
GREASE
Scandinavia SUSPENSION Shock Absorbers
(EUR) Inspect shock absorber for leaks,
(P/N 779226) bump stop wear out or other damages.
Verify fasteners are still well tightened.
SYNTHETIC
All other GREASE Front suspension arms
countries SUSPENSION
(P/N 779163) Check suspension arms for cracks,
bending or other damages.
There is one grease fitting on each Rear suspension arms
front suspension side.
Check suspension arms, trailing and
control links for cracks, bending or
other damages.
Verify the transverse suspension arm
nuts tightening torque.
219001761-110_a
TYPICAL - FRONT STABILIZER BAR

1. Grease fitting
219001799-017_a
There is one grease fitting on each rear
suspension side.
TIGHTENING TORQUE
Transverse 105 N•m ± 15 N•m
arm nuts (77 lbf•ft ± 11 lbf•ft)
______________ 123
Brakes Recommended Brake Fluid

Always use brake fluid meeting the
Brake Fluid Reservoir Level specification DOT 4 only.
Verification
Remove the front service cover. WARNING
To avoid serious damage to the
braking system, do not use fluids
other than the recommended one,
nor mix different fluids for topping
up.
Brake Inspection
WARNING
The brake fluid replacement or
219001761-207_a brake system maintenance and
1. Front service cover repairs should be performed by an
authorized Can-Am dealer.
Verify the following between visits to

your authorized Can-Am dealer:
– Brake fluid level
– Brake system for fluid leaks
– Brake pad wear
– Brake cleanliness.
Seat Belts
219001950-004_a
1. MIN Seat Belt Cleaning

2. MAX To clean dirt and debris from the seat
3. Master cylinder reservoirs
belts, sponge the straps with mild soap
With vehicle on a level surface, check and water. Do not use bleach, dye, or
brake fluid in reservoirs for proper household detergents.
level. Brake fluid level should be be-
tween MIN and MAX. marks. WARNING
NOTE: A low level may indicate leaks Do not use pressure washer to
or worn brake pads. clean seat belt components. Use
of pressure washer can perma-
Adding Brake Fluid nently damage seat belt compo-
Clean filler cap before removing. nents.
Add fluid as required. Do not overfill.
NOTE: Ensure filler cap diaphragm is
pushed inside the cap before closing
the brake fluid reservoir.
124 ______________
VEHICLE CARE
Post-Operation Care
When vehicle is used in salt-water
environment rinsing the vehicle with
fresh water is necessary to preserve
vehicle and its components. Metal-
lic parts lubrication is highly recom-
mended. Use LUB. & ANTI-CORRO-
SIVE (P/N 779168) or an equivalent.
This must be performed at the end of
each operating day.
When vehicle is operated in muddy
conditions, rinsing the vehicle is rec-
ommended to preserve vehicle and its
components.
Vehicle Cleaning and

Protection
Never use a high pressure washer to
clean the vehicle. USE LOW PRES-
SURE ONLY (like a garden hose).
High pressure can cause damage to
electrical or mechanical components.
Pay attention to certain areas where
mud or debris can accumulate and po-
tentially cause wear, interferences or
promote corrosion. The list includes
but is not limited to:
– Around exhaust system and be-
tween mufflers and muffler covers
– Under and around the fuel tank
– Radiator
– Shock absorbers
– Around front and rear differentials
– Around and underneath engine and
gearbox
– Inside wheels
– On top of skid plates.
Painted parts which are damaged
should be properly repainted to pre-
vent rust.
When required, wash the body with
warm water and soap (only use mild
detergent). Apply non-abrasive wax.
NOTICE Never clean plastic parts
with strong detergent, degreasing
agent, paint thinner, acetone, etc.
______________ 125
STORAGE AND PRESEASON PREPARATION
When a vehicle is not in use for more
than 4 months, proper storage is a ne-
cessity.
If the vehicle is to be dormant for more
than 21 days, disconnect the BLACK (-)
cable of the battery.
Using electrical accessories increases
the risk of discharging the battery. Us-
ing a low amperage trickle charger
is advised when low engine speeds
and/or high electrical demand acces-
sories are installed on a vehicle.
When using your vehicle after storage,
a preparation is required.
See an authorized Can-Am dealer, re-
pair shop, or person of your own choos-
ing to have your vehicle prepared for
either storage or the preseason.
126 ______________
TECHNICAL
INFORMATION
______________ 127
VEHICLE IDENTIFICATION
The main components of your vehicle Compliance Label
(engine and frame) are identified by
different serial numbers. It may some- Regulation (EU) 2016/1628
times become necessary to locate applicable for Non-Road Mobile
these numbers for warranty purposes Machineries
or to trace your vehicle in the event Vehicles who comply to Regulation
of loss. These numbers are required (EU) 2016/1628 (NRMM) are identified
by the authorized Can-Am dealer to on the engine valve cover.
complete warranty claims properly.
We strongly recommend that you take NOTE: Only the vehicles who have an
note of all the serial numbers on your intercooler are NRMM certified.
vehicle and supply them to your insur-
ance company.
Vehicle Identification
Number
219001949-700_a
TYPICAL
Rotax
# M#######
704902366 Production date: MM-YYYY
TYPICAL — VEHICLE SERIAL NUMBER Family type: ######
LABEL BEHIND PASSENGER SEAT 7469 e13 AT1/P V-####
EN-704907469-DEC
Engine Identification TYPICAL NRMM IDENTIFICATION
Number
Radio Frequency Digitally
Encoded Security System
(RF D.E.S.S. key)
This device complies with FCC Part 15
and Industry Canada license exempt
RSS standard(s). Operation is subject
to the following two conditions: (1) this
device may not cause interference,
and (2) this device must accept any in-
terference, including interference that
219001761-140_a may cause undesired operation of the
TYPICAL — ENGINE SERIAL NUMBER
device.
LABEL
1. EIN (Engine Identification Number)
128 ______________
VEHICLE IDENTIFICATION
Changes or modifications not ex-

pressly approved by the party respon-
sible for compliance could void the
user’s authority to operate the equip-
ment.
IC Registration Number: 12006A-
M01456
FCC ID: 2ACERM01456
We, the party responsible for compli-
ance, declare under our sole respon-
sibility that the device is in confor-
mity with the provisions of the follow-
ing Council Directive: 2014/53/EU.
To which this declaration relates is
in conformity with the essential re-
quirements and other relevant require-
ments. The product is in conformity
with the following directives, har-
monized standards and regulations:
Radio Equipment Directive (RED)
2014/53/EU and Harmonized Stan-
dards: EN 300 330-2, EN 60950-1.
______________ 129
EVAPORATIVE EMISSION CONTROL SYSTEM
California Models with Evaporative Emission Control System
Beginning with the 2018 model-year vehicles, some California models are certi-
fied to meet the CARB (California Air Resources Board) TP-933. These models
are equipped with an evaporative emission control system consisting of a low
permeation fuel tank (LPFT), low permeation fuel lines (LPFL) and an actively
purged carbon canister.
The following statement is required by the CCR (California Code of Regulation): An
add-on or modified part must be compliant with applicable ARB evaporative emis-
sion control standards. A violation of this requirement is punishable by civil and/or
criminal punishment.
130 ______________
NOISE EMISSION CONTROL SYSTEM REGULATION
USA and Canada Only
Tampering with Noise Control System Is Prohibited!
U.S. Federal law and Canadian provincial laws may prohibit the following acts or
the causing there of:
1. The removal or rendering inoperative by any person other than for purposes of
maintenance, repair or replacement of any device or element of design incorpo-
rated into any new vehicle for the purpose of noise control prior to its sale or de-
livery to the ultimate purchaser or while it is in use or
2. The use of the vehicle after such device or element of design has been re-
moved or rendered inoperative by any person.
Among those Acts Presumed to Constitute Tampering Are the Acts Listed Be-
low:
1. Removal or alteration or the puncturing of the mufflers or any engine compo-
nent which conducts removal of engine exhaust gases.
2. Removal or alteration or the puncturing of any part of the intake system.
3. Replacing any moving parts of the vehicle or parts of the exhaust or intake sys-
tem, with parts other than those specified by the manufacturer.
4. Lack of proper maintenance.
______________ 131
The EC-Declaration of Conformity does not appear in this version of the
Operator's Guide.
Please refer to the printed version that was delivered with your vehicle.
ddd2009-001 EN
SPECIFICATIONS
ENGINE
ROTAX® 900 ACE TURBO
/ TURBO R
Engine type 4-stroke, Double Over
Head Camshaft (DOHC),
dry sump,liquid cooled
Number of cylinders 3
12 valves (self adjusting
Number of valves
hydraulic valve lifters)
Bore 74 mm (2.91 in)
Stroke 69.7 mm (2.74 in)
Displacement 899.31 cm³ (54.88 in³)
Maximum HP RPM 7250 RPM
Spark arrester approved
Exhaust system by USDA Forest Service
Catalyst on NRMM models
Donaldson high
Air filter
performance filter
LUBRICATION SYSTEM
Type Dry sump
Replaceable cartridge
Oil filter
oil filter
______________ 133
SPECIFICATIONS
LUBRICATION SYSTEM
Engine oil
Capacity and filter 3.5 L (3.7 qt (U.S. liq.))
replacement
4T 10W50 SYNTHETIC
OIL (EUR) (P/N 779240)
or 4T 5W40 SYNTHETIC
Recommended oil
Scandinavia
BLEND OIL (EUR)
(P/N 779290).
OIL (EUR) (P/N 779286)
Engine oil 4T 10W50 SYNTHETIC
OIL (P/N 779234)
Recommended oil 4T 5W40 SYNTHETIC
All other countries BLEND OIL (P/N 779133)
OIL (P/N 779139)
If not available, use a 5W40
or 10W50 motor oil that
Alternate oil if XPS products are not meets the requirements for
available API service classification
SJ, SL, SM or SN. Refer to
RECOMMENDED OIL
COOLING SYSTEM
Ethyl glycol/water
mix (50%/50%).
Scandinavia: EXTENDED
LIFE PRE-MIXED
COOLANT (P/N 779150)
All other countries:
Type
Coolant EXTENDED LIFE
PRE-MIXED COOLANT
(EUR) (P/N 779223)
or coolant specifically
designed for aluminum
engines
Capacity 4.8 L (1.27 U.S. gal.)
134 ______________
SPECIFICATIONS
ELECTRICAL SYSTEM
Type Maintenance free SLA
Voltage 12 volts
Battery
Nominal rating 18 A•h
Power starter output 1.34 kW
Headlight 2 x 20W LED
Taillight 2 x 3W LED
Signature lights 2 x 2W LED
Refer to FUSES in
Fuses
MAINTENANCE
FUEL SYSTEM
Fuel pump Type Electric (in fuel tank)
Premium unleaded
Type gasoline - Refer to FUEL
REQUIREMENTS
North America 87 (R+M)/2
Minimum
Fuel Octane rating Outside North
92 RON
America
North America 91 (R+M)/2
Recommended
Octane rating Outside North
95 RON
America
Fuel tank capacity ± 40 L (10.6 U.S. gal.)
Fuel remaining when low fuel light turns ON ± 12 L (3.2 U.S. gal.)
______________ 135
SPECIFICATIONS
GEARBOX
Dual range (HI-LO) with
Type
PARK, neutral and reverse
1.25 L (42 U.S. oz) refill
Capacity (1.5 L (51 U.S. oz) when
new)
Scandinavia: 75W140
Gearbox oil SYNTHETIC GEAR OIL
(EUR) (P/N 779215)
Recommended All other countries:
75W140 SYNTHETIC
or a 75W 140 API GL-5
DRIVE SYSTEM
Models with Selectable 2WD / 4WD with
Visco-Lok front Visco-Lok auto-locking front
differential differential, spiral gears
Front drive Selectable 2WD / 4WD
Models with
with Smart-Lok electronic
Smart-Lok front
locking differential, spiral
differential
gears
Front drive ratio 3.6:1
Integrated to transmission,
Rear drive
helical gears
Rear drive ratio 3.43:1
Capacity 400 ml (14 U.S. oz)
Scandinavia:75W90
SYNTHETIC GEAR OIL
(EUR) (P/N 779212)
Front differential oil (Visco-Lok) All other countries:
Recommended
75W90 SYNTHETIC
or synthetic gear oil 75W90
API GL-5
136 ______________
SPECIFICATIONS
DRIVE SYSTEM
Scandinavia:75W90
SYNTHETIC GEAR OIL
(EUR) (P/N 779212)
Front differential oil (Smart-Lok) All other countries:
Recommended
75W90 SYNTHETIC
or synthetic gear oil
75W140 API GL-5
CV JOINT GREASE
CV joint grease (P/N 293 550 062) or
an equivalent
STEERING
Type Rack and pinion
Steering wheel Adjustable tilt steering

Turning radius 528 cm (208 in)
FRONT SUSPENSION
Double suspension arm
Suspension type
with stabilizer bar
Turbo
X ds 508 mm (20 in)
X rc Turbo
Suspension travel
X rs
R
QTY 2
HPG shocks with
Turbo
piggyback reservoir. QS3
X rc Turbo
compression adjustments
X ds
adjustments
X rs
reservoir and bypass, dual
X rc Turbo
speed compression and
R
rebound adjustments
______________ 137
SPECIFICATIONS
REAR SUSPENSION
Torsional Trailing
Suspension-arm
Suspension type
Independent (TTX) with
external stabilizer bar
Turbo
X ds 508 mm (20 in)
X rc Turbo
Suspension travel
X rs
R
QTY 2
HPG shocks with
Turbo piggyback reservoir. QS3†
X rc Turbo compression adjustments
with bottom-out control
Type X ds compression and rebound
adjustments and bottom
out control
X rs
reservoir with bypass, dual
X rc Turbo
speed compression and
R
rebound adjustments
BRAKES
Qty 2
262 mm (10.3 in) ventilated
Front brake brake disc with hydraulic
Type
twin-pistons calipers of
32 mm (1.26 in)
Qty 2
248 mm (9.8 in) ventilated
Rear brake brake disc with hydraulic
Type
twin-pistons calipers of
28 mm (1.1 in)
Type DOT 4
Brake fluid
Caliper Floating
138 ______________
SPECIFICATIONS
BRAKES
Brake pad material Sintered high performance
Minimum brake pad thickness 0.5 mm (.02 in)

Minimum brake disc thickness 4 mm (.157 in)
Maximum brake disc warpage 0.2 mm (.01 in)
TIRES
Loaded above 195 kg
(429.9 lb) : 179 kPa (26 PSI)
27 inches
Loaded up to 195 kg
(429.9 lb) : 193 kPa (28 PSI)
Loaded above 195 kg
(429.9 lb) : 159 kPa (23 PSI)
28 inches
Loaded up to 195 kg
(429.9 lb) : 152 kPa (22 PSI)
Front
Loaded above 195 kg
(429.9 lb) : 138 kPa (20 PSI)
29 inches
Loaded up to 195 kg
(429.9 lb) : 131 kPa (19 PSI)
Loaded above 195 kg
(429.9 lb) : 124 kPa (18 PSI)
30 inches
Loaded up to 195 kg
(429.9 lb) : 117 kPa (17 PSI)
Pressure
Loaded above 195 kg
(429.9 lb) : 179 kPa (26 PSI)
27 inches
Loaded up to 195 kg
(429.9 lb) : 234 kPa (34 PSI)
Loaded above 195 kg
(429.9 lb) : 207 kPa (30 PSI)
28 inches
Loaded up to 195 kg
(429.9 lb) : 152 kPa (22 PSI)
Rear
Loaded above 195 kg
(429.9 lb) : 186 kPa (27 PSI)
29 inches
Loaded up to 195 kg
(429.9 lb) : 138 kPa (20 PSI)
Loaded above 195 kg
(429.9 lb) : 214 kPa (31 PSI)
30 inches
Loaded up to 195 kg
(429.9 lb) : 165 kPa (24 PSI)
______________ 139
SPECIFICATIONS
TIRES
Turbo 28 x 9 x 14 (in)
X ds 29 x 9 x 14 (in)
Front
X rs
30 x 10 x 14 (in)
X rc
Size
Turbo 28 x 11 x 14 (in)
Rear X ds 29 x 11 x 14 (in)
X rs
30 x 10 x 14 (in)
X rc
Minimum tire thread depth 3 mm (.118 in)
WHEELS
Turbo
X rc Cast aluminum wheels
TURBO
Type
X ds
X rs Cast aluminum beadlock
X rc wheels
TURBO R
Front 14 x 7 in
Turbo
14 x 8 in
Rim size X ds
Rear
X rs
14 x 7 in
X rc
CHASSIS
47 mm (1.85 in) diameter,
Cage type high strength steel,
ROPS-approved cage
DIMENSIONS
Turbo
335.3 cm (132 in)
X ds
X rs 337.8 cm (133 in)
Overall length
X rc
R
140 ______________
SPECIFICATIONS
DIMENSIONS
Turbo
162.5 cm (64 in)
X ds
X rs 182.9 cm (72 in)
Overall width
X rc Turbo
169.4 cm (66.7 in)
R
Turbo
166.1 cm (65.4 in)
X ds
X rs 170.2 cm (67 in)
Overall height
X rc Turbo
168.4 cm (66.3 in)
R
Wheelbase 259.1 cm (102 in)
Turbo
136 cm (53.5 in)
X ds
X rs 156.3 cm (61.5 in)
Front
X rc Turbo
159.1 cm (62.6 in)
R
Wheel track
Turbo
133.1 cm (52.4 in)
X ds
X rs 153.4 cm (60.4 in)
Rear
X rc Turbo
156.2 cm (61.5 in)
R
Turbo
X ds 35.6 cm (14 in)
X rc Turbo
Ground clearance
X rs
R
______________ 141
SPECIFICATIONS
LOADING CAPACITY AND WEIGHT

Turbo
666.9 kg (1,470 lb)
Turbo R
X ds 675.9 kg (1,490 lb)
Dry weight X rs 720.9 kg (1,589.4 lb)
X rc Turbo 739.8 kg (1,631 lb)
X rc Turbo
794.2 kg (1,751 lb)
R
Weight distribution (front/rear) 45/55
Total vehicle load allowed (including driver, passengers,
286 kg (630 lb)
all other loads and added accessories)
Turbo 982 kg (2,165 lb)
Turbo R 982 kg (2,165 lb)
X ds 991 kg (2,185 lb)
Gross vehicle weight rating X rs 1 041.4 kg (2,296 lb)
X rc Turbo 1 055.1 kg (2,326 lb)
X rc Turbo
1 109.5 kg (2,446 lb)
R
Cargo rack capacity 90 kg (200 lb)
142 ______________
TROUBLESHOOTING
______________ 143
TROUBLESHOOTING GUIDELINES
CVT BELT IS SLIPPING

1. Water has entered in the CVT.
– Refer to SPECIAL PROCEDURES.
"--" IS DISPLAYED ON THE GEARBOX POSITION DISPLAY

1. Shift lever is between 2 positions.
– Properly position the shift lever in the desired position.
2. Shift lever is not properly adjusted.
– Contact an authorized Can-Am dealer.
3. Electrical communication error.
ENGINE DOES NOT TURN

1. D.E.S.S. key is not installed on D.E.S.S. post.
– Securely install key to D.E.S.S. post.
2. Shift lever is not set on PARK or NEUTRAL.
– Set shift lever to either in PARK or in NEUTRAL or press the brake pedal.
3. Burnt fuse.
– Check fuses.
4. Weak battery or loose connections.
– Check charging system fuse.
– Check fault message in cluster.
– Check battery connections and terminals condition.
– Have the battery checked by an authorized Can-Am dealer.
5. Defective engine start button.
6. Defective starter solenoid.
7. D.E.S.S. key not recognized is displayed in the multifunction gauge.
– Clean D.E.S.S. key.
144 ______________
ENGINE TURNS OVER BUT FAILS TO START

1. Flooded engine (spark plug wet when removed).
– (If the engine does not start and it is fuel-flooded, the drowned mode can be
activated to prevent fuel injection and to cut ignition while cranking. Proceed
as follows:
• Install key on D.E.S.S. post.
• Press completely and HOLD accelerator pedal.
• Press the engine START button.
The engine should be cranked for 10 seconds. Release engine START but-
ton.
Release accelerator pedal and start/crank engine again to allow starting.
If it does not work:
• Remove the spark plugs (tools are supplied in tool kit). Refer to SPARK
PLUGS in MAINTENANCE PROCEDURES.
• Crank engine several times.
• Install new spark plugs if possible or clean and dry spark plugs.
• If engine does not start, seek service from an authorized Can-Am dealer,
repair shop, or person of your own choosing for maintenance, repair, or re-
placement. Please refer to the US EPA EMISSIONS-RELATED WARRANTY
contained herein for information about warranty claims.
2. No fuel to the engine (spark plug dry when removed).

– Check fuel tank level.
– Check fuel pump fuse.
– Obstructed fuel pump pre-filter or fuel pump failure. Seek service from
an authorized Can-Am dealer, repair shop, or person of your own choos-
ing for maintenance, repair, or replacement. Please refer to the US EPA
EMISSIONS-RELATED WARRANTY contained herein for information about
warranty claims.
3. Spark plug/ignition (no spark).
– Check ignition fuse.
– Remove spark plug then reconnect to ignition coil.
– Start engine with spark plug grounded to the engine away from spark plug
hole. If no spark appears, replace spark plug.
– If trouble persists, seek service from an authorized Can-Am dealer, repair
shop, or person of your own choosing for maintenance, repair, or replace-
ment. Please refer to the US EPA EMISSIONS-RELATED WARRANTY
contained herein for information about warranty claims.
ENGINE LACKS ACCELERATION OR POWER

1. Seat belt not buckled properly. Check cluster message.
– Buckle up seat belt.
2. Fouled or damaged spark plug.
– Replace spark plugs.
3. Engine air filter plugged or dirty.
– Check air filter and replace if necessary.
– Check deposits in engine air filter housing.
______________ 145
ENGINE LACKS ACCELERATION OR POWER (cont’d)

4. Water in CVT
– Drain water from CVT. Refer to SPECIAL PROCEDURES.
5. CVT dirty or worn-out.
6. Lack of fuel
– Dirty or clogged fuel pump pre-filter. Seek service from an authorized
Can-Am dealer, repair shop, or person of your own choosing for mainte-
nance, repair, or replacement. Please refer to the US EPA EMISSIONS-RE-
LATED WARRANTY contained herein for information about warranty claims.
7. Engine is in limp home mode.
– Check multifunction gauge display for messages.
– Multifunction gauge CHECK ENGINE indicator lamp is on and display shows
LIMP HOME, seek service from an authorized Can-Am dealer, repair shop,
or person of your own choosing for maintenance, repair, or replacement.
Please refer to the US EPA EMISSIONS-RELATED WARRANTY contained
herein for information about warranty claims.
ENGINE OVERHEATS
1. Low coolant level in cooling system.
– Check coolant level and refill. See MAINTENANCE PROCEDURES. Seek
service from an authorized Can-Am dealer, repair shop, or person of your
own choosing for maintenance, repair, or replacement. Please refer to the
US EPA EMISSIONS-RELATED WARRANTY contained herein for informa-
tion about warranty claims.
2. Cooling fan is not working.
– Ensure cooling fan is not jammed and working properly.
– Check fan fuse. See FUSES in the MAINTENANCE PROCEDURES.
3. Dirty radiators fins.
– Check and clean radiator fins. See MAINTENANCE PROCEDURES.
ENGINE MISFIRE
1. Fouled/damaged/worn spark plug.
– Replace spark plugs as required.
2. Water in fuel.
– Drain fuel system and refill with fresh fuel.
THE RPM INCREASES BUT THE VEHICLE DOES NOT MOVE

1. Water in the CVT.
– Drain water from CVT. See SPECIAL PROCEDURES.
2. CVT dirty or worn-out or belt failure.
146 ______________
PARTIAL OR NO RESPONSE FROM THE ACCELERATOR PEDAL INPUTS (CHECK

ENGINE IS ON AND PPS FAULT MESSAGE IS DISPLAYED)
1. Partial failure of the accelerator pedal sensors (PPS).
– Use the override switch to retrieve accelerator pedal operation. Contact an
authorized Can-Am dealer.
2. Total failure of the accelerator pedal sensors (PPS).
– Use the override switch to bypass the accelerator pedal and increase the en-
gine speed in order to move vehicle. Contact an authorized Can-Am dealer.
______________ 147
MESSAGES IN MULTIFUNCTION GAUGE
If an abnormal engine condition occurs, the following messages can be combined
with a pilot lamp.
MESSAGE DESCRIPTION
D.E.S.S. KEY NOT
D.E.S.S. key requires cleaning.
RECOGNIZED
Indicates that you have used the wrong D.E.S.S. key, use the
BAD KEY
proper key for this vehicle.
All active or previously activated faults that require attention.
CHECK ENGINE
No engine limitation engaged.
Critical faults requiring diagnostic as soon as possible.
LIMP HOME An engine limitation is engaged and/or the engine behavior is
modified.
ECM CRC ERROR Error message from ECM.
TPS FAULT Throttle body fault, generally followed by a Limp Home message.
BRAKE SWITCH
Brake signal fault.
FAULT
ECM NOT
Message displayed when the gauge is unable to identify the ECM.
RECOGNIZED
Check engine pilot light on. Indicates that the DPS (Dynamic
CHECK DPS Power Steering) does not work properly. See an authorized
Can-Am dealer.
Faulty Pedal Position Sensor(s) (PPS). Refer to OVERRIDE
PPS FAULT SWITCH in SECONDARY CONTROLS to drive the vehicle in
the limp home mode.
MANUAL LIMP Confirms the Manual Limp Home is engaged using the Override
HOME Switch in case of a PPS fault.
FUEL SENDER When the fuel sender resistor value is out of range the
RANGE multifunction gauge (analog/digital) will detect it and display the
PERFORMANCE message.
Check engine pilot light on. Indicates that the Smart-Lok does not
CHECK SMARTLOK
work properly. See an authorized Can-Am dealer.
148 ______________
WARRANTY
______________ 149
BRP LIMITED WARRANTY USA AND CANADA: 2019
CAN-AM® SSV
1) SCOPE OF THE LIMITED WARRANTY
Bombardier Recreational Products Inc. (“BRP”)* warrants its 2019 Can-Am
side-by-side vehicles (“SSV”) sold by authorized Can-Am SSV dealers (as here-
inafter defined) in the United States of America (“USA”) and in Canada from
defects in material or workmanship for the period and under the conditions de-
scribed below. This limited warranty will become null and void if: (1) the SSV was
used for racing or any other competitive activity, at any point, even by a previous
owner; or (2) the SSV has been altered or modified in such a way so as to adversely
affect its operation, performance or durability, or has been altered or modified to
change its intended use.
Non-factory installed parts and accessories are not covered under this limited war-
ranty. Please refer to the applicable parts and accessories limited warranty text.
2) LIMITATIONS OF LIABILITY
THIS WARRANTY IS EXPRESSLY GIVEN AND ACCEPTED IN LIEU OF ANY
AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING
WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FIT-
NESS FOR A PARTICULAR PURPOSE. TO THE EXTENT THAT THEY CANNOT
BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION
TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSE-
QUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS
WARRANTY. SOME STATES/ PROVINCES DO NOT ALLOW FOR THE DIS-
CLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A
RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU
SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS
WHICH MAY VARY FROM STATE TO STATE, OR PROVINCE TO PROVINCE.
Neither the distributor, any BRP dealer nor any other person has been authorized
to make any affirmation, representation or warranty regarding the product, other
than those contained in this limited warranty, and if made, shall not be enforceable
against BRP. BRP reserves the right to modify this limited warranty at any time, be-
ing understood that such modification will not alter the warranty conditions appli-
cable to the products sold while this warranty is in effect.
3) EXCLUSIONS – ARE NOT WARRANTED

The following are not warranted under any circumstances:
– Normal wear and tear;
– Routine maintenance items, tune ups, adjustments;
– Damage caused by failure to provide proper maintenance and/or storage, as de-
scribed in the Operator's Guide;
– Damage resulting from removal of parts, improper repairs, service, mainte-
nance, modifications or use of parts not manufactured or approved by BRP
or resulting from repairs done by a person that is not an authorized servicing
Can-Am SSV dealer;
– Damage caused by abuse, abnormal use, neglect or operation of the product
in a manner inconsistent with the recommended operation described in the
Can-Am SSV Operator’s Guide;
150 ______________
– Damage resulting from accident, submersion, fire, theft, vandalism or any act of
God;
– Operation with fuels, oils or lubricants which are not suitable for use with the
product (see the Operator’s Guide);
– Damages from rust, corrosion or exposure to the elements;
– Damage resulting from water or snow ingestion;
– Incidental or consequential damages, or damages of any kind including without
limitation towing, storage, telephone, rental, taxi, inconvenience, insurance
coverage, loan payments, loss of time, loss of income.
4) WARRANTY COVERAGE PERIOD

This limited warranty will be in effect from (1) the date of delivery to the first retail
consumer or (2) the date the product is first put into use, whichever occurs first and
for the following period:
– SIX (6) CONSECUTIVE MONTHS, for private use or commercial use owners.
– For emission-related components; please also refer to the US EPA Emission-re-
lated warranty contained herein.
– For evaporative emission-related components of California models equipped
with evaporative emission control system produced by BRP for sale in the
State of California that are originally sold to a resident or subsequently warranty
registered to a resident in the State of California, please also refer to the CAL-
IFORNIA EVAPORATIVE EMISSIONS CONTROL WARRANTY STATEMENT
contained herein.
The repair or replacement of parts or the performance of service under this war-
ranty does not extend the life of this warranty beyond its original expiration date.
5) CONDITIONS TO HAVE WARRANTY COVERAGE

This warranty coverage is available only if each of the following conditions has
been fulfilled:
– The 2019 Can-Am SSV must be purchased as new and unused by its first owner
from a Can-Am SSV dealer authorized to distribute Can-Am SSV's in the country
in which the sale occurred (“Can-Am SSV dealer”);
– The BRP specified pre-delivery inspection process must be completed and doc-
umented and signed by the purchaser;
– The 2019 Can-Am SSV must have undergone proper registration by an autho-
rized Can-Am SSV dealer;
– The 2019 Can-Am SSV must be purchased in the country in which the purchaser
resides;
– Routine maintenance outlined in the Operator’s Guide must be timely per-
formed in order to maintain warranty coverage. BRP reserves the right to make
warranty coverage contingent upon proof of proper maintenance.
BRP will not honor this limited warranty to any private use owner or commercial
use owner if one of the preceding conditions has not been met. Such limitations
are necessary in order to allow BRP to preserve both the safety of its products,
and also that of its consumers and the general public.
______________ 151
6) WHAT TO DO TO OBTAIN WARRANTY COVERAGE
The customer must cease using the SSV upon the appearance of an anomaly.
The customer must notify a servicing BRP dealer within three (3) days of the
appearance of a defect, and provide it with reasonable access to the product and
reasonable opportunity to repair it. The customer must also present to the autho-
rized BRP dealer, proof of purchase of the product and must sign the repair/work
order prior to starting the repair in order to validate the warranty repair. All parts
replaced under this limited warranty become the property of BRP.
7) WHAT BRP WILL DO

BRP’s obligations under this warranty are limited to, at its sole discretion, repairing
parts found defective under normal use, maintenance and service, or replacing
such parts with new genuine Can-Am SSV parts without charge for parts and
labor, at any authorized BRP dealer during the warranty coverage period under the
conditions described herein. BRP's responsibility is limited to making the required
repairs or replacements of parts. No claim of breach of warranty shall be cause for
cancellation or rescission of the sale of the SSV to the owner.
In the event that service is required outside of the country of original sale, the
owner will bear responsibility for any additional charges due to local practices
and conditions, such as, but not limited to, freight, insurance, taxes, license fees,
import duties, and any and all other financial charges, including those levied by
governments, states, territories and their respective agencies.
BRP reserves the right to improve or modify products from time to time without as-
suming any obligation to modify products previously manufactured.
8) ADDITIONAL SUPPLIER WARRANTIES

A GPS receiver may be supplied by BRP as standard equipment on certain 2019
Can-Am SSV. The GPS receiver is covered under BRP’s limited warranty policy.
Additional warranty coverage if offered by the GPS receiver “supplier” that is
longer than BRP's limited warranty is to be dealt by the dealer or consumer directly
with the GPS receiver “supplier”.
9) TRANSFER
If the ownership of a product is transferred during the warranty coverage period,
this limited warranty, subject to its terms and conditions, shall also be transferred
and be valid for the remaining coverage period provided BRP or an authorized
Can-Am SSV Distributor/Dealer receives a proof that the former owner agreed to
the transfer of ownership, in addition to the co-ordinates of the new owner.
10) CONSUMER ASSISTANCE

In the event of a controversy or a dispute in connection with this limited warranty,
BRP suggests that you try to resolve the issue at the dealership level. We recom-
mend discussing the issue with the authorized dealer's service manager or owner.
152 ______________
If the matter still remains unresolved, contact BRP by filling out the customer con-
tact form at www.brp.com or contact BRP by mail at one of the addresses listed
under the CONTACT US section of this guide.
* In the USA, products are distributed and serviced by BRP US Inc.

© 2018 Bombardier Recreational Products Inc. All rights reserved.
® Trademark of Bombardier Recreational Products Inc. or its affiliates.
______________ 153
US EPA EMISSION-RELATED WARRANTY
Bombardier Recreational Products Inc. (“BRP”)** warrants to the ultimate pur-
chaser and each subsequent purchaser that this new engine, including all parts of
its exhaust emission control system and its evaporative emission control system,
meets two conditions:
1. It is designed, built, and equipped so it conforms at the time of sale to the ulti-
mate purchaser with the requirements of 40 CFR 1051 and 40 CFR 1060.
2. It is free from defects in materials and workmanship that may keep it from
meeting the requirements of 40 CFR 1051 and 40 CFR 1060.
Where a warrantable condition exists, BRP will repair or replace, as it elects, any
part or component with a defect in materials or workmanship that would increase
the engine’s emissions of any regulated pollutant within the stated warranty
period at no cost to the owner, including expenses related to diagnosing and
repairing or replacing emission-related parts. All defective parts replaced under
this warranty become the property of BRP.
For all emission-related warranty claims, BRP is limiting the diagnosis and repair of
emission-related parts to the authorized Can-Am dealers, unless for emergency re-
pairs as required by item 2 of the following list.
As a certifying manufacturer, BRP will not deny emission-related warranty claims
based on any of the following:
1. Maintenance or other service BRP or BRP's authorized facilities performed.
2. Engine/equipment repair work that an operator performed to correct an unsafe,
emergency condition attributable to BRP as long as the operator tries to restore
the engine/equipment to its proper configuration as soon as possible.
3. Any action or inaction by the operator unrelated to the warranty claim.
4. Maintenance that was performed more frequently than BRP specify.
5. Anything that is BRP fault or responsibility.
6. The use of any fuel that is commonly available where the equipment operates
unless BRP written maintenance instructions state that this fuel would harm
the equipment’s emission control system and operators can readily find the
proper fuel. See maintenance information section and fuel requirements of
fueling section.
Emission-Related Warranty Period

The emission-related warranty is valid for the following period whichever comes
first:
HOURS MONTHS KILOMETERS
Exhaust emission-related components 500 30 5000
Evaporative emission-related components N/A 24 N/A
154 ______________
Components Covered
The emission-related warranty covers all components whose failure would in-
crease an engine’s emissions of any regulated pollutant, including the following
listed components:
1. For exhaust emissions, emission-related components include any engine parts
related to the following systems:
– Air-induction system
– Fuel system
– Ignition system
– Exhaust gas recirculation systems
2. The following parts are also considered emission-related components for
exhaust emissions:
– Aftertreatment devices
– Crankcase ventilation valves
– Sensors
– Electronic control units
3. The following parts are considered emission-related components for evapora-
tive emissions:
– Fuel tank
– Fuel cap
– Fuel line
– Fuel line fittings
– Clamps*
– Pressure relief valves*
– Control valves*
– Control solenoids*
– Electronic controls*
– Vacuum control diaphragms*
– Control cables*
– Control linkages*
– Purge valves
– Vapor hoses
– Liquid/vapor separator
– Carbon canister
– Canister mounting brackets
– Carburetor purge port connector
4. Emission-related components also include any other part whose only purpose
is to reduce emissions or whose failure will increase emissions without signifi-
cantly degrading engine/equipment performance.
*As related to the evaporative emission control system
______________ 155
Limited Applicability
As a certifying manufacturer, BRP may deny emission-related warranty claims
for failures that have been caused by the owner’s or operator’s improper main-
tenance or use, by accidents for which the manufacturer has no responsibility,
or by acts of God. For example, an emission-related warranty claim need not be
honored for failures that have been directly caused by the operator’s abuse of the
engine/equipment or the operator’s use of the engine/equipment in a manner for
which it was not designed and are not attributable to the manufacturer in any way.
If you have any question regarding your warranty rights and responsibility, you
should contact Bombardier Recreational Products at 1-888-272-9222.
** In the USA, products are distributed and serviced by BRP US Inc.
156 ______________
CALIFORNIA EVAPORATIVE EMISSIONS CONTROL
WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board is pleased to explain the evaporative emissions
control system warranty on your 2019 Off-Road Sport Vehicle. In California, new
off-highway recreational vehicles must be designed, built, and equipped to meet
the State’s stringent anti-smog standards. Bombardier Recreational Products
Inc. (“BRP”)** must warrant the evaporative emissions control system on your
Off-Road Sport Vehicle for the periods of time listed below provided there has
been no abuse, neglect, improper maintenance, or unapproved modification of
your Off-Road Sport Vehicle.
Your evaporative emissions control system may include parts such as the carbu-
retor or fuel-injection system, fuel tank, fuel hoses, carbon canister, and engine
computer. Also included may be hoses, belts, connectors and other evaporative
emissions-related assemblies. Where a warrantable condition exists, Bombardier
Recreational Products Inc. will repair your Off-Road Sport Vehicle at no cost to
you including diagnosis, parts and labor.
OHRV MANUFACTURER’S WARRANTY COVERAGE

The warranty period for this OHRV is 60 months, or 5000 miles, or 500 hours,
whichever comes first.
Parts covered:
– Canister Mounting Bracket(s)
– Carbon Canister
– Purge Port Connector
– Clamp(s)*
– Electronic Control*
– Fuel Cap
– Filler Neck
– Filler Neck Hose
– Fuel Line(s)
– Fuel Line Fitting(s)
– Fuel Tank
– Pressure Relief Valve(s)*
– Purge Valve(s)
– Check Valve(s)*
– Vapor Hose(s)
– Flow Reducer
– Filter(s)*
– All other parts not listed that may affect the evaporative emissions control sys-
tem
If any evaporative emissions-related part on your Off-Road Sport Vehicle is defec-
tive the part will be repaired or replaced by Bombardier Recreational Products Inc.
______________ 157
OWNER’S WARRANTY RESPONSIBILITIES
As the Off-Road Sport Vehicle owner you are responsible for the performance of
the required maintenance listed in your owner’s manual. Bombardier Recreational
Products Inc. recommends that you retain all receipts covering maintenance on
your Off-Road Sport Vehicle, but Bombardier Recreational Products Inc. cannot
deny warranty solely for the lack of receipts or for failure to ensure the perfor-
mance of a scheduled maintenance.
As an owner you are responsible for presenting your Off-Road Sport Vehicle to a
Bombardier Recreational Products Inc. dealer as soon as a problem exists. The
warranty repairs should be completed in a reasonable time, not to exceed 30 days.
As an Off-Road Sport Vehicle owner, you should also be aware that Bombardier
Recreational Products Inc. may deny you warranty coverage if your Off-Road
Sport Vehicle or a part has failed due to abuse, neglect, improper maintenance or
unapproved modifications.
If you have any questions regarding your warranty rights and responsibilities, you
should contact Bombardier Recreational Products Inc. at 1-888-272-9222 or the
California Air Resources Board at 9528 Telstar Avenue, El Monte, CA 91731.
*As related to the evaporative emission control system

** In the USA, products are distributed and serviced by BRP US Inc.
158 ______________
BRP INTERNATIONAL LIMITED WARRANTY: 2019
CAN-AM® SSV
SSV sold by Can-Am SSV distributors or dealers authorized by BRP to distribute
Can-Am SSVs ("Can-Am SSV Distributor/Dealer") outside of the fifty United States,
Canada, member states of the European Economic Area (which is comprised
of the states of the European Union plus Norway, Iceland and Liechtenstein)
(“EEA”), member states of the Commonwealth of the Independent States (in-
cluding Ukraine and Turkmenistan) (“CIS”) and Turkey, from defects in material or
workmanship for the period and under the conditions described below.
This limited warranty will become null and void if: (1) The SSV was used for racing
or any other competitive activity, at any point, even by a previous owner; or (2)
the SSV has been altered or modified in such a way so as to adversely affect its
operation, performance or durability, or has been altered or modified to change its
intended use.
TO THE EXTENT PERMITTED BY LAW, THIS WARRANTY IS EXPRESSLY
GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EX-
PRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. TO THE
EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES
ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY.
INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM
COVERAGE UNDER THIS WARRANTY. SOME JURISDICTIONS DO NOT AL-
LOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED
ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY
GIVES YOU SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH MAY VARY FROM COUNTRY TO COUNTRY. (FOR PROD-
UCTS PURCHASED IN AUSTRALIA SEE CLAUSE 4 BELOW).
Neither the Can-Am SSV Distributor/Dealer nor any other person has been autho-
rized to make any affirmation, representation or warranty regarding the product,
other than those contained in this limited warranty, and if made, shall not be
enforceable against BRP.
BRP reserves the right to modify this warranty at any time, being understood that
such modification will not alter the warranty conditions applicable to the products
sold while this warranty is in effect.
3) EXCLUSIONS ARE NOT WARRANTED

The following are not warranted under this limited warranty under any circum-
stances:
– Routine maintenance items, tune ups, adjustments (parts and labor);
– Damage caused by negligence or failure to provide proper maintenance and/or
storage, as described in the Operator's Guide;
______________ 159
Can-Am SSV Distributor/Dealer;
– Damage caused by abuse, abnormal use, neglect or operation of the product in
a manner inconsistent with the recommended operation described in the Oper-
ator’s Guide;
– Damage resulting from accident, submersion, fire, theft, vandalism or any act of
God;
– Damage resulting from rust, corrosion or exposure to the elements;
– Damage resulting from water or snow ingestion;
limitation towing, transportation expenses, storage, telephone, rental, taxi, in-
convenience, insurance coverage, loan payments, loss of time, loss of income
or time missed for downtime experience due to service work.

This warranty will be in effect from (1) the date of delivery to the first retail con-
sumer or (2) the date the product is first put into use, whichever occurs first and
for a period of:
– SIX (6) CONSECUTIVE MONTHS for private use or commercial use.
FOR PRODUCTS SOLD IN AUSTRALIA ONLY

Nothing in these Warranty terms and conditions should be taken to exclude,
restrict or modify the application of any condition, warranty, guarantee, right or
remedy conferred or implied under the Competition and Consumer Act 2010
(Cth), including the Australian Consumer Law or any other law, where to do so
would contravene that law, or cause any part of these terms and conditions to be
void. The benefits given to you under this limited warranty hereto are in addition
to other rights and remedies that you have under Australian law.
Our goods come with guarantees that cannot be excluded under the Australian
Consumer Law. You are entitled to a replacement or refund for a major failure
and for compensation for any other reasonably foreseeable loss or damage. You
are also entitled to have the goods repaired or replaced if the goods fail to be of
acceptable quality and the failure does not amount to a major failure.

been fulfilled:
from a Can-Am SSV Distributor/Dealer authorized to distribute Can-Am SSVs in
the country in which the sale occurred;
umented;
160 ______________
– The product must have undergone proper registration by an authorized Can-Am
SSV Distributor/Dealer;
– The 2019 Can-Am SSV must be purchased in the country or union of countries
in which the purchaser resides; and

The customer must cease using the SSV upon the appearance of an anomaly. The
customer must notify a servicing Can-Am SSV Distributor/Dealer within two (2)
days of the appearance of a defect, and provide it with reasonable access to the
product and reasonable opportunity to repair it. The customer must also present
to the authorized Can-Am SSV Distributor/Dealer proof of purchase of the product
and must sign the repair/work order prior to starting the repair in order to validate
the warranty repair. All parts replaced under this limited warranty become the
property of BRP.
Note that the notification period is subject to the applicable national or local legisla-
tion in customer's country.
7) WHAT BRP WILL DO

To the extent permitted by law, BRP’s obligations under this warranty are limited
to, at its sole discretion, repairing parts found defective under normal use, mainte-
nance and service; or replacing such parts with new genuine Can-Am SSV parts
without charge for parts and labour, at any authorized Can-Am SSV Distributor/
Dealer during the warranty coverage period under the conditions described herein.
BRP's responsibility is limited to making the required repairs or replacements of
parts. No claim of breach of warranty shall be cause for cancellation or rescission
of the sale of the Can-Am SSV to the owner. You may have other legal rights which
may vary from country to country.
In the event that service is required outside of the country of original sale, the
owner will bear responsibility for any additional charges due to local practices
and conditions, such as, but not limited to, freight, insurance, taxes, license fees,
import duties, and any and all other financial charges, including those levied by
governments, states, territories and their respective agencies.
8) TRANSFER
this limited warranty, subject to its terms and conditions, shall also be transferred
and be valid for the remaining coverage period provided BRP or an authorized
Can-Am SSV Distributor/Dealer receives a proof that the former owner agreed to
the transfer of ownership, in addition to the coordinates of the new owner.
______________ 161
9) CONSUMER ASSISTANCE
In the event of a controversy or a dispute in connection with this limited warranty,
BRP suggests that you try to resolve the issue at the Can-Am SSV Distribu-
tor/Dealer level. We recommend discussing the issue with the authorized
Can-Am SSV Distributor/Dealer's service manager or owner.
If the matter still remains unresolved, contact BRP by filling out the customer con-
tact form at www.brp.com or contact BRP by mail at one of the addresses listed
under the CONTACT US section of this guide.
* For the territory covered by this limited warranty, products are distributed and serviced by
Bombardier Recreational Products Inc. or its affiliates.
© 2018 Bombardier Recreational Products Inc. All rights reserved.
® Trademark of Bombardier Recreational Products Inc. or its affiliates.
162 ______________
BRP LIMITED WARRANTY FOR THE EUROPEAN
ECONOMIC AREA, THE COMMONWEALTH OF
THE INDEPENDANT STATES AND TURKEY: 2019
CAN-AM® SSV
SSVs sold by Can-Am SSV distributors or dealers authorized by BRP to distribute
Can-Am SSVs (“Can-Am SSV Distributor/Dealer”).in member states of the Euro-
pean Economic Area (which is comprised of the member states of the European
Union plus Norway, Iceland and Liechtenstein) (“EEA”), in member states of the
Commonwealth of the Independent States (including Ukraine and Turkmenistan)
(“CIS”) and Turkey from defects in material or workmanship for the period and
under the conditions described below.
This limited warranty will become null and void if: (1) The SSV was used for racing
or any other competitive activity, at any point, even by a previous owner; or (2)
the SSV has been altered or modified in such a way so as to adversely affect its
operation, performance or durability, or has been altered or modified to change its
intended use.
TO THE EXTENT PERMITTED BY LAW, THIS WARRANTY IS EXPRESSLY
GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EX-
PRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. TO THE
EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES
ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY.
INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM
COVERAGE UNDER THIS WARRANTY. SOME JURISDICTIONS DO NOT AL-
LOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED
ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY
GIVES YOU SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH MAY VARY FROM COUNTRY TO COUNTRY.
Neither the Can-Am SSV Distributor/Dealer nor any other person has been autho-
rized to make any affirmation, representation or warranty regarding the product,
other than those contained in this limited warranty, and if made, shall not be
enforceable against BRP.
BRP reserves the right to modify this warranty at any time, being understood that
such modification will not alter the warranty conditions applicable to the products
sold while this warranty is in effect.
3) EXCLUSIONS – ARE NOT WARRANTED

The following are not warranted under this limited warranty under any circum-
stances:
– Routine maintenance items, tune ups, adjustments (parts and labor);
______________ 163
– Damage caused by negligence or failure to provide proper maintenance and/or
storage, as described in the Operator's Guide;
Can-Am SSV Distributor/Dealer;
– Damage caused by abuse, abnormal use, neglect or operation of the product in
a manner inconsistent with the recommended operation described in the Oper-
ator’s Guide;
– Damage resulting from accident, submersion, fire, snow or water ingestion,
theft, vandalism or any act of God;
– Damage resulting from rust, corrosion or exposure to the elements;
limitation towing, transportation expenses, storage, telephone, rental, taxi, in-
convenience, insurance coverage, loan payments, loss of time, loss of income
or time missed for downtime experience due to service work.

This warranty will be in effect from (1) the date of delivery to the first retail con-
sumer or (2) the date the product is first put into use, whichever occurs first and
for a period of:
– TWENTY-FOUR (24) CONSECUTIVE MONTHS for private use.
– SIX (6) CONSECUTIVE MONTHS for commercial use or rental use.
The product is used commercially when it is used in connection with any work or
employment that generates income during any part of the warranty period. The
product is also used commercially when, at any point during the warranty period,
it is licensed for commercial use.
Note that the duration and any other modalities of the warranty coverage are sub-
ject to the applicable national or local legislation in your country.

been fulfilled:
from a Can-Am SSV Distributor/Dealer authorized to distribute Can-Am SSVs in
the country in which the sale occurred;
umented;
– The product must have undergone proper registration by an authorized Can-Am
SSV Distributor/Dealer;
164 ______________
– The 2019 Can-Am SSV must be purchased in the country or union of countries
in which the purchaser resides; and

The customer must cease using the SSV upon the appearance of an anomaly. The
customer must notify a servicing Can-Am SSV Distributor/Dealer within two (2)
months of the appearance of a defect and provide it with reasonable access to the
product and reasonable opportunity to repair it. The customer must also present
to the authorized Can-Am SSV Distributor/Dealer, proof of purchase of the product
and must sign the repair/work order prior to starting the repair in order to validate
the warranty repair. All parts replaced under this limited warranty become the
property of BRP.
Note that the notification period is subject to the applicable national or local legisla-
tion in your country.
7) WHAT BRP WILL DO

To the extent permitted by law, BRP’s obligations under this warranty are limited
to, at its sole discretion, repairing parts found defective under normal use, mainte-
nance and service, or replacing such parts with new genuine Can-Am SSV parts
without charge for parts and labor, at any authorized Can-Am SSV Distributor/
Dealer during the warranty coverage period under the conditions described herein.
BRP's responsibility is limited to making the required repairs or replacements of
parts. No claim of breach of warranty shall be cause for cancellation or rescission
of the sale of the Can-Am SSV to the owner. You may have other legal rights which
may vary from country to country.
In the event that service is required outside of the EEA, the owner will bear respon-
sibility for any additional charges due to local practices and conditions, such as, but
not limited to, freight, insurance, taxes, license fees, import duties, and any and all
other financial charges, including those levied by governments, states, territories
and their respective agencies.
8) TRANSFER
this warranty shall also be transferred and be valid for the remaining coverage
period provided BRP or an authorized Can-Am SSV Distributor/Dealer receives a
proof that the former owner agreed to the transfer of ownership, in addition to the
co-ordinates of the new owner.
______________ 165
166 ______________
______________ 167
This page is
intentionally blank
168 ______________
CUSTOMER
INFORMATION
______________ 169
170 ______________
______________ 171
172 ______________
CHANGE OF ADDRESS/OWNERSHIP
______________ 173
This page is
intentionally blank
174 ______________
______________ 175
176 ______________
WARNING
To reduce risk of serious injury or death, read this
Operator’s Guide and safety labels, watch the safety
video and:
2019
Be prepared
• Fasten seat belts and make sure nets and/or doors
are securely latched in place.
• Each rider must be able to sit with back against
seat, foot flat on the floor or on footrest, and hands
on steering wheel or handholds. Stay completely
Operator’s
inside the vehicle.
Drive responsibly
• Avoid loss of control and rollovers.
Guide
• Avoid abrupt maneuvers, sideways sliding, skidding
or fishtailing and never do donuts.
• Avoid hard acceleration when turning, even from
MAVERICK Series
Includes
a stop.
• Slow down before entering a turn.
• Plan for hills, rough terrain, ruts and other changes Safety, Vehicle
in traction and terrain.
• Avoid paved surfaces. and Maintenance Information
• Avoid side hilling (riding across slopes).
Be Qualified and Responsible

• Driver must be at least 16 years old with a valid
driver's license.
• Do not operate after using drugs or alcohol.
• Do not allow operation on public roads (unless
designated for off-highway vehicle access) –
collisions with cars and trucks can occur.
• Do not exceed vehicle seating capacity.
MAVERICKTM Series
WARNING
Read this guide thoroughly. It contains important safety information.
Minimum age: Operator: 16 or older with a valid driver's license. Keep this Operator’s Guide in the vehicle.
219 001 949 The removal or modification of evaporative emission-related parts on this OHRV is illegal.
OPERATOR’S GUIDE MAVERICK Series / ENGLISH Violators may be subject to civil and/or criminal penalties under California and federal law.
GUIDE DU CONDUCTEUR Série MAVERICK / ANGLAIS
2019
FAIT AU / MADE IN CANADA U/M:P.C.
2 1 9 0 0 1 9 4 9 Original Instructions

Can-Am 2019 Maverick x3 Turbo Service Manual Electronic Version

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Can-Am 2019 Maverick x3 Turbo Service Manual Electronic Version

Uploaded by

Copyright:

Available Formats

SAFETY NOTICE

NOTICE Indicates an instruction which, if not

equipment and taking all necessary safety precau-

We have provided you with some of the most

NUMBER (VIN) TYPICAL — ENGINE SERIAL NUMBER LABEL

TYPICAL — VEHICLE IDENTIFICATION NUMBER LABEL

Lift front of vehicle and install a jack stand on each

LIFTING THE VEHICLE WITH A

Lower hydraulic lift and ensure vehicle is sup-

WARNING 6. Strap the rear tires by using tire towing straps.

MANUAL INFORMATION MANUAL LAYOUT

This manual uses technical terms which may be

Section 06 ENGINE Page heading

Subsection title MAGNETO

Loctite 243 Drop represents a

Bold face number

Document number for 55 Page number

NOTICE Pay attention to torque specifications.

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

Bold face number following part

4.8 8.8 9.8 10.9 12.9

FASTENER FASTENER GRADE/TORQUE

FASTENER INFORMATION Threadlocker Application for

1. Clean threads (bolt and nut) with solvent.

1. Clean threads (bolt and hole) with solvent.

Threadlocker Application for Stud

1. Adjust screw to proper setting.

NOTE: If it is difficult to readjust, heat screw with Gasket Compound Application

Application for Stripped Thread Repair 1 2

3. Apply a strip of proper strength Loctite on lead-

Threadlocker Application for Case-In

1. Clean inner housing diameter and outer gasket

PERIODIC MAINTENANCE SCHEDULE

SEVERE DUSTY CONDITIONS

MAINTENANCE SCHEDULE LEGEND

Replace engine oil and filter

Verify fuel pump pressure (idle and wide open throttle)

EVERY 5 YEAR OR 12 000 KM (8,000 MI) (whichever comes first)

GENERAL Removing the Air Filter

Remove the seat backrest. CAUTION Never perform this operation

Remove the filter cartridge.

Inspect air filter housing for cleanliness. 1. Retaining screws

Installing the Engine Air Filter X mr model

NOTICE Use a soft brush and be careful to

1. Start engine and let it idle for at least 20 sec-

NOTE: Do not overfill. Wipe off any spillage.

Replace oil filter. Refer to REPLACING THE EN-

After filling, check the oil level, refer to VERIFYING

1. Oil filter cover

Removing the Oil Filter

Allow oil to drain completely from the crankcase.

30 N•m ± 3 N•m Installing the Oil Filter

Verifying the Engine Coolant Level

1. Place vehicle on a level surface.

NOTICE Pay attention to avoid pinching the

10 N•m ± 1 N•m LIFTING REAR OF SERVICE COVER

Wipe off any oil spillage on engine.

5. Add coolant in system as necessary. Use a fun-

Checking the Engine Coolant Specific

1. Lift the rear of the vehicle approximately 30 cm

6. Wait until the coolant flow stops or decreases.

9. Fill cooling system with coolant, refer to

1. Lower radiator hose

4. Slowly detach hose from radiator.