2004 2005 Bombardier Outlander 330 400 SM 03740 (1) 4 ROUES A STEPH

2004
Shop Manual
OUTLANDERTM
330-HO
2x4/4x4
400-HO
2x4/4x4/XT
MAX/MAX XT
Legal deposit:
National Library of Québec
4th trimester 2003
National Library of Canada 2003
All rights reserved. No parts of this manual may be reproduced in any
form without the prior written permission of Bombardier Inc.
©Bombardier Inc. 2003
Technical Publications
Bombardier Inc.
Valcourt (Quebec) Canada
Printed in Canada
® Registered trademarks of Bombardier Inc.
TM Trademarks of Bombardier Inc.
This document contains the registered trademarks of the following companies:

Loctite ® is a registered trademark of Loctite Corporation
Molykote ® is a registered trademark of Dow Corning Corporation
Snap-on ® is a registered trademark of Snap-on Tools Corporation
TABLE OF CONTENTS
SECTION SUBSECTION PAGE
SAFETY NOTICE ................................................................................................................................... III
INTRODUCTION .................................................................................................................................. IV
01 SERVICE TOOLS AND 01 – Table of contents...................................................................... 01-01-1

SERVICE PRODUCTS 02 – Service tools............................................................................. 01-02-1
03 – Service products....................................................................... 01-03-1
02 MAINTENANCE 01 – Table of contents...................................................................... 02-01-1

02 – Maintenance chart.................................................................... 02-02-1
03 – Maintenance procedures.......................................................... 02-03-1
04 – Storage/preseason preparation ................................................ 02-04-1
03 ENGINE 01 – Table of contents...................................................................... 03-01-1

02 – Troubleshooting........................................................................ 03-02-1
03 – Leak test................................................................................... 03-03-1
04 – Removal and installation........................................................... 03-04-1
05 – Cooling system......................................................................... 03-05-1
06 – Rewind starter.......................................................................... 03-06-1
07 – Magneto system ...................................................................... 03-07-1
08 – Lubrication system ................................................................... 03-08-1
09 – Cylinder and head..................................................................... 03-09-1
10 – Crankshaft/Balancer shaft ........................................................ 03-10-1
11 – Gearbox .................................................................................... 03-11-1
12 – CVT........................................................................................... 03-12-1
04 FUEL SYSTEM 01 – Table of contents...................................................................... 04-01-1

02 – Fuel circuit ................................................................................ 04-02-1
03 – Carburetor ................................................................................ 04-03-1
04 – Air intake silencer ..................................................................... 04-04-1
05 ELECTRICAL 01 – Table of contents...................................................................... 05-01-1

02 – Overview .................................................................................. 05-02-1
03 – Charging system ...................................................................... 05-03-1
04 – Starting system ........................................................................ 05-04-1
05 – Ignition system......................................................................... 05-05-1
06 – Instruments and accessories ................................................... 05-06-1
06 DRIVE TRAIN 01 – Table of contents...................................................................... 06-01-1

02 – Front drive ................................................................................ 06-02-1
03 – Rear drive ................................................................................ 06-03-1
07 STEERING SYSTEM 01 – Table of contents...................................................................... 07-01-1

02 – Steering system ....................................................................... 07-02-1
08 SUSPENSION 01 – Table of contents...................................................................... 08-01-1

02 – Front suspension...................................................................... 08-02-1
03 – Rear suspension....................................................................... 08-03-1
09 BRAKES 01 – Table of contents...................................................................... 09-01-1

02 – Hydraulic brakes ....................................................................... 09-02-1
VMR2004_120_00_02A.FM I
TABLE OF CONTENTS
SECTION SUBSECTION PAGE
10 BODY/FRAME 01 – Table of contents ..................................................................... 10-01-1

02 – Body......................................................................................... 10-02-1
03 – Frame....................................................................................... 10-03-1
11 TECHNICAL DATA 01 – SI metric information guide...................................................... 11-01-1

02 – Outlander 330 .......................................................................... 11-02-1
03 – Outlander 400 .......................................................................... 11-03-1
04 – Outlander MAX ........................................................................ 11-04-1
12 WIRING DIAGRAM 01 – Wiring diagram......................................................................... 12-01-1
II VMR2004_120_00_02A.FM
SAFETY NOTICE
SAFETY NOTICE 0
This manual has been prepared as a guide to correctly service and repair 2004 ATVs.
This edition was primarily published to be used by ATV mechanical technicians who are already familiar
with all service procedures relating to Bombardier made vehicles. Mechanical technicians should attend
continuous training courses given by Bombardier Training Department.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This Shop Manual uses technical terms which may be slightly different from the ones used in Parts Catalog.
It is understood that this manual may be translated into another language. In the event of any discrepancy,
the english version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Service
and Warranty Bulletins may be published to update the content of this manual. Make sure to read and
understand these. It does not include dealer modifications, whether authorized or not by Bombardier,
after manufacturing the product.
In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the
general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas
of the parts.
The use of Bombardier parts is most strongly recommended when considering replacement of any com-
ponent. Dealer and/or distributor assistance should be sought in case of doubt.
The engines and the corresponding components identified in this document should not be utilized on
product(s) other than those mentioned in this document.
This manual emphasizes particular information denoted by the wording and symbols:
 WARNING
Identifies a potentially hazardous situation which, if not avoided, could result in serious injury or death.
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
This information relates to the preparation and use of Bombardier ATV and has been utilized safely and
effectively by Bombardier Inc. However, Bombardier Inc. disclaims liability for all damages and/or injuries
resulting from the improper use of the contents. We strongly recommend that any services be carried
out and/or verified by a highly skilled professional mechanic. It is understood that certain modifications
may render use of the vehicle illegal under existing federal, provincial and state regulations.
 WARNING
Torque wrench tightening specifications must strictly be adhered to.
Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or
replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be
renewed.
VMR2004_120_00_02A.FM III
INTRODUCTION
INTRODUCTION 0
This Shop Manual covers the following Bombardier This shop manual covers the European Community
made 2004 ATVs: models and must be used in conjunction with the
Shop Manual Supplement 2004 Outlander Euro-
Models pean Community.
Outlander TM Outlander TM
North America and International Models European Community Models
330-HO 2x4 (laurentian green)............... 7932 400-HO 4x4 (viper red) ........................... 8108
330-HO 2x4 (viper red) ........................... 7987 400-HO 4x4 (yellow) ............................... 8110
330-HO 2x4 (yellow) ............................... 7986 400-HO XT 4x4 (2-tone).......................... 8139
330-HO 2x4 INTL (viper red) .................. 7969 400-HO XT 4x4 (yellow) ......................... 8111
330-HO 4x4 (camo) ................................. 8101 MAX (yellow) .......................................... 8130
330-HO 4x4 (laurentian green)............... 7931 MAX XT (yellow) .................................... 8112
330-HO 4x4 (viper red) ........................... 7985 TM Trademark of Bombardier Inc.
330-HO 4x4 (yellow) ............................... 7930
330-HO 4x4 INTL (laurentian green)...... 7936 1
400-HO 2x4 (laurentian green)............... 7984
400-HO 2x4 (viper red) ........................... 7966
400-HO 4x4 (camo) ................................. 7978
400-HO 4x4 (laurentian green)............... 7929
400-HO 4x4 (viper red) ........................... 7928
400-HO 4x4 (yellow) ............................... 7964 V06M05A
400-HO 4x4 INTL (viper red) .................. 7933 TYPICAL — VEHICLE SERIAL NUMBER LABEL
1. Model number
400-HO 4x4 INTL (yellow) ...................... 7967
400-HO XT 4x4 (2-tone) .......................... 7982
400-HO XT 4x4 (camo) ........................... 7981
400-HO XT 4x4 (laurentian green) ......... 7980
400-HO XT 4x4 (viper red)...................... 7979
400-HO XT 4x4 (yellow).......................... 7965
400-HO XT 4x4 INTL (2-tone) ................. 8137
400-HO XT 4x4 INTL (yellow)................. 7968
MAX (laurentian green).......................... 7761
MAX (viper red) ...................................... 7759
MAX INTL (viper red) ............................. 7971
MAX XT (laurentian green) .................... 7990
MAX XT (viper red)................................. 7989
MAX XT (yellow)..................................... 7970
MAX XT INTL (yellow)............................ 7974
TM Trademark of Bombardier Inc.
IV VMR2004_120_00_02A.FM
INTRODUCTION
ENGINE AND VEHICLE SERIAL LIST OF ABBREVIATIONS USED

NUMBERS LOCATION IN THIS MANUAL
A ampere
1
amp ampere
A•h ampere-hour
AC alternate current
BDC bottom dead center
BTDC before top dead center
°C degree Celsius
CDI Capacitor discharge ignition
cm centimeter
cm² square centimeter
cm³ cubic centimeter

2
V07A08D
CVT Continuously variable transmission
TYPICAL DC direct current

1. E.I.N. (Engine Identification Number)
2. V.I.N. (Vehicle Identification Number) °F degree Fahrenheit
ARRANGEMENT OF THE fl. oz fluid ounce

MANUAL ft foot
The manual is divided into 12 major sections: GRD ground
01 SERVICE TOOLS AND SERVICE PRODUCTS
hal. halogen
02 MAINTENANCE
I.D. inside diameter
03 ENGINE
04 FUEL SYSTEM IDI induction discharge ignition
05 ELECTRICAL imp. oz imperial ounce
06 DRIVE TRAIN
in inch
07 STEERING SYSTEM
in² square inch
08 SUSPENSION
09 BRAKES in³ cubic inch
10 BODY/FRAME k kilo (thousand)
11 TECHNICAL DATA
kg kilogram
12 WIRING DIAGRAM
km/h kilometer per hour
Each section is divided in various subsections, and
again, each subsection has one or more division. kPa kilo pascal
VMR2004_120_00_02A.FM V
INTRODUCTION
L liter
LH left hand
lb pound
lbf pound (force)
m meter
MAG magneto
Max. maximum
Min. minimum
mL milliliter
mm millimeter
MPH mile per hour
N newton
N.A. not applicable
no. number
00.0 continuity
O.L. overload (open circuit)
O.D. outside diameter
OHC Over head camshaft
OPT optional
oz ounce
P/N part number
PSI pounds per square inch
PTO power take off
RPM revolution per minute
Sp. Gr. specific gravity
TDC top dead center
U.S. oz ounce (United States)
USFD U.S. Forest Service
V volt
Vac volt (alternative current)
VI VMR2004_120_00_02A.FM
INTRODUCTION
This Shop Manual uses technical terms wich may be

slightly different from the ones in the parts catalog.
TYPICAL PAGE Page heading

indicates section
and subsection
detailed.
Section 03 ENGINE
Subsection 04 (REMOVAL AND INSTALLATION)
REMOVAL AND INSTALLATION Subsection title

indicates
beginning of the
26
10 Nm subsection.
21 (89 lbfin)
26
22
11 Nm
(97 lbfin)
5 24
23
6
4 13 Nm
(115 lbfin) Exploded view
19
assists you in
20
identifying parts and
13 Nm 18 related positions.
(115 lbfin) 24 Nm 13 Nm
(18 lbfft) 19 (115 lbfin)
48 Nm
(35 lbfft)
24 Nm
8 (18 lbfft)
24 Nm
(18 lbfft)
10 Nm
Ti ghtening torque (89 lbfin)
nearby fastener. In this 25
13
case, nut must be 24 Nm 11
(18 lbfft) 15
torqued to 1 13 Synthetic
10 Nm or 89 lbfin. grease
Drop represents a
CAUTION: Pay attention 27 14 liquid product to
to torque specifications. 10 Nm
(89 lbfin)
16
Synthetic be applied to
10
Some of these are in 48 Nm
17 grease
a surface.
11
lbfin instead of lbfft. (35 lbfft) 17
24 Nm
Use appropriate torque 2 16 (18 lbfft)
17
wrench. 10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
28 11 24 Nm
9 (18 lbfft)
10 Nm 3 48 Nm
29 (89 lbfin) (35 lbfft)
Illustration V04C0VS
number for
publishing
process.
VMR2001-037_03-04A.FM 03-04-1
Document Bold face number Page numbering system:

number for indicates special 03: ENGINE section
publishing procedure 04: REMOVAL AND INSTALLATION
process. concerning this subsection
part. 1: First page of this subsection
V01A39S
VMR2004_120_00_02A.FM VII
INTRODUCTION
TYPICAL PAGE
Section 03 ENGINE
Subsection 06 (MAGNETO SYSTEM)
Title indicates BEARING STATOR AND TRIGGER COIL

main procedure
to be carried-out. Inspection Removal
Ball bearing no. 10 must rotate freely. Othewise, Remove.
replace it. magneto housing cover no. 7 Bold face number
Removal screw no. 11 and 12 following part
Heat up the magneto housing cover to about
stator with trigger coil no. 13. name refers to
o o
100 C (212 F) for an easy ball bearing removal. 4 3 4 exploded view
1 at beginning of
subsection.
m
R610motr12A
Call-outs for 1. Ball bearing R610motr20A 1 2

above illustration. Installation
1. Stator
2. Stator screws
3. Trigger coil
For installation also heat the magneto housing 4. Trigger coil screws
o o
up to about 100 C (212 F) to put ball bearing in
place. Inspection
Place new ball bearing in freezer for 10 minutes Check stator and trigger coil condition. If damaged
approximately. replace the faulty part.
Reinstall other removed parts in the reverse order. For electrical inspection, refer to CHARGING SYS-
TEM for the stator and IGNITION SYSTEM for the
trigger coil.
Reference to look
up a certain section
and subsection.
In this case it
concerns
IGNITION SYSTEM.
03-06-6 VMR2002_010_03-06A.FM
V01A3AS
VIII VMR2004_120_00_02A.FM
INTRODUCTION
GENERAL INFORMATION
The information and component/system descrip- 1 2
tions contained in this manual are correct at time
of publication. Bombardier Inc. however, main-
tains a policy of continuous improvement of its
products without imposing upon itself any obliga-
tion to install them on products previously manu-
factured.
Due to late changes, there may be some differences
between the manufactured product and the descrip-
tion and/or specifications in this document.
Bombardier Inc. reserves the right at any time to
discontinue or change specifications, designs,
features, models or equipment without incurring
obligation.
ILLUSTRATIONS AND
PROCEDURES
V07A0GA
Illustrations and photos show the typical construc-

1. Left
tion of the different assemblies and, in all cases, 2. Right
may not reproduce all details or the exact shape
of the parts shown; however, they represent parts SELF-LOCKING FASTENERS
that have the same or a similar function. PROCEDURE
CAUTION: Most components in the vehicles are
built with parts dimensioned in the metric sys- The following describes the most common appli-
tem. Most fasteners are metric and must not be cation procedures when working with self-locking
replaced by customary fasteners or vice-versa. fasteners.
Mismatched or incorrect fasteners could cause Use a metal brush or a screwtap to clean the hole
damage to the vehicle or possible personal injury. properly then use a solvent (Methyl-Chloride), let
As many of the procedures in this manual are inter- it sit for 30 minutes and wipe off. The solvent en-
related, we suggest that before undertaking any sures that adhesive works properly.
task, you read and thoroughly understand the entire
section or subsection concerning the procedure. LOCTITE APPLICATION
A number of procedures throughout the book re- PROCEDURE
quire the use of special tools. Before starting any
The following describes the most common appli-
procedure, be sure that you have on hand all re-
cation procedures when working with Loctite
quired tools, or approved equivalents.
products.
The use of RIGHT and LEFT indications in the text,
NOTE: Always use proper strength Loctite prod-
always refers to the driving position (sitting on the
uct as recommended in this Shop Manual.
vehicle).
VMR2004_120_00_02A.FM IX
INTRODUCTION
Threadlocker 1. Clean threads (bolt and hole) with solvent.

Uncovered Holes (bolts and nuts) 2. Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30 sec-
onds.
3. Choose proper strength Loctite threadlocker.
4. Apply several drops along the threaded hole and
1 at the bottom of the hole.
5. Apply several drops on bolt threads.
6. Tighten as required.
Stud in Blind Holes
2 1 3
A00A3LA
2
1. Apply here
2. Do not apply
1. Clean threads (bolt and nut) with solvent.

2. Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
A00A5RA
3. Choose proper strength Loctite threadlocker.

1. On threads
4. Fit bolt in the hole. 2. On threads and in the hole
3. Onto nut threads
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area. 1. Clean threads (stud and hole) with solvent.
6. Position nut and tighten as required. 2. Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
Blind Holes
3. Put several drops of proper strength Loctite
threadlocker on female threads and in hole.
4. Apply several drops of proper strength Loctite
1
on stud threads.
5. Install stud.
2
6. Install cover, etc.
7. Apply drops of proper strength Loctite on un-
covered threads.
8. Tighten nuts as required.
A00A3MA
1. On threads
2. On threads and at the bottom of hole
X VMR2004_120_00_02A.FM
INTRODUCTION
Adjusting Screw NOTE: Retaining compound is always forced out

when applied on shaft.
3. DO NOT use anti-seize Loctite or any similar
2 product.
1 4. No curing period is required.
Mounting in Tandem
1. Apply retaining compound on internal element
bore.
2. Continue to assemble as shown above.
Case-In Components
Metallic Gaskets
A00A3PA
1. Apply here
2. Plunger
1. Adjust screw to proper setting.

2. Apply drops of proper strength Loctite thread-
locker on screw/body contact surfaces.
3. Avoid touching metal with tip of flask.
NOTE: If it is difficult to readjust, heat screw with
a soldering iron (232°C (450°F)).
Mounting on Shaft
Mounting with a Press
A00A3VA 1
1. Proper strength Loctite
1. Clean inner housing diameter and outer gasket

diameter.
2. Spray housing and gasket with Loctite Primer N
(P/N 293 800 041).
1 3. Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
2 NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
3 strength and gap are required.
4. Install according to standard procedure.
A00A3UA
5. Wipe off surplus.
1. Bearing 6. Allow it to cure for 30 minutes.
2. Proper strength Loctite
3. Shaft NOTE: Normally used on worn-out housings to
Standard prevent leaking or sliding.
1. Clean shaft external part and element internal It is generally not necessary to remove gasket
part. compound applied on outer gasket diameter.
2. Apply a strip of proper strength Loctite on shaft
circumference at insert or engagement point.
VMR2004_120_00_02A.FM XI
INTRODUCTION
TIGHTENING TORQUES
Tighten fasteners to torque mentioned in exploded views and text. When they are not specified refer to
following table.The table also gives the metric conversion.
 WARNING
Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking
tab, elastic stop nut, self-locking fasteners, etc.) must be installed or replaced with new ones,
where specified. If the efficiency of a locking device is impaired, it must be renewed.
In order to avoid a poor assembling, tighten screws and bolts in accordance with the following procedure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply the half of the recommended torque value.
CAUTION: Be sure to use the proper tightening torque for the proper strength grade.
NOTE: When possible, always apply torque on the nut.
3. Torque to the recommended torque value.
NOTE: Always torque screws, bolts and/or nuts in a criss-cross sequence.
TIGHTENING STRENGTH GRADE

TORQUE GRADE 5.8 GRADE 8.8 GRADE 10.9 GRADE 12.9
1.5 to 2 N•m 2.5 to 3 N•m 3.5 to 4 N•m 4 to 5 N•m
M4
(13 to 18 lbf•in) (22 to 27 lbf•in) (31 to 35 lbf•in) (35 to 44 lbf•in)
3 to 3.5 N•m 4.5 to 5.5 N•m 7 to 8.5 N•m 8 to 10 N•m
M5
(27 to 31 lbf•in) (40 to 47 lbf•in) (62 to 75 lbf•in) (71 to 89 lbf•in)
DIMENSION
6.5 to 8.5 N•m 8 to 12 N•m 10.5 to 15 N•m

M6 16 N•m (12 lbf•ft)
(58 to 75 lbf•in) (71 to 106 lbf•in) (93 to 133 lbf•in)
M8 15 N•m (11 lbf•ft) 24.5 N•m (18 lbf•ft) 31.5 N•m (23 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) 72.5 N•m (53 lbf•ft)
M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105 N•m (77 lbf•ft) 127.5 N•m (94 lbf•ft)
M14 85 N•m (63 lbf•ft) 135 N•m (100 lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft)
XII VMR2004_120_00_02A.FM
Bombardier SERVICE PUBLICATIONS REPORT
Publication title and year ________________________ Page______
Machine___________________ Report of error ❏ Suggestion ❏
____________________________________________________________
We would be pleased if you could
communicate to Bombardier any sug-
gestions you may have concerning
____________________________________________________________
our publications. ____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________
City and State/Prov. ________________________ Date___________
Zip code/Postal code ________________________________________

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
Name ______________________________________________________
Address ____________________________________________________
✁

AFFIX
PROPER
POSTAGE
After Sales Service
565 de la Montagne Street
Valcourt, Québec, Canada J0E 2L0
AFFIX
PROPER
POSTAGE
After Sales Service
AFFIX
PROPER
POSTAGE
After Sales Service
Section 01 SERVICE TOOLS AND SERVICE PRODUCTS
Subsection 01 (TABLE OF CONTENTS)
TABLE OF CONTENTS 0
SERVICE TOOLS.................................................................................................................... 01-02-1
SERVICE PRODUCTS ............................................................................................................ 01-03-1
VMR2004_154_01_01ATOC.FM 01-01-1
Subsection 02 (SERVICE TOOLS)
SERVICE TOOLS 0
This is a list of tools to properly service ATV vehicles. If you need to replace or add to your tool inventory,
these items can be ordered through the regular parts channel.
NEW
Following mention points out new tool:
VMR2004_121_01_02A.FM 01-02-1
MANDATORY
Small Hose Pincher
295 000 076 Valve Spring Compressor
All Models 529 035 724
Installer Handle
420 877 650
Large Hose Pincher

529 032 500
Flexible Spout for Oil Container

414 837 300
RECOMMENDED
All Models
Fuel System Pressure Tester
529 033 100
Idle Speed Screw Adjuster

RECOMMENDED
529 035 732
All Models Vacuum/Pressure Pump

529 021 800
4
3
2
1
Float Level Gauge

529 035 520
Carburetor Kit
404 112 000 Leak Down Tester
529 035 661
01-02-2 VMR2004_121_01_02A.FM
Terminal Remover
Snap-On TT660-4
Shock Tool
529 035 636
Multimeter Fluke 111
RECOMMENDED
529 035 868
All Models
Handle Grip Installer

529 035 897
RECOMMENDED
All Models
Battery Crimping Tool
529 035 730
Oil Pressure Gauge Adapter
529 035 652
Pressurizing Cap
529 021 400
Oil Pressure Gauge

529 035 709
Disconnecting Tool
529 035 714
VMR2004_121_01_02A.FM 01-02-3
Caillau Pliers
295 000 054
Digital/Inductive Type Tachometer

529 014 500
RECOMMENDED
DS 650/Baja/X
Youth models
Outlander 330 CV Boot Clamp Tool
Outlander 400 295 000 069
Quest 500/650
Traxter
Ring Compressor
Snap-On RC980
MANDATORY
DS 650/Baja/X
Outlander 330
Outlander 400
Quest 500/650
Traxter
Cable Luber
529 035 738 Crankshaft Protector
420 876 557
MANDATORY
DS 650/Baja/X
Outlander 330
Outlander 400
Crankshaft Locking Bolt Quest 500/650
529 035 617 Rally 200
RECOMMENDED
DS 650/Baja/X
Valve Stem Seal Pliers Outlander 330
Snap-On YA 8230 Flywheel Puller
Outlander 400
Quest 500/650 529 035 748
Rally 200
RECOMMENDED
DS 650/Baja/X
Outlander 330
Valve Spring Compressor Cup Outlander 400
529 035 764
Quest 500/650
Traxter
Exhaust Spring Tool

529 035 401
01-02-4 VMR2004_121_01_02A.FM
RECOMMENDED
Outlander 330
Outlander 400
Quest 500/650
Rally 200
Traxter Hub Puller
529 035 612
Shock Spring Tool

529 035 504
RECOMMENDED
Differential Socket Outlander 330
529 035 649
RECOMMENDED
Outlander 400
Outlander 330 Quest 500/650
Outlander 400 Traxter
Quest 500/650
Rally 200
Needle Bearing Installer
(main shaft in crankcase)
529 035 762
Backlash Measurement Tool
529 035 665
MANDATORY
Outlander 330
Outlander 400
Quest 500/650
Traxter
Choke Nut Socket

41 mm Socket 529 035 660
PROTO 5541
VMR2004_121_01_02A.FM 01-02-5
Bevel Gear Lock Pin/Driven

Pulley Expander
529 035 747
MANDATORY
Oil Seal Installer
(crankshaft oil seal Outlander 330
in magneto cover) Outlander 400
529 035 759 Quest 500/650
Drive Pulley Puller
529 035 746
Outlander 330 RECOMMENDED

Outlander 400
Quest 500/650 Driven Pulley Holding Tool
Traxter 529 035 771
Oil Seal Installer
(shift shaft oil seal
in magneto cover)
529 035 758
Torque Angle
Water Pump Ceramic Seal Installer Snap-On TA 36
529 035 766
RECOMMENDED
DS 650/Baja/X
RECOMMENDED
Outlander 330
Outlander 400 Outlander 330
Engine Lifting Tool Outlander 400
529 035 619 Oil Seal Installer
(crankshaft oil seal in crankcase) Quest 500/650
529 035 760
RECOMMENDED
DS 650/Baja/X Starter Drive Pinion Needle

Outlander 330 Bearing Installer
Outlander 400 529 035 756
Quest 500/650
Valve Stem Seal Installer

529 035 687
Starter drive needle bearing

installer
529 035 934
01-02-6 VMR2004_121_01_02A.FM
MANDATORY
Quest 500/650
Traxter
6 Pin Harness for Magneto
529 035 604
Needle Bearing Installer
MANDATORY
(bevel gear shaft in crankcase)
529 035 763 Rally 200
Traxter
46 mm Socket
529 035 648
Outlander 330 RECOMMENDED

Crankcase Support (CVT side) Outlander 400 Magneto Cover Remover
529 035 754 Quest 500/650 529 035 622
MANDATORY
DS 650/Baja/X
Output Shaft Oil Seal Installer Rear Axle Key

529 035 941 529 035 951
Oil Seal Installer

(water pump shaft oil seal) Clutch Basket Holder
529 035 757 529 035 618
RECOMMENDED
Valve Guide Installer

529 035 853 Quest 500/650
Rally 200
Blind Hole Bearing Puller

Snap-On
VMR2004_121_01_02A.FM 01-02-7
Front Knuckle Wear Ring Installer

529 035 637
Front Hub Seal Installer UP to 2003 models
529 035 632
Brake Hub Remover

Clutch Shaft Bearing Installer 529 035 695
529 035 691
Clutch Shaft Seal Installer

529 035 693
RECOMMENDED
Shock Charging Tool DS 650/Baja/X
529 035 570
RECOMMENDED
DS 650/Baja/X
Ball Joint Installer
529 035 705
Gas fill tool kit (needle type)

503 190 102
Ball Joint Support

529 035 706
UP to 2003 models
Swing Arm Key Rear Axle Wear Ring Installer

529 035 696 529 035 694
Rear Hub Seal Installer

529 035 634
01-02-8 VMR2004_121_01_02A.FM
ILLUSTRATION
NOT AVAILABLE
Flywheel Puller
(4-stroke engines)
529 035 792
Crankshaft Plain Bearing Installer
529 035 689
Valve Gap Adjuster

(4-stroke engines)
529 035 793
MANDATORY
Crankshaft Gear Puller
RECOMMENDED
529 035 624 Youth Models
DS 650/Baja/X
Oil Filter Rotor Puller

(4-stroke engines)
529 035 795
Crankshaft Plain Bearing Remover
529 035 688
UP to 2003 models
Magneto Puller
(4-stroke engines)
529 035 798
64 mm (2-1/2 in) Rear Axle Key

529 035 729
VMR2004_121_01_02A.FM 01-02-9
Crankshaft Puller
RECOMMENDED
(2-stroke engines)
529 035 799
Youth Models
Crankshaft Bearing Puller

(4-stroke engines)
529 035 791
Bearing Puller Kit

RECOMMENDED
(2-stroke engines)
Valve Seat Tool (4-stroke engines) 529 035 800
529 035 794 Youth Models
MANDATORY
Outlander 330
Outlander 400
Crankcase Puller Trailing Arm Socket

(2-stroke engines) 529 035 925
529 035 796
Crankcase Installer
(2-stroke engines)
529 035 797
01-02-10 VMR2004_121_01_02A.FM
Balancer Shaft Oil Seal Installer

Camshaft Locking Tool 529 035 933
529 035 926
Valve Guide Remover

529 035 924
Oil Seal Protector
529 035 935
RECOMMENDED
Piston Ring Compressor Trailing Arm Bearing Tool
(wheel side) Outlander 330
529 035 919 Outlander 400
529 035 918
RECOMMENDED
Outlander 330
Outlander 400
Piston Circlip Installer
529 035 921
Trailing Arm Bearing Tool
(frame side)
529 035 920
Crankshaft Plain Bearings Tool

529 035 917
Trailing Arm Support

529 035 922
Crankshaft Support (MAG side)

529 035 916
Clutch Holding Tool

529 006 400
VMR2004_121_01_02A.FM 01-02-11
Drive Pulley Holding Tool

Wear Ring Installer 529 035 745
(front drive shafts)
MANDATORY
529 035 927
Quest 500/650
RECOMMENDED
Wear Ring Installer

(rear drive shafts)
529 035 915 Outlander 330
Bearing Alignment Tool
Outlander 400
529 035 806
Shock Spring Tool Adaptor

(must be used with 529 035 504)
529 035 928
RECOMMENDED
Lifting Ring
Engine Lifting Tool 529 035 770
(must be used with 529 035 619) Quest 500/650
529 035 898
Oil Seal Installer

(main shaft oil seal in crankcase)
529 035 761
Piston Circlip Installer

529 035 765
01-02-12 VMR2004_121_01_02A.FM
Pulley Holding Tool

529 035 862
Crankcase Plain Bearing Tool
(CVT side)
529 035 752
RECOMMENDED
MANDATORY
Quest 500/650 Driven Pulley Support
529 035 863
Rally 200
Crankcase Plain Bearing Tool
(MAG side)
529 035 753
51 mm (2 in) Open Key

529 035 866
Crankcase Support (MAG side)

529 035 755
51 mm (2 in) Rear Axle Key
529 035 884
VMR2004_121_01_02A.FM 01-02-13
Driven Pulley Holding Support Crankshaft Plain Bearing Tool

529 035 864 529 035 855
Crankshaft Oil Seal Installer Driven Pulley Needle Bearing

529 035 847 Installer
529 035 858
Water Pump Oil Seal Installer
RECOMMENDED
529 035 849 Piston Circlip Installer
529 035 859
Rally 200
RECOMMENDED
Rally 200
Shifter Oil Seal Installer
529 035 851
Allen Socket
529 035 861
Valve Guide Remover

529 035 852
Rear Axle Bearing Puller

420 276 930
Gearbox Oil Seal Installer

529 035 854
Pliers Oetiker 1099

295 000 070
Magneto Puller
(use bolt from magneto
puller P/N 529 035 748)
529 035 883
01-02-14 VMR2004_121_01_02A.FM
Self Diagnostic Jumper

529 035 605
AMP Crimping Tool

295 100 164
MANDATORY
Crankshaft Locking Bolt
529 035 645
Traxter
RECOMMENDED
Lifting Ring
529 035 644
Spanner Tool for Clutch Basket UP to 2000 Traxter
529 035 647
Front Suspension Spacer Bar

529 035 611
Solenoids Diagnostic Harness

529 035 653
Valve Spring Compressor Cup

529 035 725
Lifting Bar
529 035 610
VMR2004_121_01_02A.FM 01-02-15
Subsection 03 (SERVICE PRODUCTS)
SERVICE PRODUCTS 0
This is a list of products to properly service ATV vehicles. If you need to replace or add to your product inventory,
these items can be ordered through the regular parts channel.
Following mention points out new product: NEW
VMR2004_122_01_03A.FM 01-03-1
Loctite® 567
Pipe Sealant
(250 mL)
293 800 013
Loctite® 243
Medium-Strength Threadlocker
(10 mL) (blue) Suspension Synthetic Grease
293 800 060 (400 g)
293 550 033
Synthetic Grease
(400 g)
293 550 010
Loctite® 609
Retaining Compound Loctite RC All Models
(10 mL) (green)
413 703 100 All Models
Bombardier ATV Tire Sealant

(946 mL)
715 000 130
Loctite® Primer
Primer N
128 g (5 oz)
293 800 041
Brake Fluid DOT 4

(354 mL)
293 600 062
Loctite® Anti-Seize Lubricant
(236 mL)
293 800 070
01-03-2 VMR2004_122_01_03A.FM
Bombardier Fuel Stabilizer BOMBARDIER LUBE

(12 x 8 oz) (12 x 14 oz)
413 408 600 293 600 016
All Models
All Models
Bombardier Premixed Coolant 50/50

- 37°C (- 35°F) Bombardier Pulley Flange Cleaner
(16 x 1 L) (320 g)
293 600 038 413 711 809
Bombardier Storage Oil Bombardier Heavy Duty Cleaner

(350 g spray can) 293 110 001 (400 g)
(12 x 350 g) 293 110 002 (4 L)
Canada: 413 711 600
U.S. : 413 711 900
VMR2004_122_01_03A.FM 01-03-3
DS 650/Baja/X
Quest 500/650
Traxter
Loctite® 271
High Strength Threadlocker
(10 mL) (red)
293 800 005
Bombardier Plastic & Vinyl Cleaner
(6 x 1 L)
413 711 200
All Models
Loctite® 277
High Strength Retaining Compound
(10 mL) (red)
293 800 073
Bombardier Synthetic
4-Stroke Oil 5W-40
(12 x 1 L)
293 600 039
Air Filter Cleaner Loctite® 518

(2 L) Paste Gasket
Gasket Eliminator (50 mL) Rally 200
293 600 059
293 800 038
Air Filter Oil

(1 L)
293 600 058
Loctite® 384
Thermally Conductive Adhesive
(25 mL)
293 800 089
Silicone Dielectric Grease CAUTION: This product must be
(3 oz) stored at 5°C (41°F).
293 550 004
Loctite® 5150
Clear Silicone Sealant
(300 mL)
293 800 086
01-03-4 VMR2004_122_01_03A.FM
Bombardier Chaincase Oil

(16 x 250 mL)
413 801 900 Loctite® Chisel
Rally 200 DS 650/Baja/X
Gasket/Paint Remover
510 g (18 oz) Quest 500/650
413 708 500 Rally 200
Traxter
Bombardier Synthetic Chaincase Oil

(12 x 355 mL)
413 803 300
Cable Lubricant
(400 g)
293 600 041
DS 650/Baja/X
DS 650/Baja/X Outlander 330
Outlander 330 Outlander 400
Outlander 400 Synthetic Grease Quest 500/650
Rally 200 (60 g) Traxter
Traxter 293 550 019
Loctite® 648
High Temperature and Strength
Retaining Compound
(5 mL) (green)
413 711 400
VMR2004_122_01_03A.FM 01-03-5
High Temp RTV Silicone

ULTRA COPPER
(85 g)
413 800 090
Quest 500/650
Loctite® 406 Traxter
Instant Adhesive
(must be used with tapered tip)
(20 g)
293 800 095
DS 650/Baja/X
Smoothflow Tapered Tips

Kayaba Shock absorber oil 16ga #511 rtt-b
293 600 035 (not sold by Bombardier),
call EFD Inc, 1 800 556-3484
Loctite® 5900
RTV Silicone Sealant
(300 mL)
293 800 066
Marvin Shock Absorber oil

503 190 103 Outlander 330
Outlander 400
Loctite® Maxi-Coat
Heavy Duty Rustproofing
(340 g)
293 800 105
01-03-6 VMR2004_122_01_03A.FM
Outlander 330
Outlander 400 Rally 200
Loctite®5910 Quest 500/650 Traxter
Flange Sealant
(300 mL) Molykote G-n Paste
293 800 081 (50 g)
711 297 433
Outlander 330
DS 650/Baja/X Outlander 400
Loctite® 515 Traxter Traxter
Paste Gasket Molykote PG 54
Gasket Eliminator (10 g)
(50 mL) 420 899 763
413 702 700
111
DS 650/Baja/X
Rally 200
Traxter
Molykote 111
(150 g)
413 707 000
Outlander 330
Outlander 400
Quest 500/650
Traxter
DS 650/Baja/X
Rally 200
Traxter
Bombardier Differential Oil
(946 mL)
293 600 043
Super Lube Grease
293 550 030
VMR2004_122_01_03A.FM 01-03-7
Section 02 MAINTENANCE
TABLE OF CONTENTS 0
MAINTENANCE CHART ........................................................................................................ 02-02-1
NOISE EMISSION CONTROL SYSTEM REGULATION ................................................... 02-02-1
MAINTENANCE CHART .................................................................................................... 02-02-2
MAINTENANCE PROCEDURES............................................................................................ 02-03-1

SPECIAL PROCEDURES .................................................................................................... 02-03-1
AIR FILTER CLEANING/DRAINING................................................................................... 02-03-2
BOLTS, FASTENERS AND NUTS ..................................................................................... 02-03-3
ENGINE OIL AND FILTER.................................................................................................. 02-03-3
OIL STRAINER ................................................................................................................... 02-03-5
SPARK ARRESTER ............................................................................................................ 02-03-5
TIRES AND WHEELS ......................................................................................................... 02-03-5
ENGINE AREA ................................................................................................................... 02-03-6
STORAGE/PRESEASON PREPARATION............................................................................. 02-04-1

STORAGE........................................................................................................................... 02-04-1
FUEL STABILIZER .............................................................................................................. 02-04-1
ENGINE LUBRICATION ..................................................................................................... 02-04-1
VEHICLE CLEANING AND PROTECTION......................................................................... 02-04-2
COOLANT DENSITY .......................................................................................................... 02-04-3
PRESEASON PREPARATION............................................................................................ 02-04-4
VMR2004_154_02_01ATOC.FM 02-01-1
Subsection 02 (MAINTENANCE CHART)
MAINTENANCE CHART 0
NOISE EMISSION CONTROL SYSTEM REGULATION
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 incorporated into any new vehicle for the purpose of
noise control prior to its sale or delivery 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 removed or rendered inoperative
by any person.
Among Those Acts Presumed to Constitute Tampering Are the Acts Listed Below:
1. Removal or alteration or the puncturing of the muffler or any engine component which conducts re-
moval 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 system, with parts other
than those specified by the manufacturer.
4. Lack of proper maintenance.
VMR2004_123_02_02A.FM 02-02-1
MAINTENANCE CHART
Some items may not apply to your particular model.
EVERY
10 HOURS OR 30 DAYS
OR 1500 KM (930 m.)

INITIAL INSPECTION
OR 300 KM (185 m.)
OR 750 KM (470 m.)
3000 KM (1865 m.)
6000 KM (3730 m.)
THE SUBSECTION
OR ONCE A YEAR
I : Inspect, verify, clean, adjust, lubricate, replace if necessary
100 HOURS OR
200 HOURS OR
C : Clean
OR 2 YEARS
L : Lubricate
25 HOURS
50 HOURS
REFER TO
R : Replace
ENGINE/TRANSMISSION
Engine/transmission oil and filter R R
Engine/transmission oil strainer cleaning C Lubrication
Spark arrester C
Engine mount fasteners I I Removal/
Exhaust system I I installation
Valve adjustment I I Cylinder and head
Coolant I ➀ R
Radiator cap/cooling system pressure test I I Cooling system
Radiator condition/cleanliness (air ducts and radiator fins) ➁ I I
Rewind starter rope condition I
N.A.
Condition of seals I I
Drive belt I
Cleaning/condition of drive and driven pulleys C
CVT
One-way bearing inside CVT L
CVT air inlet duct condition/cleanliness and sealing I I
FUEL SYSTEM
Air filter C➁ R➁ Maintenance
procedures
Fuel lines and connections I I
Fuel circuit
Fuel tank strainer R
Carburetor I I Carburetor and
Carburetor valve piston I fuel pump
ELECTRICAL SYSTEM
Spark plug I➂ R➂ Ignition system
Battery connections I I Starting system
Wiring harness, cables and lines I I
Condition of ignition switch, start button and engine stop switch I I Instruments/
Condition of lighting system (HI/LO intensity, brake light, etc.) I I accessories
Headlamp beam aiming I I
Winch connections Refer to ATV Winch N.A.
Operator’s Manual
DRIVE TRAIN
Drive shaft boots and protectors I I
Propeller shaft joints I L
Drive shaft joints I Front drive/
rear drive
Wheel bearings I
Front and rear differentials oil level, seals and vents I I R
02-02-2 VMR2004_123_02_02A.FM
EVERY
10 HOURS OR 30 DAYS
OR 1500 KM (930 m.)

INITIAL INSPECTION
OR 300 KM (185 m.)
OR 750 KM (470 m.)
3000 KM (1865 m.)
6000 KM (3730 m.)
THE SUBSECTION
OR ONCE A YEAR
I : Inspect, verify, clean, adjust, lubricate, replace if necessary
100 HOURS OR
200 HOURS OR
C : Clean
OR 2 YEARS
L : Lubricate
25 HOURS
50 HOURS
REFER TO
R : Replace
STEERING SYSTEM
Throttle/housing/cable I I Carburetor
Handlebar fastener I
Steering system mechanism ➁ I I
Tie rod ends I Steering/
control systems
Front wheel alignment I I
Choke I I
Wheel nuts/studs I I Maintenance
Tyre wear and pressure EVERY INSPECTION procedures
SUSPENSION
Trailing arms I
Rear
Trailing arm bearings I suspension
Shock absorbers I
A-arms I
McPherson struts I Front
suspension
Ball joints I
BRAKE
Brake fluid front/rear I I R
Hydraulic
Brake system (discs, hoses, etc.) I brakes
Brake pads I
BODY/FRAME
Engine area C C Maintenance
Frame fastener I procedures
Hitch/trailer ball condition (if installed) I I
Seat fastners I
Frame I
Vehicle cleaning and protection C Body and
frame
Storage cover latches I
Grab handles EVERY INSPECTION
Backrest EVERY INSPECTION
The initial maintenance is very important and must not be neglected.

➀ Every 100 hours, check coolant strength.
➁ More often under severe use such as dusty area, sand, snow, wet or muddy conditions.
➂ Make sure that the spark plug gap is correct.
N.A.: Not Available
VMR2004_123_02_02A.FM 02-02-3
Subsection 03 (MAINTENANCE PROCEDURES)
MAINTENANCE PROCEDURES 0
SPECIAL PROCEDURES ATV Submerged for a Short Time
(fewer one hour)
Turn Over Check if engine oil is contaminated. If so, perform
If the oil pressure light stays ON after starting en- the following instructions.
gine and the engine oil level is good, check the – Drain engine oil.
following: – Drain air box then clean and dry air filter.
– Oil filter for contamination. – Look for water in fuel tank, in doubt, flush fuel
• Replace oil filter and oil. tank and refill with new gas. Refer to FUEL CIR-
– Oil pressure regulator valve stays open in the CUIT.
crankcase due to contamination (metallic parti- – Remove the CVT cover drain plug to drain the
cles). CVT housing. Remove the CVT cover then clean
• Clean and/or replace the valve. and check all parts of CVT. Refer to CVT section.
– Valve piston stuck in the oil pump housing. Callout
• Repair valve piston.
– Oil pressure switch for damages.
• Replace it if necessary.
– Oil pump cleanliness and working.
• Clean and/or replace oil pump if necessary.
ATV Immersion
ATV Submerged for a Long Time
(over one hour)
Disassemble the engine to clean the internal parts
and check if there is no rust or corrosion on any
internal parts. Refer to the specific sections.
V07C0VA 1
Drain air box then clean and dry air filter.
1. CVT cover drain plug
Remove muffler and empty it. Let muffler dry then
reinstall it on the vehicle. – Lubricate throttle/choke cables. Check if the ca-
bles operate properly.
Flush fuel tank and refill with new gas. Refer to FUEL
CIRCUIT. – Remove spark plug and using the rewind start-
er, crank engine slowly several times.
Clean carburetor. Refer to CARBURETOR.
– Add a small quantity of engine oil in cylinder (ap-
Look for water in: proximately 2 teaspoonfuls). Do not reinstall
– brake system (replace brake fluid) spark plug at this moment.
– differentials (drain oil and check internal parts – Refill engine at the proper level with the recom-
for rust or corrosion then refill). mended oil. Using the rewind starter, crank en-
Lubricate throttle/choke cables. Check if the cables gine several times.
operate properly. – Install new spark plug.
Spray all metal parts with BOMBARDIER LUBE – Start the engine and allow it to run at idle speed
(P/N 293 600 016). until the engine reaches its operating temperature.
Test drive to confirm all is working well (electrical – Stop the engine.
and mechanical components). – Change engine oil and filter.
VMR2004_123_02_03A.FM 02-03-1
NOTE: Change oil as many times as necessary, NOTE: If vehicle is used in dusty areas, inspect more
until there is no white appearance in engine oil. frequently than specified in maintenance chart.
Spray all metal parts with BOMBARDIER LUBE If liquid/deposits are found, squeeze the clamp
(P/N 293 600 016). and remove. Pull drain tube out and empty it.
Test drive to confirm all is working well (electrical CAUTION: Do not start engine when liquid or
and mechanical components). deposits are found in the drain tube. If you have
oil in the air box, check engine oil level. Maybe
AIR FILTER CLEANING/DRAINING oil level is too high.
When liquid/deposits are found, air filter must be
Air Filter Box Draining inspected/dried/replaced depending on its condi-
Periodically inspect air filter box drain plug for liq- tion.
uid or deposits. Refer to the maintenance chart. Remove air filter as explained below.
3 Air Filter Removal

CAUTION: Never remove or modify any com-
ponent in the air box. Always use genuine parts
when replacing air filter and foam. Otherwise,
engine performance degradation or damage
can occur.The engine carburation is calibrated
to operate specifically with these components.
Remove seat and left side cover.
Release clamps and remove air filter box cover.
1
2
1 4
V07C0GA
V07C0FA
1. Release clamps
TYPICAL
1. Air filter box
2. Drain plug
3. Clamp
4. CVT cover
02-03-2 VMR2004_123_02_03A.FM
Loosen clamp and remove air filter. ENGINE OIL AND FILTER
Oil Viscosity
SAE 5W30 is recommended for all seasons.
Another viscosity should be used if the average
temperature is outside the range of the recom-
mended oil. See chart below.
°C °F
60 140
50
120
BOMBARDIER SYNTHETIC OIL 5W40 (P/N 293 600 039)

40
V07C0HA 1 2 100
SAE 20W50
1. Clamp
2. Air filter 30
80
Pour air filter cleaning solution (P/N 293 600 059 or
SAE 15W40
an equivalent) into a bucket. Put the filter in to soak. 20
60
SAE 10W40
While filter soaks, clean inside of air box.
10
Rinse the filter with warm water and let it dry com-
SAE 10W30
pletely. 40
When the filter is dried, re-oil with air filter oil (P/N SAE 5W30 0
293 600 058 or an equivalent).
20
If air filter foam is still dirty, replace with a new one. -10
Properly reinstall removed parts in the reverse or-
der of their removal. 0
-20
BOLTS, FASTENERS AND NUTS

-30 -20
Check that all fasteners, bolts and nuts are tight-
ened to the proper torque.
During assembly/installation, use the torque val- V01A38A
ues and service products as in the exploded views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
Oil Change and Oil Filter Replacement
APPLICATION at the beginning of this manual for
complete procedure.  WARNING
The engine oil can be very hot. Wait until en-
 WARNING gine oil is warm.
Torque wrench tightening specifications must NOTE: Oil and filter are to be replaced at the same
strictly be adhered to. time. Oil change should be done with a warmed
Locking devices (ex.: locking tabs, elastic stop up engine.
nuts, self-locking fasteners, cotter pin, etc.) Ensure vehicle is on a level surface.
must be installed or replaced with new ones
where specified. If the efficiency of a locking Clean the drain plug area.
device is impaired, it must be renewed. Remove dipstick and/or the filler cap.
Place a drain pan under the engine drain plug area.
VMR2004_123_02_03A.FM 02-03-3
Clean the drain plug area. CAUTION: Only use Bombardier filter. The
Unscrew drain plug. Bombardier filter is specifically designed for this
engine. Using a non-recommended filter may
CAUTION: Pay attention not to lose gasket ring cause serious engine/transmission damage.
on drain plug.
Check O-rings on filter cover and change them if-
necessary.
1
R400motr151A 1 2
1. Magnetic drain plug
2. Gasket ring
Allow enough time for oil to flow out of oil filter (10
minutes approximately). R400motr152A
NOTE: Oil condition gives information about en- TYPICAL

gine condition. See TROUBLESHOOTING section. 1. O-ring
Unscrew oil filter cover. Check and clean oil filter inlet and outlet area for
dirt and other contaminations.
V07C25A 1 R400motr153A 2 1
1. Inlet bore from oil pump to oil filter
1. Filter cover 2. Outlet bore to engine oil provinding system
Remove oil filter and replace with a new one. Install filter cover and torque screws to 10 N•m
(89 lbf•in).
Wipe out any oil spillage on engine.
02-03-4 VMR2004_123_02_03A.FM
Inspect gasket on drain plug and replace as nec- Momentarily increase engine RPM several time to
essary. Clean gasket area on engine and drain plug purge accumulated carbon from the muffler.
then reinstall plug. Stop engine and allow muffler to cool.
Refill engine at the proper level with the recom- Remove shop rag and reinstall the clean out plug.
mended oil. Refer to TECHNICAL DATA for capac-
ity. Do not overfill.  WARNING
Start engine and let idle for a few minutes. Ensure Never run engine in an enclosed area.
oil filter area and drain plug areas are not leaking. Never perform this operation immediately af-
Stop engine. Wait a while to allow oil to flow down ter the engine has been run because exhaust
to crankcase then check oil level. Refill as necessary. system is very hot.
Dispose oil as per your local environmental regu- Make sure that there are no combustible ma-
lations. terials in the area.
Wear eye protector and gloves.
OIL STRAINER Never stand behind the vehicle while purging
exhaust system.
Refer to LUBRICATION section.
Respect all applicable laws and regulations.
SPARK ARRESTER Check the exhaust system for damage, crack or
The muffler must be periodically purged of accu- leak (exhaust pipe). Repair or change if necessary.
mulated carbon.
Select a well-ventilated area and make sure the TIRES AND WHEELS
muffler is cool.
Tire Pressure
Place transmission on park position.
CAUTION: Underpressure may cause tire to de-
Remove the clean out plug. flate and rotate on wheel. Overpressure might
burst the tire. Always follow recommended
pressure. Since tires are low-pressure type, a
manual pump should be used.
Check pressure when tires are cold before using
the vehicle.
NOTE: Tire pressure changes with temperature
and altitude. Recheck pressure if one of these con-
ditions has changed.
TIRE PRESSURE
FRONT REAR
RECOMMENDED 28 kPa 31 kPa
(4 PSI) (4.5 PSI)
V07C0BA 2 1
24 kPa 28 kPa
1. Clean out plug MINIMUM
2. Muffler (3.5 PSI) (4 PSI)
Block the end of muffler with a shop rag and start

engine.
VMR2004_123_02_03A.FM 02-03-5
Tire/Wheel Condition
Check tire for damage and wear. Measure thread
height. It should be 3 mm (7/64 in) minimum. Re-
place if damaged or worn.
V01A05A
A. 3 mm (7/64 in)
NOTE: Do not make a tire rotation. The front and

rear tires have a different size. Besides, these tires
are directional and their rotation must be kept in a
specific direction for proper operation.
Wheel Removal
Untighten nuts then lift vehicle where needed.
Place a support under vehicle. Remove nuts then
withdraw wheel.
At installation, it is recommended to apply anti-
seize lubricant on threads. Gently tighten nuts in a
criss-cross sequence then apply a final torque of
70 N•m (52 lbf•ft).
CAUTION: Always use the recommended wheel
nuts (P/N 250 100 039). Using a different nut
could cause damages to the rim.
ENGINE AREA
Check in the engine area, for leak or other dam-
age. Clean mud, leaves, etc. from engine area.
02-03-6 VMR2004_123_02_03A.FM
Subsection 04 (STORAGE/PRESEASON PREPARATION)
STORAGE/PRESEASON
PREPARATION 0
STORAGE – Remove air box cover and air filter to spray stor-
age oil (P/N 413 711 600) into carburetor bore.
If the ATV is to be stored for an extended period
– Restart engine and run at idle speed.
of time, more than 1 month, be sure to thoroughly
check the vehicle for repairs and have them per- – Inject storage oil until the engine stalls or until
formed. a sufficient quantity of oil has entered the en-
gine (approximately a quarter of can).
FUEL STABILIZER – Remove spark plug(s) and spray storage oil into
cylinder. Press start button, 1 or 2 seconds max-
A fuel stabilizer (P/N 413 408 600) can be added in imum, to lubricate cylinder.
the fuel tank to prevent fuel deterioration and avoid
draining the fuel system during storage. Follow the – Stop the engine and remove the battery. Store
manufacturer’s instructions for proper use. it in dry and cool place out of the sun, refer to BAT-
TERY.
If no stabilizer is used, drain fuel system including
the fuel tank and carburetor. – Reinstall the spark plug(s), air filter and air box
cover.
CAUTION: Fuel stabilizer should be added prior
to engine lubrication to protect carburetor – Turn the fuel valve to OFF and drain carburetor.
against varnish deposits. – Using cleans rags, block the following locations:
CVT inlet and oulet hoses, air intake inlet and
ENGINE LUBRICATION muffler. The rags will prevent the intrusion of
small animals, leaves or other debris.
Engine internal parts must be lubricated to protect
them from rust formation during the storage period.
 WARNING
This procedure must only be performed in a
well-ventilated area. Do not run engine during
storage period.
Proceed as follows:
– Start the engine and allow it to run at idle speed
until the engine reaches its operating tempera-
ture.
– Stop the engine.
– Change engine oil and filter. Refer to MAINTE-
NANCE PROCEDURES.
V07D03A 2 1 3
CVT INLET HOSE
1. CVT inlet hose
2. Fuel valve
3. Air filter box cover
VMR2004_124_02_04A.FM 02-04-1
2 1 3
V07D04A V07C0WA
CVT OUTLET HOSE MUFFLER

1. CVT outlet hose
2. Fuel tank CAUTION: Remove all rags at preseason prep-
3. LH rear shock absorber aration.
VEHICLE CLEANING AND

PROTECTION
Wash and dry the vehicle.
CAUTION: 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 flannel
clothes with Bombardier Vinyl & Plastic Cleaner (P/N
413 711 200).
CAUTION: It is necessary to use flannel cloths
on plastic parts to avoid damaging surfaces.
Never clean plastic parts with strong detergent,
degreasing agent, paint thinner, acetone, prod-
ucts containing chlorine, etc.
To clean the entire vehicle, including metallic parts
V07F0FA 3 2 1 use Bombardier Cleaner (P/N 293 110 001(400 g)
AIR INTAKE INLET or 293 110 002 (4 L)).
1. Air intake inlet
2. Carburetor
3. Air filter box
02-04-2 VMR2004_124_02_04A.FM
Inspect the vehicle and repair any damage. Touch

up all metal spots where paint has been scratched
off. Spray all metal parts with BOMBARDIER LUBE
(P/N 293 600 016).
NOTE: Protect the vehicle with a cover to prevent
dust accumulation during storage.
CAUTION: The vehicle has to be stored in a cool
and dry place and covered with an opaque tar-
paulin. This will prevent sun rays and grime from
affecting plastic components and vehicle finish.
COOLANT DENSITY
Test coolant density using an antifreeze hydrometer.
NOTE: Follow manufacturer’s instructions for proper
use.
A 50/50 mixture of antifreeze and distilled water
will provide the optimum cooling, corrosion protec-
tion and antifreeze protection.
CAUTION: Do not use tap water, straight anti-
freeze or straight water in the system. Tap water
contains minerals and impurities which build
up in the system. Straight water will cause the
system to freeze while straight antifreeze will
cause system temperature problems.
Change coolant if necessary.
VMR2004_124_02_04A.FM 02-04-3
PRESEASON PREPARATION
TO BE PERFORMED BY
SYSTEM PRESEASON OPERATIONS REFER TO SECTION
CUSTOMER DEALER
Test Run Vehicle. Check Clutch and Transmission Operation ✔ N.A.
Engine Oil and Filter Oil Replacement ➀ ✔
Spark Arrester ✔ Maintenance
Rags Removal (CVT Hoses, Intake and Muffler) ➁ ✔
Coolant Replacement and Pressurization of System ✔ Cooling System
Valve Adjustment ✔ Cylinder and Head
Condition of Seals ✔ N.A.
Exhaust System Condition ✔ Removal/Installation
CVT System Condition ✔ CVT
Rewind Starter, Rope Condition ✔ N.A.
Fuel Line and Connectors Condition ✔ Fuel Circuit
Carburetor Adjustment ✔ Carburetor
Air Filter Cleaning/Replacement ✔ Maintenance
Spark Plug Replacement ➂ ✔ Ignition System
Battery Condition/Charging and Installation ✔
Starting System
Starter Connections and Routing ✔
Instruments/
Operation of Lighting System ✔
Accessories
Drive Shaft Boots Inspection ✔
Front/Rear Propeller Shafts Lubrication ✔ Front Differential/
Rear Axle
Front/Rear Differential Oil Level and Vent Condition ✔
Steering System Inspection and Adjustment ✔
Handle Bar Fastener Tightness ✔ Steering/
Control Systems
Throttle and Choke Cable Inspection/Adjustment/Lubrication ✔
Wheel Tightness ✔
Maintenance
Tire Pressure/Condition ✔
Suspension System Inspection ✔
Bearing Condition ✔
p Front/Rear Suspension
A-Arm Lubrication ✔
Trailing Arm Condition ✔
Brake Fluid Change ✔

Hydraulic Brakes
Brake Condition ✔
Frame Condition ✔
Hitch/Trailer Ball Condition ✔ ✔
Body
Rear Cover Compartment Cover Latch Condition ✔ ✔
Seat Latch Condition ✔
➀ Replace oil and filter only if it has not been previously performed at the storage.
➁ Before starting the engine, remove rags in CVT inlet and outlet hoses, air intake inlet and muffler that
were installed at the storage.
➂ Before installing new spark plugs at preseason preparation, it is suggested to remove excess storage
oil by starting the engine with the old spark plugs. Only perform this operation in a well-ventilated area.
02-04-4 VMR2004_124_02_04A.FM
Section 03 ENGINE
TABLE OF CONTENTS 0
TROUBLESHOOTING............................................................................................................ 03-02-1
COOLING SYSTEM ........................................................................................................... 03-02-1
MAGNETO SYSTEM ......................................................................................................... 03-02-2
LUBRICATION.................................................................................................................... 03-02-4
CYLINDER AND HEAD ...................................................................................................... 03-02-6
CRANKSHAFT AND BALANCER SHAFT.......................................................................... 03-02-7
GEARBOX .......................................................................................................................... 03-02-7
REWIND STARTER ............................................................................................................ 03-02-9
CVT ..................................................................................................................................... 03-02-10
ENGINE GENERAL ............................................................................................................ 03-02-15
LEAK TEST ............................................................................................................................. 03-03-1

GENERAL VERIFICATION ................................................................................................. 03-03-1
LEAK TEST PROCEDURE .................................................................................................. 03-03-1
PREPARATION AND TEST................................................................................................ 03-03-1
INSTALLATION.................................................................................................................. 03-03-3
REMOVAL AND INSTALLATION .......................................................................................... 03-04-1

GENERAL ........................................................................................................................... 03-04-3
ENGINE REMOVAL ........................................................................................................... 03-04-3
ENGINE INSTALLATION ................................................................................................... 03-04-8
ANTI-VIBRATION SYSTEM............................................................................................... 03-04-9
EXHAUST SYSTEM .......................................................................................................... 03-04-9
SHIFTING SYSTEM............................................................................................................ 03-04-10
COOLING SYSTEM ............................................................................................................... 03-05-1

WATER PUMP.................................................................................................................... 03-05-1
COOLING SYSTEM ........................................................................................................... 03-05-2
GENERAL ........................................................................................................................... 03-05-3
COOLING SYSTEM LEAK TEST ....................................................................................... 03-05-3
INSPECTION ...................................................................................................................... 03-05-3
DRAINING THE SYSTEM .................................................................................................. 03-05-4
COOLANT REPLACEMENT ............................................................................................... 03-05-4
THERMOSTAT ................................................................................................................... 03-05-5
WATER TEMPERATURE SWITCH..................................................................................... 03-05-6
WATER PUMP HOUSING ................................................................................................. 03-05-6
WATER PUMP IMPELLER ................................................................................................. 03-05-7
WATER PUMP SHAFT ....................................................................................................... 03-05-7
PRESSURE CAP ................................................................................................................. 03-05-10
RADIATOR ......................................................................................................................... 03-05-10
COOLANT TANK ............................................................................................................... 03-05-11
VMR2004_154_03_01ATOC.FM 03-01-1
Section 03 ENGINE
COOLING FAN.................................................................................................................... 03-05-11

TEMPERATURE SENDER .................................................................................................. 03-05-12
REWIND STARTER ................................................................................................................. 03-06-1

GENERAL............................................................................................................................ 03-06-2
REWIND STARTER............................................................................................................. 03-06-2
STARTING PULLEY............................................................................................................ 03-06-5
MAGNETO SYSTEM .............................................................................................................. 03-07-1

GENERAL............................................................................................................................ 03-07-2
MAGNETO HOUSING COVER........................................................................................... 03-07-2
OIL SEAL............................................................................................................................. 03-07-4
STATOR .............................................................................................................................. 03-07-5
CPS (Crankshaft Position Sensor) .................................................................................... 03-07-6
ROTOR ................................................................................................................................ 03-07-6
LUBRICATION SYSTEM......................................................................................................... 03-08-1

GENERAL............................................................................................................................ 03-08-2
ENGINE OIL PRESSURE TEST .......................................................................................... 03-08-2
OIL CHANGE....................................................................................................................... 03-08-3
OIL FILTER .......................................................................................................................... 03-08-3
OIL STRAINER .................................................................................................................... 03-08-4
ENGINE OIL PRESSURE REGULATOR ............................................................................. 03-08-6
OIL PUMP ........................................................................................................................... 03-08-6
CYLINDER AND HEAD ........................................................................................................... 03-09-1

GENERAL............................................................................................................................ 03-09-3
SPARK PLUG ...................................................................................................................... 03-09-3
THERMOSTAT.................................................................................................................... 03-09-3
VALVE COVER .................................................................................................................... 03-09-4
VALVE ADJUSTMENT ....................................................................................................... 03-09-4
CHAIN TENSIONER............................................................................................................ 03-09-5
CHAIN TENSIONER HOUSING.......................................................................................... 03-09-5
DECOMPRESSOR............................................................................................................... 03-09-6
CAMSHAFT TIMING GEAR................................................................................................ 03-09-8
ROCKER ARM..................................................................................................................... 03-09-9
TIMING CHAIN ................................................................................................................... 03-09-11
CYLINDER HEAD ................................................................................................................ 03-09-11
CAMSHAFT......................................................................................................................... 03-09-13
VALVE SPRING................................................................................................................... 03-09-14
VALVE ................................................................................................................................. 03-09-16
VALVE GUIDE PROCEDURE .............................................................................................. 03-09-18
CYLINDER ........................................................................................................................... 03-09-19
PISTON ............................................................................................................................... 03-09-21
PISTON RINGS ................................................................................................................... 03-09-24
03-01-2 VMR2004_154_03_01ATOC.FM
Section 03 ENGINE
CRANKSHAFT/BALANCER SHAFT ...................................................................................... 03-10-1

CRANKCASE ...................................................................................................................... 03-10-1
CRANKSHAFT/BALANCER SHAFT .................................................................................. 03-10-2
GENERAL ........................................................................................................................... 03-10-3
CRANKSHAFT LOCKING PROCEDURE............................................................................ 03-10-3
TIMING CHAIN .................................................................................................................. 03-10-4
TIMING CHAIN GUIDE ...................................................................................................... 03-10-5
CRANKCASE ...................................................................................................................... 03-10-5
BALANCER SHAFT ............................................................................................................ 03-10-9
CRANKSHAFT.................................................................................................................... 03-10-10
GEARBOX .............................................................................................................................. 03-11-1

OUTPUT SHAFT AND TRANSMISSION .......................................................................... 03-11-1
CRANKCASE ...................................................................................................................... 03-11-2
GENERAL ........................................................................................................................... 03-11-3
OIL SEALS.......................................................................................................................... 03-11-3
OUTPUT SHAFT ................................................................................................................ 03-11-3
CRANKCASE ...................................................................................................................... 03-11-6
GEARBOX .......................................................................................................................... 03-11-12
SHIFTING INDICATOR SWITCH ....................................................................................... 03-11-21
STARTER DRIVE PINION .................................................................................................. 03-11-22
CVT ......................................................................................................................................... 03-12-1

GENERAL ........................................................................................................................... 03-12-2
BELT REPLACEMENT............................................................................................................... 03-12-2
DRIVE PULLEY ................................................................................................................... 03-12-3
DRIVEN PULLEY ....................................................................................................................... 03-12-10
VMR2004_154_03_01ATOC.FM 03-01-3
Section 03 ENGINE
Subsection 02 (TROUBLESHOOTING)
TROUBLESHOOTING 0
The following charts are provided to help in diagnosing the probable source of troubles. It should be used
as a guideline. This section pertains to engine mechanical components only. Some related problems can
come from other systems such as ignition system, fuel system, etc. and have an impact on the engine.
Ensure to check the other systems prior to concluding that the engine is in fault.
COOLING SYSTEM
SYMPTOM HIGH ENGINE OPERATING TEMPERATURE.
CONDITION NORMAL USE.

Test/Inspection 1. Check coolant level.
a. Coolant less than recommended level.
Refill.
2. Check temperature sensor for electrical/mechanical failure.
a. Temperature sensor defective.
Replace.
3. Check thermostat.
a. Thermostat defective.
Replace.
4. Check gasket(s) underneath water pump cover.
a. Leakage in water pump cover area.
Retighten screws and/or replace gasket.
5. Check leak indicator hole (water pump housing area MAG side) if coolant leaks.
a. Coolant leaking from leak indicator hole means a damaged rotary seal inside mag-
neto cover.
Replace both rotary seal and oil seal (refer to COOLING SYSTEM and MAGNETO
SYSTEM).
6. Check coolant bleeding screw on thermostat housing.
a. Screw is loosed/missing and/or gasket ring is missing/broken.
Retighten/add screw and replace gasket ring.
7. Check condition of hoses and hose clamps fixation.
a. Hoses are brittle and/or hard.
Replace.
b. Hose clamps are loose.
Retighten clamps.
8. Check condition of impeller located on the water pump shaft.
a. Impeller wings broken and/or impeller thread is damaged.
Replace.
9. Check coolant drain screw on water pump housing MAG side (marked “Drain”).
a. Copper ring on drain screw leaks.
Retighten screw and/or replace copper gasket ring.
VMR2004_125_03_02A.FM 03-02-1
Section 03 ENGINE

Test/Inspection 10. Check cooling fan and connection.
a. Fan motor faulty.
Replace.
b. Wire harness is brittle or hard (no connection).
Replace.
11. Check cylinder head and/or cylinder base gasket.
a. Worn out gasket(s) is (are) causing water leakage.
Replace gasket(s) and refill with coolant and oil (refer to COOLING/LUBRICATION
SYSTEM and TECHNICAL DATA).
12. Check intermediate gear(s) behind magneto cover.
a. Worn out and/or broken gear(s) is (are) causing less coolant supply.
Replace worn out and/or broken gear(s) (refer to LUBRICATION/MAGNETO SYSTEM).
13. Check radiator fan switch and fuse 20A.
a. Faulty fan switch and/or faulty fuse.
Replace defective part(s).
14. Check radiator condition for leakage.
a. Radiator cracked or deformed.
Replace radiator.
15. Check mud/dust in radiator fins.
a. Radiator fin obstructed, hard air cooling.
Clean radiator fins
16. Check if water pump shaft is seized.
a. Water pump shaft does not turn.
MAGNETO SYSTEM
SYMPTOM NO SPARK.
Test/Inspection 1. Check engine stop switch position.
a. Engine stop switch is in OFF position.
Place engine stop switch to RUN position.
2. Check battery.
a. Battery shows less power.
Reload battery.
b. Battery has electrical failure.
Replace battery.
3. Check condition of fuse(s).
a. Faulty fuse(s).
Replace.
03-02-2 VMR2004_125_03_02A.FM
Section 03 ENGINE
SYMPTOM NO SPARK.
Test/Inspection 4. Check spark plug electrode condition.
a. Gap is too big.
Readjust gap (refer to TECHNICAL DATA).
b. Spark plug condition is bad.
Diagnose spark plug condition and replace it (refer to IGNITION SYSTEM).
5. Check spark plug cable and ignition wire.
a. Cable and/or ignition wire is (are) damaged and/or shows electrical failure.
Replace damaged part(s).
6. Check ignition coil for damage and/or electrical failure.
a. Ignition coil damaged and/or resistance value out of specification
(refer to TECHNICAL DATA).
Replace ignition coil.
b. Connector is corroded or ignition coil shows electrical failure.
Clean connector area and/or replace ignition coil.
c. Wire harness is brittle or hard (no connection).
Replace.
7. Check CPS (crankshaft position sensor) for damage and/or electrical failure.
a. Sensor shows electrical failure and/or damages.
Replace CPS.
b. Connector is corroded.
Clean and reconnect.
c. Resistance value is out of specification (refer to TECHNICAL DATA).
Replace CPS.
8. Check wire harness for cracks or other damages.
a. Harness shows electrical failure and/or other damages.
Replace wire harness and/or damaged wire section.
9. Check magneto for damage and/or electrical failure.
a. Radial position of rotor wrong due to a broken woodruff key.
Replace woodruff key.
b. Connector on magneto is damaged and/or has electrical failure.
Repair and clean contacts of connector.
c. Coating on stator winding is damaged.
Replace magneto.
d. Resistance value is out of specification (refer to TECHNICAL DATA).
Replace magneto.
10. Check electronic module.
a. Module shows electrical failure or damages.
Replace electronic module.
b. Connectors are corroded.
Clean and reconnect.
c. Electronic module has bad ground to the vehicle frame.
Clean metal surface for good ground.
VMR2004_125_03_02A.FM 03-02-3
Section 03 ENGINE
LUBRICATION
SYMPTOM LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION.
Test/Inspection 1. Check oil level and search for leakage on crankcase and/or defective seals.
a. Crankcase is leaking due to damage.
Rebuild engine with new crankcase and gasket parts. Use a high quality oil
b. Crankcase is leaking due to loose screws.
Retighten screws with recommended torque.
c. Sealing rings, O-rings and/or gaskets are brittle and/or hard or damaged.
Replace damaged parts.
d. Piston rings worn out (blue-colored engine exhaust emission).
Replace piston rings (refer to CYLINDER AND HEAD).
e. Piston rings are broken (low compression and blue-colored engine exhaust emission).
Replace piston rings (refer to CYLINDER AND HEAD).
f. Valve stem seal damaged and/or sealing lip is hard and/or brittle.
Replace all valve stem seals.
2. Check oil filter for contamination.
a. Oil filter clogged.
Replace oil filter and oil at the same time. Use a high quality oil
3. Check oil pressure regulator valve (spring) function.
a. Valve spring damaged (valve always open).
Replace spring.
b. Valve stays open in crankcase PTO due to contamination (metallic particles).
Clean and/or repair valve piston.
4. Check oil drain plug on engine bottom.
a. Plug is loosed and/or gasket ring is missing.
Retighten the plug and/or place gasket ring.
5. Check oil strainer on engine bottom.
a. Screw(s) is (are) loosed and/or gasket is damaged, brittle or hard.
Retighten screw and/or replace gasket.
b. Oil strainer is clogged due to contamination.
Clean or replace strainer and diagnose causes. Replace possible damaged parts.
Use high quality oil (refer to TECHNICAL DATA).
6. Check leak indicator hole for oil leaks (water pump housing area MAG side).
a. Oil leaking from leak indicator hole means a damaged oil seal inside magneto cover
on water pump shaft.
Replace both rotary seal and oil seal
(refer to COOLING SYSTEM and MAGNETO SYSTEM).
7. Check oil pressure switch function.
a. Oil pressure switch damaged.
Replace oil pressure switch.
03-02-4 VMR2004_125_03_02A.FM
Section 03 ENGINE
SYMPTOM LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION.

Test/Inspection 8. Check oil orifice(s) on the oil pump suction side.
a. Oil orifice(s) is (are) clogged.
Clean from contamination. Replace oil and oil filter if necessary
(refer to MAINTENANCE or LUBRICATION).
9. Check oil pump operation.
a. Oil pump rotor is out of wear limit.
Replace oil pump shaft (refer to LUBRICATION).
b. Oil pump seized due to oil leakage and/or air inclusion.
Replace oil pump (refer to LUBRICATION).
c. Gears driving oil pump are broken or damaged.
Replace gears.
d. Incorrect oil being used.
Use a high quality oil (refer to TECHNICAL DATA).
10. Check plain bearings in crankcase for heavy wear.
a. Plain bearings out of specification (increased clearance).
Replace all plain bearings at the same time (refer to CRANKSHAFT).
SYMPTOM OIL CONTAMINATION (WHITE APPEARANCE).

Test/Inspection 1. Check leak indicator hole (water pump housing area MAG side) if water and oil
leaks.
a. Leakage of oil/water mixture from leak indicator hole means damaged oil seal and
rotary seal inside magneto cover on water pump shaft.
Replace both rotary seal and oil seal and refill with recommended oil and/or coolant
(refer to COOLING SYSTEM and MAGNETO SYSTEM).
2. Check cylinder head and/or cylinder base gasket.
a. Gasket damaged or leaking.
Retighten cylinder head with recommended torque and/or replace gasket.
3. Check screws for torque.
a. Screws not fixed.
Retighten screws with recommended torque and/or replace oil.
4. Check oil for particles (may indicate possible damages inside the engine).
a. Oil contamination due to metal or plastic particles.
Replace possibly damaged parts. Use a high quality oil (refer to TECHNICAL DATA).
VMR2004_125_03_02A.FM 03-02-5
Section 03 ENGINE
CYLINDER AND HEAD

SYMPTOM UNUSUAL ENGINE NOISE AND/OR VIBRATION IN IDLE SPEED.
Test/Inspection 1. Check operation of decompressor located on camshaft.
a. Decompressor shaft stucks and/or torsion spring is damaged.
Replace spring and/or decompressor mechanism.
b. Loose camshaft gear.
Retighten camshaft gear (refer to CYLINDER AND HEAD).
2. Check chain tensioner operation.
a. Faulty chain tensioner.
Replace spring and/or mechanism.
3. Check valve adjustment.
a. Intake and/or exhaust valves not adjusted correctly.
Adjust valves.
SYMPTOM UNUSUAL ENGINE NOISE AND/OR VIBRATION WHILE OPERATING.

Test/Inspection 1. Check items 1 and 2 of UNUSUAL ENGINE NOISE AND/OR VIBRATION IN IDLE
SPEED.
2. Check noise coming from cylinder head area.
a. Check valve clearance.
Readjust valve clearance and/or replace defective part(s).
b. Chain guide worn out.
Replace chain guide.
c. Stretched chain and/or worn out sprocket.
Replace chain and sprocket at the same time.
d. Sprocket screw got loose.
Retighten screw with recommended torque.
e. Rocker arm(s) is (are) worn out (valve adjustment).
Readjust valve clearance and/or replace rocker arm(s).
f. Thrust washer(s) on rocker arm shaft is (are) missing.
Fit thrust washer(s) (refer to CYLINDER AND HEAD).
SYMPTOM OIL CONTAMINATION ON CYLINDER AND/OR HEAD.

Test/Inspection 1. Check screws for torque.
a. Loose screws.
Retighten screws with recommended torque.
b. Gaskets are brittle, hard, worn out or damaged.
Replace damaged gasket(s).
03-02-6 VMR2004_125_03_02A.FM
Section 03 ENGINE
CRANKSHAFT AND BALANCER SHAFT

SYMPTOM UNUSUAL ENGINE NOISE AND/OR VIBRATIONS.
Test/Inspection 1. Check for possible plain bearing failure.
a. Oil pressure is out of specified values.
Replace damaged parts (refer to LUBRICATION).
b. Connecting rod small end bearing is damaged and/or out of specification.
Replace damaged and/or worn out part(s).
c. Connecting rod big end clearance is out of specification.
Replace damaged and/or worn out part(s).
d. Crankshaft plain bearing MAG/PTO side is damaged and/or out of specification.
Replace crankshaft and plain bearing MAG/PTO at the same time
(refer to CRANKSHAFT).
2. Check ball bearing(s) on balancer shaft end(s).
a. Ball bearing(s) do(es) not move freely.
Replace bearing(s).
3. Check that mark on balancer shaft is aligned with crankshaft position mark.
a. Mark on balancer shaft and crankshaft are not aligned.
Readjust position of balancer shaft and crankshaft
(refer to CRANKSHAFT/BALANCER SHAFT).
GEARBOX
SYMPTOM UNUSUAL ENGINE NOISE AND/OR VIBRATIONS.
Test/Inspection 1. Check oil level in engine.
a. Oil leakage from engine.
Replace damaged gasket(s) and/or oil seal(s), torque screws and refill with oil up
to specified level (refer to TECHNICAL DATA).
2. Check bearings in the gearbox for free movement.
a. Bearing(s) do(es) not move freely.
Replace bearing(s).
3. Check for knocking noise.

a. Tooth of gears are damaged and/or worn.
Replace respective gears.
VMR2004_125_03_02A.FM 03-02-7
Section 03 ENGINE
SYMPTOM GEAR INDICATION FAILS.

Test/Inspection 1. Check wire harness connector pins (gear indicator) and/or electronical system.
a. Connector pins are corroded and/or damaged.
Clean connector and/or replace wire harness if damaged.
b. Electronical system failed and/or damaged.
Repair and/or replace damaged part(s).
2. Check contact screws on PTO side (behind CVT driven pulley) for damage
and/or wear.
a. Shifting indicator switch(es) pin(s) is (are) worn and/or damaged.
Replace shifting indicator switch(es).
b. Contact(s) is (are) corroded and/or contact screw for wire harness got loose.
Clean contact surface and retighten contact screw(s) with recommended torque.
c. Wire harness has broken cables.
Replace wire harness.
SYMPTOM GEAR(S) IS (ARE) HARD TO SHIFT.

Test/Inspection 1. Check shift shaft spline and/or shift forks for wear and/or damages.
a. Shift shaft is worn out and/or shows damaged splines.
Replace shift shaft.
b. Shift drum track(s) and/or splines is (are) worn out or damaged.
Replace shift drum and damaged part(s).
c. Shift fork(s) is (are) worn out and/or engagement pins are damaged.
Replace shift fork(s).
d. Shift fork(s) is (are) worn out and/or fork(s) is (are) damaged.
Replace shift fork(s).
e. Shift gear(s) is (are) worn out.
Replace shift gear(s).
f. Shifting indicator switch(es) pin(s) is (are) worn out (no roundings on top of pin).
Replace shifting indicator switch(es).
2. Check engine idle speed (choke in use).
a. Idle speed is too high (CVT starts to work).
Adjust idle speed.
b. Choke is in use and increases the engine RPM.
Release choke.
3. Check CVT one way clutch on drive pulley.
a. CVT one way clutch was not lubricated correctly.
Lubricate CVT one way clutch (refer to CVT).
b. CVT one way clutch is worn out or damaged.
Replace defective part(s) (refer to CVT).
03-02-8 VMR2004_125_03_02A.FM
Section 03 ENGINE
SYMPTOM GEAR(S) IS (ARE) HARD TO SHIFT.

Test/Inspection 4. Check transmission lever and connecting rod.
a. Ball joint and/or ball joint nut is (are) loose.
Retighten or replace the ball joint.
5. Check spring on shifter plate.
a. Broken spring.
Replace the spring.
6. Check for any mud intrusion.s
a. CVT parts dirty.
Clean all CVT parts.
REWIND STARTER
SYMPTOM REWIND STARTER ROPE DOES NOT REWIND.
Test/Inspection 1. Check rewind spring.
a. Broken spring.
Replace spring (refer to REWIND STARTER).
SYMPTOM REWIND STARTER PAWL DOES NOT ENGAGE.

Test/Inspection 1. Check stop spring.
a. Broken stop spring.
Replace.
2. Check pawl and pawl lock.
a. Pawl and pawl lock are stuck together because of heat.
Replace.
3. Check pawl and rope sheaves.
a. Pawl and rope sheaves are stuck together because of heat.
Replace.
VMR2004_125_03_02A.FM 03-02-9
Section 03 ENGINE
CVT
SYMPTOM THE ATV ACCELERATES SLOWLY, ESPECIALLY WHEN IT IS STOPPED.
Test/Inspection 1. Check drive belt condition.
a. Belt is too narrow (drive belt engagement is higher in drive pulley).
Replace belt if width is less than specified (refer to CVT and/or TECHNICAL DATA).
2. Check roller(s) on governor cup and/or lever condition on drive pulley sliding
half.
a. Roller(s) is (are) worn and/or damaged (refer to CVT).
Replace governor cup assembly.
b. Lever(s) on drive pulley sliding half is (are) worn and/or damaged (refer to CVT).
Replace all levers at the same time (lever kit).
3. Check drive pulley sliding half for free axial movement.
a. Sliding half is stuck (refer to CVT).
4. Check condition of drive/driven pulley spring.
a. Drive pulley spring tension is too smooth and/or damaged (refer to CVT).
Replace spring.
b. Driven pulley spring tension is too stiff (refer to CVT).
Replace spring.
5. Check carburator adjustment and/or high altitude calibration.
a. Carburator is not adjusted according to specified values and/or high altitude calibration.
Readjust carburator.
6. Check engine condition.
a. Low engine compression.
7. Check ignition condition.
a. Faulty spark plug.
Install new spark plug(s).
8. Check valve adjustment.
a. Intake and/or exhaust valves are not adjusted correctly.
Adjust valves.
9. Check differentials operation.
a. Vehicle on Neutral is hard to move.
Repair or replace defective part(s).
03-02-10 VMR2004_125_03_02A.FM
Section 03 ENGINE
SYMPTOM ENGINE MAXIMUM RPM IS TOO HIGH AND TOP SPEED IS NOT REACHED.
Test/Inspection 1. Check items 1 to 3 of THE ATV ACCELERATES SLOWLY, ESPECIALLY WHEN IT
IS STOPPED.
2. Check drive/driven pulley spring tension.
a. Drive pulley spring tension is too stiff.
Replace spring (recommended Bombardier spring).
b. Driven pulley spring tension is too smooth and/or damaged (refer to CVT).
Replace spring.
3. Check drive/driven pulley area for contamination and/or water intrusion.
a. CVT area is contaminated with water, dirt or oil.
Clean CVT system and replace damaged part(s).
SYMPTOM DRIVE PULLEY NOISE IN IDLE SPEED.

Test/Inspection 1. Check slider shoes (drive pulley).
a. Worn slider shoes (increased clearance between governor cup and drive pulley
sliding half).
Replace all slider shoes at the same time (slider shoes kit).
2. Check driven pulley sliding mechanism (between driven pulley outer and inner
half).
a. Mechanism is stucked and/or damaged.
Replace driven pulley assembly.
3. Check roller(s) and/or levers for wear (located on sliding half of drive pulley).
a. Roller(s) on governor cup is (are) worn out and/or damaged (refer to CVT).
Replace governor cup assembly.
b. Lever(s) on drive pulley sliding half is (are) worn out and/or damaged (refer to CVT).
Replace all levers at the same time (lever kit).
4. Check drive pulley screw for torque.
a. Loose screw.
5. Check one-way clutch condition on drive pulley sliding half.
a. Bearing(s) do(es) not move freely.
Replace damaged part(s) and lubricate inside of one-way clutch (refer to CVT).
b. Spring sleeve(s) inside one-way clutch is (are) worn out.
Replace both sleeves and springs and lubricate inside of one-way clutch
(refer to CVT).
c. Spring(s) inside one-way clutch is (are) worn out.
Replace both pins and springs and lubricate inside of one-way clutch (refer to CVT).
VMR2004_125_03_02A.FM 03-02-11
Section 03 ENGINE
SYMPTOM DRIVE PULLEY NOISE WHEN ACCELERATING/DECELERATING.

Test/Inspection 1. Check items 1 to 5 of DRIVE PULLEY NOISE IN IDLE SPEED.
2. Check if belt runs in dry conditions.
a. Drive pulley area is wet/contaminated due to water/dirt intrusion.
Clean driven pulley area and/or drain water out of CVT cover.
3. Check drive/driven pulley screw for torque.
a. Loose screw on drive and/or driven pulley.
4. Check cam and driven pulley fixed half for wear.
a. Cam and/or drive pulley fixed half out of wear limit and/or damaged.
5. Check torque gear fixed in driven pulley sliding half for wear.
a. Torque gear out of wear limit and/or damaged.
Replace torque gear (refer to CVT).
6. Check for foreign particles in CVT area (stones, dirt, etc.).
a. Small particles damaged belt and/or pulley surface(s).
Clean system and replace damaged parts (refer to CVT).
SYMPTOM VIBRATIONS ORIGINATING FROM DRIVE PULLEY.

Test/Inspection 1. Check tightening torque of drive pulley nut.
a. Moving sliding half.
Retighten nut.
2. Check fixed half bushings.
a. Excessive gap between bushings and fixed half shaft, thus restraining sliding half
movements.
Replace fixed half assembly.
3. Check starter ring gear condition.
a. Starter ring gear loosened.
Retighten ring gear and/or mount it in original position (balanced system).
4. Check if slider shoes are present and/or placed in correct position.
a. Slider shoe(s) is (are) missing and/or damaged.
Replace all slider shoes at the same time (slider shoes kit).
03-02-12 VMR2004_125_03_02A.FM
Section 03 ENGINE
SYMPTOM VIBRATIONS ORIGINATING FROM DRIVEN PULLEY.

Test/Inspection 1. Check fixed and sliding half bushings on driven pulley.
a. Excessive gap between bushings and CVT shaft, thus restraining sliding half
movements.
Replace fixed and/or sliding half of driven pulley, polish CVT shaft area with fine
emery cloth and wipe clean with a cloth.
SYMPTOM PULLEYS DO NOT DOWN/UP SHIFT PROPERLY.

Test/Inspection 1. Check drive pulley bushings (cleanliness, wear, etc.).
a. Bushings stick to fixed half pulley shaft.
Clean or replace.
b. Spring seat sticks to sliding half pulley bushing.
Clean system and/or replace sliding half pulley.
c. One-way clutch does not operate properly.
Clean system and/or replace damaged part(s).
2. Check driven pulley spring tension.
a. Driven pulley spring tension is too weak and/or broken.
Replace.
b. Driven pulley cam is worn or damaged.
Replace.
SYMPTOM BELT GLAZED EXCESSIVELY OR HAVING BAKED APPEARANCE.

Test/Inspection 1. Check if CVT air intake and/or outlet is clogged.
a. CVT area heats up due to contamination.
Clean air intake and/or outlet from contamination.
b. Fans located on drive pulley fixed half (underneath ring gear) are clogged.
Clean from contamination.
2. Check if pulley halves are clean.
a. Oil on pulley surfaces.
Clean pulley halves and replace belt.
b. Water intrusion in CVT area.
A00D0AY
Find root cause and repair. Drain water and replace belt.
VMR2004_125_03_02A.FM 03-02-13
Section 03 ENGINE
SYMPTOM BELT WORN EXCESSIVELY IN TOP WIDTH.

Test/Inspection 1. Check drive belt width.
Considerable a. Considerable wear.
use Replace belt if narrower than specified (refer to CVT or TECHNICAL DATA).
2. Check drive belt identification number.

a. Improper belt angle (wrong type of belt).
Replace belt with an appropriate drive belt.
3. Check for localized belt wear caused by belt slippage.

New belt a. Localized wear.
A00D0BY
Replace belt.
SYMPTOM BELT DISINTEGRATION.

Test/Inspection 1. Check drive belt identification number.
a. Excessive belt speed.
Using unspecified type of belt. Replace belt with proper type of belt
2. Check if pulley halves are clean.
a. Oil on pulley surfaces.
Clean pulley surfaces with fine emery cloth and wipe clean using Pulley Flange
Cleaner (P/N 413 711 809) and a cloth.
b. Drive/driven pulley halves are damaged through stones inside CVT area.
Clean pulley surfaces with fine emery cloth, wipe clean with a cloth or replace
A00DOEY drive/driven pulley halves and belt.
SYMPTOM FLEX CRACKS BETWEEN COGS.

Test/Inspection 1. Check drive belt condition.
a. Considerable use, belt wearing out.
Replace.
b. Brittle belt condition through aging.
Replace belt.
A00D0GY
03-02-14 VMR2004_125_03_02A.FM
Section 03 ENGINE
ENGINE GENERAL
SYMPTOM ENGINE BACKFIRES.
Test/Inspection 1. Check spark plug and/or electrical system.
a. Carbon accumulation caused by defective spark plug.
Clean carbon accumulation and replace spark plug.
b. Electrical system has failure.
2. Check leakage on intake manifold.
a. Air leak on intake system.
Retighten screws and/or replace intake manifold.
3. Check exhaust air leaking.
a. Exhaust gasket is leaking.
Retighten screws and/or replace exhaust gasket.
4. Check intake valve(s) for leaking.
a. Intake valve(s) is (are) leaking.
Repair or replace valve(s).
5. Check if fuel supply is insufficient at high RPM.
a. Fuel line is contaminated and/or bent (engine gets lean).
Clean and/or replace defective part(s).
6. Check carburation.
a. Faulty carburetor settings.
Adjust carburetor.
SYMPTOM ENGINE SUDDENLY TURNS OFF.

Test/Inspection 1. Check spark plug cap contact and/or cable.
a. Spark plug cap loose.
Replug cap.
b. Spark plug cable melted and/or damaged.
Replace spark plug cable.
2. Check condition of spark plug (blue spark ideal).
a. Red, jumping spark means a damaged spark plug.
Replace spark plug with appropriate heat range (refer to TECHNICAL DATA).
b. Condition of spark plug.
Readjust carburator and/or replace spark plug.
VMR2004_125_03_02A.FM 03-02-15
Section 03 ENGINE

Test/Inspection 3. Check fuel supply to engine intake.
a. Fuel valve is switched off.
Turn on fuel valve.
b. Run out of fuel.
Turn fuel valve to “RES” position and refill.
c. Poor quality and/or wrong fuel.
Clean from contamination and use appropriate fuel (refer to TECHNICAL DATA).
d. Carburetor contaminated.
Clean jets and carburetor float chamber from contamination.
e. Fuel line clogged and/or bent.
Clean fuel supply from contamination and/or replace defective part(s).
f. Fuel supply insufficient at high RPM.
Clean fuel supply from contamination.
4. Perform engine leak test. Refer to ENGINE LEAK TEST procedure. Check for
possible piston seizure.
a. Damaged head gasket and/or seal and/or leaking inlet/exhaust valve(s).
Replace and/or repair defective parts.
5. Piston seizure (piston ring(s) damaged and/or cylinder shows grooves).
a. Spark plug heat range is too low.
Replace damaged parts and install spark plug with appropriate heat range
b. Compression ratio is too high.
Install genuine parts.
c. Poor oil quality.
Use a high quality oil.
d. Leaks at air intake manifold (engine gets too lean).
Retighten screws or replace air intake manifold.
e. Contamination (like sand) through engine intake.
Replace defective part(s) and use new air filter.
6. Melted and/or perforated piston dome; melted section at ring end gap.
a. Spark plug heat range is too low.
Install recommended spark plug (refer to TECHNICAL DATA).
b. Coolant less than recommended level (engine gets too hot).
Repair cooling circuit and/or refill with recommended liquid.
03-02-16 VMR2004_125_03_02A.FM
Section 03 ENGINE

Test/Inspection 7. Cracked or broken piston.
a. Cracked or broken piston due to excessive piston/cylinder clearance or engine
overreving.
Replace piston. Check piston/cylinder clearance (refer to CYLINDER AND HEAD).
8. Check connecting rod, crankshaft, rocker arm rollers movement.
a. Connecting rod failure due to lack of oil.
Repair and replace defective parts and use a high quality oil.
b. Crankshaft failure due to lack of oil.
Repair and replace defective parts and use a high quality oil.
c. Oil contamination due to clogged oil filter.
Replace oil filter and oil at the same time, replace defective part(s)
(refer to MAINTENANCE CHART).
9. Check valve springs exhaust/inlet.
a. Broken valve spring damages the cylinder head, valve(s), rocker arm(s)/piston.
Replace defective part(s) and do the valve adjustment.
10. Check for water intrusion through intake system into combustion chamber.
a. Water in intake system and/or combustion chamber.
SYMPTOM ENGINE TURNS OVER BUT FAILS TO START.

Test/Inspection 1. Check items of ENGINE DOES NOT START — NO SPARK AT SPARK PLUG.
2. Check spark plug.
a. Inspect spark plug (no spark) or wrong spark plug gap.
Readjust gap and clean spark plug or replace.
3. Check for fuel on spark plug.
a. Flooded engine (spark plug wet when removed).
Do not overchoke. Remove wet spark plug, turn ignition switch to OFF and crank
engine several times. Install clean dry spark plug. Start engine following usual
starting procedure.
4. Check engine compression.
a. Insufficient engine compression.
Replace defective part(s) (ex.: piston, ring(s), etc.).
b. Valve seat worn and/or damaged.
Repair by performing valve guide procedure (refer to CYLINDER AND HEAD).
Readjust valve clearance.
VMR2004_125_03_02A.FM 03-02-17
Section 03 ENGINE
ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH
SYMPTOM
MAXIMUM OPERATING RPM.
Test/Inspection 1. Check items of ENGINE SUDDENLY TURNS OFF.
2. Check air intake system.
a. Air filter is clogged due to contamination.
Replace air filter.
3. Check spark plug condition and/or gap.
a. Fouled spark plug or wrong spark plug gap.
Readjust gap and clean spark plug or replace.
4. Check spark plug type.
a. Improper spark plug heat range.
5. Check engine compression and perform engine leak test. Refer to ENGINE LEAK
TEST procedure. Check for possible piston seizure.
a. Damaged head gasket and/or seal and/or leaking inlet/exhaust valve(s).
Replace and/or repair defective parts.
b. Worn piston and/or piston ring(s).
Replace (refer to CYLINDER AND HEAD).
6. Check for water in fuel (wrong fuel).
a. There is water in fuel or wrong fuel.
Drain fuel system, search for leakage and refill it with appropriate fuel.
7. Check drive belt/CVT condition.
a. Worn belt.
Replace belt if width is less than specified (refer to CVT).

Test/Inspection 1. Check if cooling system shows any failure (see COOLING SYSTEM).
a. System is leaking.
Repair and/or replace damaged part(s).
2. Check condition and heat range of spark plug.
a. Melted spark plug tip or inadequate heat range.
3. Check air inlet and outlet of the CVT cover.
a. Air circulation is clogged (overheating).
Clean air circulation from contamination.
b. Drive belt worn and/or damaged.
Replace belt with an appropriate drive belt (refer to TECHNICAL DATA).
03-02-18 VMR2004_125_03_02A.FM
Section 03 ENGINE
SYMPTOM STARTER TURNS, BUT ENGINE DOES NOT CRANK.

Test/Inspection 1. Check gear condition on electric starter.
a. Worn and/or damaged starter gear.
Replace electric starter and/or starter drive.
2. Check condition of starter pinion gear.
a. Worn and/or damaged starter pinion and/or ring gear.
Replace starter drive and/or drive pulley fixed half.
3. Check splines on starter drive.
a. Poor movement of pinion gear on splines.
Clean and/or replace starter drive.
SYMPTOM ENGINE DOES NOT START — NO SPARK AT SPARK PLUG (SEE MAGNETO SYSTEM).
CONDITION AT ENGINE CRANKING.
Test/Inspection 1. Verify spark plug condition.
a. Defective, improperly set, worn out, fouled.
Identify source of problem and correct. Replace spark plug.
2. Verify condition of ignition coil and resistance with an ohmmeter.
a. Mechanically damaged part. Vibration problem. Electrically damaged part.
Replace ignition coil.
3. Verify condition of CPS and resistance with an ohmmeter and connector condi-
tion.
a. Defective CPS. Corroded connector terminal.
Replace CPS. Clean terminals and apply silicone dielectric grease.
b. Mechanically damaged part. Vibration problem. Electrically damaged part.
Replace CPS and/or tighten mounting screw(s).
c. Metallic particles caused a short circuit between the soldered connections.
Clean CPS from metallic dust.
4. Check magneto for damage and/or electrical failure.
a. Windings of stator have electrical failure (no charging causes an empty battery).
Replace magneto.
VMR2004_125_03_02A.FM 03-02-19
Section 03 ENGINE
Subsection 03 (LEAK TEST)
LEAK TEST 0
GENERAL VERIFICATION Remove:
– LH side panel
Before performing the cylinder leak test, verify the
following: – radiator cap
– intake port/air filter contaminated (clogged) with – Inlet hose of CVT cover.
dirt, sand, etc. (leads to worn valves, piston Unplug and remove spark plug cable.
rings and finally to leak of power)
Remove spark plug from cylinder head.
CAUTION: In case of piston ring and/or valve re-
placement always clean the whole engine and re- 2 1
place oil and oil filter.
– blue exhaust gas means damaged/worn piston
rings
– clamp(s) tightness
– radiator and hoses
– oily contamination on leak indicator hole (speed
sensor area) means a damaged oil seal on water
pump shaft
– coolant out of leak indicator hole means a dam-
aged rotary seal on water pump shaft
(refer to COOLING SYSTEM)
R400motr104A
– coolant escaping from water pump housing
means damaged gasket(s) and/or loosened 1. Spark plug cable
2. Spark plug
screws (refer to COOLING SYSTEM).
NOTE: For all the checkpoints mentioned above Remove valve cover (refer to CYLINDER AND HEAD).
see the appropriate engine section to diagnose
3 1
and repair the engine.
LEAK TEST PROCEDURE

2
PREPARATION AND TEST
NOTE: The following procedures should be done
with a cold engine.
Disconnect battery.
 WARNING
Always respect this order for disassembly;
disconnect BLACK (-) cable first. Electrolyte or
fuel vapors can be present in engine compart-
ment and a spark may ignite them and possi- R400motr105A
bly cause personal injuries. 1. Valve cover screws

2. Valve cover
3. Oil pressure switch
VMR2004_126_03_03A.FM 03-03-1
Section 03 ENGINE
Prepare
Rotate crankshaft until piston is at TDC.
To place piston at ignition TDC, it is possible to use
two procedures.
First possible procedure:
– Remove CVT cover. Refer to CVT section.
– Turn the drive pulley until piston is at TDC.
Second possible procedure:
– Using rewind starter, rotate the crankshaft until 1
piston is at ignition TDC.
To fix piston at ignition TDC, it is possible to use
two procedures. 2
R400motr107A
Lock camshaft using camshaft locking tool (P/N
529 035 926) (refer to CYLINDER AND HEAD). 1. Vehicle front side
2. Position for crankshaft locking bolt
CAUTION: When removing camshaft screw al-
ways lock camshaft using locking tool (P/N 529 Test
035 926) to avoid stretching the timing chain.
Connect to adequate air supply.
Set needle of measuring gauge to zero.
NOTE: Each tester will have specific instruction
on the gauge operation and required pressure.
Install gauge adapter into previously cleaned spark
plug hole.
Supply combustion chamber with air pressure.
1
R400motr106A 1
1. Camshaft locking tool

Using crankshaft locking bolt (P/N 529 035 617) for
crankshaft fixation at TDC (refer to CRANKSHAFT,
see CRANKSHAFT LOCKING PROCEDURE).
V07C0KA 2
1. Leak tester
2. Air supply hose
03-03-2 VMR2004_126_03_03A.FM
Section 03 ENGINE
Note the amount of leaking or percentage (depending

on tester).
LEAKAGE ENGINE
PERCENTAGE CONDITION
0% to 7% Excellent condition.
Fair condition;
8% to 15% proceed with tune
up or adjustment.
Poor condition;
engine will run and
16% to 30%
performance might be
down in some cases.
Very poor condition;
31% and higher diagnose and
repair engine.
Diagnose
Listen for air leaks.
– air escaping on intake port/carburetor means
leaking intake valve(s)
– air escaping on exhaust port means leaking ex-
haust valve(s)
– air bubbles out of radiator means leaking cylin-
der head gasket
– air/oil escaping from crankcase means damaged
gasket and/or loosened screws
(refer to GEAR BOX)
– air/coolant escaping from cylinder/head means
damaged gasket(s) and/or loosened screws
(refer to CYLINDER AND HEAD)
– air escaping into crankcase area means exces-
sively worn cylinder and/or broken piston rings.
NOTE: For all the checkpoints mentioned above
see the appropriate engine section to diagnose
and repair the engine.
INSTALLATION
NOTE: At reassembly, use the torque values and
Loctite products from the exploded views (refer to
particular engine sections).
For installation, reverse the preparation procedure.
Install a new valve cover gasket.
VMR2004_126_03_03A.FM 03-03-3
Section 03 ENGINE
REMOVAL AND INSTALLATION 0
25
15 Nm
4 (133 lbfin)
Multi-function switch 4 Nm 24
(35 lbfin)
29 Loctite 243
26
10 Nm
27 (89 lbfin)
8
15 Nm
(133 lbfin) Synthetic grease
2 10 Nm
7 28 (89 lbfin)
23 Nm 31
4 Nm (17 lbfft)
(35 lbfin) 30
3
7 Nm
(62 lbfin)
11 10 Nm
6 (89 lbfin) 4 Nm
(35 lbfin)
2.5 Nm 4 Nm

(23 lbfin) (35 lbfin)
10
5
15
2.5 Nm
(23 lbfin)
48 Nm Loctite
(35 lbfft) 243 61 Nm
(45 lbfft)
23 Nm 15
(17 lbfft)
14
12 15
13
V07C1TT
VMR2004_127_03_04A.FM 03-04-1
Section 03 ENGINE
11 Nm
20 (97 lbfin)
9
13 Nm
(115 lbfin) 23 1 18
22
17
16
17
23 Nm
21 (17 lbfft)
21
19
V07C1US
03-04-2 VMR2004_127_03_04A.FM
Section 03 ENGINE
GENERAL Drain engine oil and engine coolant.
The following procedures can be used with all ve-

hicles from the Outlander series.
During assembly/installation, use the torque val-
complete procedure.
 WARNING
Torque wrench tightening specifications must
strictly be adhered to.
Locking devices (ex.: locking tabs, elastic stop
nuts, self-locking fasteners, cotter pin, etc.)
must be installed or replaced with new ones V07C03A 1
where specified. If the efficiency of a locking 1. Oil drain plug
device is impaired, it must be renewed.
ENGINE REMOVAL
Vehicle and Engine Preparation
Place the vehicle on a workstation that will have
access to an engine-lifting hoist. Then start with
initial preparation of vehicle by doing the following.
Place the transmission lever on P position.
Turn fuel valve OFF.
Disconnect BLACK (-) cable from battery, then RED
(+) cable.
 WARNING V07C06A 1
Always disconnect battery or starter cables 1. Cooling drain plug
exactly in the specified order, BLACK (-) cable
Remove:
first. It is recommended to disconnect electri-
cal connections prior to disconnecting fuel lines. – seat
– LH and RH side panels
– LH and RH footwells
– console screws.
Refer to BODY.
VMR2004_127_03_04A.FM 03-04-3
Section 03 ENGINE
On right side of vehicle, remove or disconnect – engine ground cables

the following: – RED starter cable
– engine cover
– exhaust support no. 1
– radiator outlet hose
V07C12A 1 2
1. Engine ground cables
V07C10A 2 1 2. Starter cable
1. Exhaust support – temperature switch connectors

2. Radiator outlet hose
– link rod no. 2 from shifting plate no. 3
V07C13A
V07C11A 2
1. Link rod
2. Shifting plate
03-04-4 VMR2004_127_03_04A.FM
Section 03 ENGINE
– throttle cable no. 4 from carburetor – engine blow-by hose from air box
– radiator inlet hose
1 2
– impulse line
V07C16A
1. Engine blow-by hose

V07C14A 1 2. Air box
1. Impulse line – rear propeller shaft bolt

– carburetor clamp (air box side) – disconnect unit bolts from engine.
– carburetor vent hose On left side of vehicle, remove the following:
– air box screws – inner fender (refer to BODY)
– air box bolt then air box
2 1
2
V07C15A
1. Carburetor vent hose

2. Air box screws
V07C18A 1
1. Air box
2. Air box bolt
VMR2004_127_03_04A.FM 03-04-5
Section 03 ENGINE
– CVT outlet hose no. 5 From top side, disconnect the following:
– magneto
– CPS (Crankshaft Position Sensor)
NOTE: The magneto and CPS connectors are lo-
cated under the console, on top of the frame.
– disconnect unit connectors (4x4 models)
– brake switch connectors
V07C19A
– CVT inlet hose no. 6 with its deflector no. 7

– choke cable no. 8 from carburetor
– carburetor fuel line
2 3
V07C1BA 2 1
4X4 MODEL SHOWN
1. Disconnect unit connector
2. Brake switch connectors
– spark plug cable no. 11

– engine pressure switch
– VSS (Vehicle Speed Sensor)
– indicator switches.
V07C1AA 1
1. CVT inlet hose
2. Choke cable
3. Carburetor fuel line
NOTE: Pinch fuel line with hose pincher (P/N 295

000 076) before removing it from carburetor.
– carburetor
– exhaust pipe nuts no. 9
– upper engine support no. 10.
V07C1CA 2 1
1. Engine pressure switch
2. VSS connector
3. Indicator switches connector
03-04-6 VMR2004_127_03_04A.FM
Section 03 ENGINE
Attach all cables, wires and hoses on the frame. From bottom side, do the following:
Install engine lifting tool (P/N 529 035 898) in lifting Remove front and rear engine mounting bolts
location. no. 12 and no. 13.
Remove front engine mounting bracket no. 14.
V07C1DA
Install the lifting tool (P/N 529 035 619) to tilt engine.
V07C1EA 2 1
1. Front engine mounting bracket
2. Master cylinder
Engine Removal
Lift engine approximately 25.4 to 38 mm (1 to
1-1/2 in).
Disconnect the rear propeller shaft from engine.
Lift engine a little more to clear rear mounting brack-
et from frame.
On 4x4 models, turn the rear of engine toward left
side to disengage the front propeller shaft from
V07C17A 1 the disconnect unit.
1. Tool to tilt engine (P/N 529 035 619)
 WARNING
Do not hit the fuel tank or fuel tank fittings.
Take the engine out of the frame.
VMR2004_127_03_04A.FM 03-04-7
Section 03 ENGINE
ENGINE INSTALLATION On right side of vehicle, install or connect the

following:
Engine Installation – rear propeller shaft bolt
Lift engine and move it into the frame (cylinder – air box screw
head first). – blow-by hose
On 4x4 models, insert the front output shaft end – carburetor clamps
into the disconnect unit.
– carburetor vent hose
Move the rear side of engine into the frame and
install the rear propeller shaft. – impulse line
Install the front engine mounting bracket. – radiator inlet hose
Lower engine into place. – throttle cable
Install front engine mounting bolt. Do not torque – temperature switch connector
yet. – RED starter cable
Install rear engine mounting bolt and torque both – engine ground cables
bolts. NOTE: Do not forget the star washer.
Remove the engine lifting tool. – link rod
From the top side, connect the following: NOTE: The transmission lever must be on PARK.
– indicator switches – exhaust support
– VSS – engine cover.
– engine pressure switch Final Assembly Procedure
– brake switch Install console, LH and RH side panels then seat.
– disconnect unit (4x4 models) Make sure coolant and oil drain plugs are rein-
– CPS stalled and tight.
– magneto. Fill cooling system. Refer to COOLING SYSTEM.
On left side of vehicle, install the following: Fill engine with the right amount of oil. Put oil of
appropriate viscosity.
– upper engine support
Reconnect battery.
– exhaust pipe nut
NOTE: Install a new gasket before screwing the  WARNING
exhaust pipe. Connect RED (+) cable then BLACK (-) cable.
– carburetor Always connect RED (+) cable in first.
– carburetor fuel line
Before starting the engine, remove spark plug and
– choke cable ground it on engine or frame. Run starter about thir-
– CVT inlet and outlet hoses ty seconds. This operation will activate the oil pump.
– radiator outlet hose Reinstall spark plug and spark plug cable.
– air box Start vehicle.
– inner fender Set carburetor.
– footrest. Stop engine and check if coolant and oil levels are
correct.
Test drive to confirm all is working well.
03-04-8 VMR2004_127_03_04A.FM
Section 03 ENGINE
ANTI-VIBRATION SYSTEM EXHAUST SYSTEM

NOTE: Use the same procedure for the front and
rear anti-vibration system.  WARNING
Never touch exhaust system components im-
Anti-Vibration System Removal mediately after the engine has been run be-
cause these components are very hot.
With the engine removed, insert a punch in hole of
anti-vibration bushing no. 15 and push the other
anti-vibration bushing out of the housing. Exhaust Pipe Removal
Remove:
– spring no. 16 from exhaust bracket no. 1
V07C1FA
Use punch to remove the other bushing.
V07C1HA
– springs no. 17 retaining exhaust pipe no. 18

and muffler no. 19
– the exhaust pipe nuts no. 9.
Push the exhaust pipe forward then remove it by
V07C1GA
the RH side.
Exhaust Pipe Inspection

Anti-Vibration System Installation
Check exhaust pipe for cracks, bending or other
Apply synthetic grease on anti-vibration bushings damages. Replace if necessary.
and insert them in engine support, one on each side.
VMR2004_127_03_04A.FM 03-04-9
Section 03 ENGINE
Exhaust Pipe Installation

Install a new gasket no. 20 on exhaust pipe end
(cylinder head side).
With muffler no. 19 secured in its rubber mounts
no. 21, secure exhaust pipe on cylinder head with
exhaust nuts no. 9.
1 3
X000000 2 1
1. Heat shield
2. Muffler tube
Muffler Heat Shield Inspection

Check if the heat shield is cracked or damaged.
Replace it if necessary.
Muffler Heat Shield Installation
The installation is the reverse of the removal pro-
cedure.
2
SHIFTING SYSTEM
V07C1IA NOTE: Always set the NEUTRAL position before re-
moving any parts from the shifting system.
1. Nut
2. Exhaust pipe
3. Cylinder head Transmission Lever Handle Removal
Tighten nuts, making sure exhaust pipe is properly Unscrew the nut no. 24 under transmission lever
aligned inside muffler ball socket then install ex- handle no. 25.
haust pipe springs no. 17 after pushing muffler
forward over exhaust pipe.
Install the exhaust bracket spring no. 16.
Muffler Removal
Remove exhaust pipe springs no. 17.
Pull muffler no. 19 backward, pull out retaining rod
from rubber mounts no. 21 and remove muffler.
Muffler Inspection
Check muffler and retaining rods for cracks or other
damages. Replace if necessary.
Check if the rubber mounts are cracked, hard, brit-
tle or damaged; change if necessary.
Muffler Installation V07C1KA 2 1

For the installation, reverse the removal procedure. 1. Transmission lever handle
2. Nut
Muffler Heat Shield Removal Unscrew transmission lever handle.
Remove the muffler no. 19.
Unscrew bolts no. 22 retaining heat shield no. 23
to muffler tube.
03-04-10 VMR2004_127_03_04A.FM
Section 03 ENGINE
Transmission Lever Handle Installation Transmission Lever Inspection

The installation is the reverse of removal procedure. Check the transmission lever for bending or cracks.
Check the tie-rod at the end of lever.
Transmission Lever Removal
Replace the lever if necessary.
Remove:
– RH side panel (refer to BODY) Transmission Lever Installation
– transmission lever handle no. 25 For installation, reverse the removal procedure.
– link rod bolt no. 26
Link Rod Removal
1 Remove:
– RH side panel (refer to BODY)
– link rod bolt no. 26
1
V07C1LA 2 3
1. Link rod bolt
2. Link rod
3. Transmission lever
– spring no. 27 and tie-rod nut no. 28 retaining

the transmission lever no. 29 to the frame V07C1LA 2 3
1. Link rod bolt
2. Link rod
3. Transmission lever
– nut no. 30 retaining link rod no. 2 to shifting

plate no. 3.
V07C1MA
– transmission lever.
V07C1NA
Remove the link rod.

VMR2004_127_03_04A.FM 03-04-11
Section 03 ENGINE
Link Rod Inspection Shifting Plate Removal

Check the link rod for bending or cracks. Remove the RH side panel (refer to BODY).
Check the tie-rod at the end of link rod. Detach the link rod no. 2 from shifting plate no. 3.
Replace the link rod if necessary. Remove the shifting plate bolt no. 31.
Link Rod Installation
For installation, reverse the removal procedure.
However, pay attention to the following details.
NOTE: The engine must be engaged on NEU-
TRAL before working on shifting system.
Place the transmission lever on NEUTRAL position.
Install link rod.
Adjust the link rod so that the transmission lever
is located in the middle of NEUTRAL slot.
V07C1QA
Remove the shifting plate.

NOTE: Mark the location of shifting plate before
removing it from shift shaft.
V07C1OA
Shifting Plate Inspection
Check shifting plate for cracks, bending or other
Torque jam nuts. damages. Replace if necessary.
Shifting Plate Installation

Align shifting plate mark with shift shaft mark or if
no marks are visible (new parts), turn ignition key
ON and check if the NEUTRAL light is on.
NOTE: The engine must be engaged on Neutral to
perform the following procedure.
Align the shifting plate slot with the location with-
out splines on shift shaft.
Install the shifting plate bolt no. 31.
Install link rod and adjust it (refer to LINK ROD IN-
STALLATION above).
Install side panel and check if the system works
V07C1PA well.
ONE NUT ON BOTH SIDES OF LINK ROD
Verify if the transmission lever moves into the

PARK and LOW slots.
Install the side panel and test drive to confirm all
is working well.
03-04-12 VMR2004_127_03_04A.FM
Section 03 ENGINE
Subsection 05 (COOLING SYSTEM)
COOLING SYSTEM 0
WATER PUMP
10 Nm
(89 lbfin) 3
2
Right hand thread

4 2.5 Nm
(22 lbfin)
5 Engine oil
1
10 Multi-purpose grease
9 8 7
R400motr131S
VMR2004_128_03_05A.FM 03-05-1
Section 03 ENGINE
COOLING SYSTEM
12
17
13 11 10 Nm
(89 lbfin)
15 17
7 Nm
(62 lbfin)
21
5.5 Nm 19
(49 lbfin)
18
16 20 18 Nm
(159 lbfin)
21
7 Nm
(62 lbfin)
14
V07C1RS
03-05-2 VMR2004_128_03_05A.FM
Section 03 ENGINE
GENERAL
complete procedure.
 WARNING
nuts, self-locking fasteners, etc.) must be in-
stalled or replaced with new ones where spec-
ified. If the efficiency of a locking device is im-
paired, it must be renewed.
V07C0NA 1
COOLING SYSTEM LEAK TEST 1. Special plug
 WARNING Check all hoses, radiator no. 13 and cylinder/base

for coolant leaks. Spray a soap/water solution and
To avoid potential burns, do not remove the look for air bubbles.
radiator cap or loosen the engine drain plug
if the engine is hot.
INSPECTION
Open the access panel and remove the radiator Check general condition of hoses and clamp tight-
cap no. 11. ness.
Install special plug (radiator cap) (P/N 529 021 400) Check the leak indicator hole if there is oil or water.
and a hose pincher (P/N 295 000 076) on overflow
hose no. 12. Pressurize all system through cool- NOTE: Flowing water indicates a damaged rotary
ant reservoir to 103 kPa (15 PSI). seal no. 5. Oil out of the leak indicator hole indi-
cates a non working oil seal no. 10.
V07C0MA 1 2
R400motr132A 1
1. Hose pincher
2. Overflow hose 1. Leak indicator hole
VMR2004_128_03_05A.FM 03-05-3
Section 03 ENGINE
DRAINING THE SYSTEM System Capacity

Refer to TECHNICAL DATA.
 WARNING
Never drain or refill cooling system when en- Coolant Replacement Procedure
gine is hot.
 WARNING
To drain cooling system, partially unscrew cooling To avoid potential burns, do not remove the
drain plug no. 1 on the engine MAG side and re- radiator cap or loosen the engine drain plug
move radiator cap no. 11. if the engine is hot.
Drain the system completely.

Pinch radiator inlet hose no. 14 between radiator
and thermostat housing with a large hose pincher
(P/N 529 032 500).
1
R400motr231A
1. Cooling drain plug
CAUTION: If the drain plug is removed com-

pletely, pay attention to the gasket ring no. 2.
Never use the gasket ring a second time. Always
install a new one.
When cooling system is drained completely, screw V07C0AA 1
the cooling drain plug and torque it to 10 N•m 1. Hose pincher
(89 lbf•in).
Unscrew bleeding screw on top of thermostat
housing.
COOLANT REPLACEMENT
2 1
Recommended Coolant
Use Bombardier premixed coolant (P/N 293 600
038) or a blend of 50% antifreeze with 50% water.
Do not reinstall radiator cap.
CAUTION: To prevent rust formation or freezing
condition, always replenish the system with the
Bombardier premixed coolant or with 50% anti-
freeze and 50% water. Do not use tap water,
straight antifreeze or straight water in the sys-
tem. Tap water contains minerals and impuri-
ties which build up in the system. During cold
weather, straight water causes the system to
freeze while straight antifreeze thickens and
does not have the same efficiency. Always use
ethylene glycol antifreeze containing corrosion
inhibitors specifically recommended for alumi-
R400motr134A
num engines.
1. Bleeding screw area
2. Water temperature switch
03-05-4 VMR2004_128_03_05A.FM
Section 03 ENGINE
With vehicle on a flat surface, engine cold, refill ra-

diator no. 13. When the coolant comes out by the
thermostat housing hole, install the bleeding screw
and remove the hose pincher. Install the pressure
cap.
NOTE: Do not forget gasket ring when bleeding
screw is installed. Torque bleeding screw to 5 N•m
(44 lbf•in).
R400motr135A 1 2
1 1. Thermostat cover
2. 2 screws
– thermostat with gasket out of the hole.
R400motr237A
1. Gasket ring
2. Bleeding screw
Refill coolant tank no. 15 up to cold level mark. Install

the coolant tank cap. Run engine until thermostat
opens then stop engine.
When engine has completely cooled down, re-
check coolant level in radiator and coolant tank and
top up if necessary.
Each year or every 100 hours, check coolant con-
centration (freezing point) with proper tester.
R400motr136A 1
THERMOSTAT 1. Thermostat with gasket
The thermostat is a single action type. Test

To check thermostat, put in water and heat water.
Removal Thermostat should open when water temperature
NOTE: The thermostat is located on the top of cyl- reaches 65°C (149°F).
inder head, on intake side. Check if the gasket is not brittle, hard or damaged.
Install a hose pincher on both radiator hoses. If so, replace thermostat and gasket.
Remove:
Installation
– bleeding screw on thermostat cover
For installation, reverse the removal procedure,
– thermostat housing screws and pull thermostat
pay attention to the following details.
cover
Install the thermostat cover then torque screws to
7 N•m (62 lbf•in).
Check coolant level in radiator and coolant tank and
VMR2004_128_03_05A.FM 03-05-5
Section 03 ENGINE
WATER TEMPERATURE SWITCH Remove:

– radiator outlet hose no. 16
Removal – screws no. 1 and no. 2 retaining water pump
NOTE: The temperature switch is located on the housing no. 3
top of cylinder head, on intake side.
Install a hose pincher on both radiator hoses.
Unplug the water temperature switch then remove it.
1 2
R400motr137A 1
1. Screws M6 x 25 with sealing ring
R400motr149A 2. Screws M6 x 25
1. Water temperature switch – water pump housing no. 3.
2. Intake port
Test Inspection
To check water temperature switch, put in coolant Check if gasket is brittle, hard or damaged and re-
and heat coolant. place as necessary.
The water temperature switch should operate
when coolant temperature reaches 115°C (239°F).
Replace coolant temperature switch if necessary. 1
Installation
CAUTION: Never use the gasket ring a second
time. Always install a new one.
Torque temperature switch to 16 N•m (142 lbf•in).
Check coolant level in radiator and coolant tank and
WATER PUMP HOUSING

It is located on the engine MAG side.
Removal R400motr138A
Drain cooling system. 1. Gasket
03-05-6 VMR2004_128_03_05A.FM
Section 03 ENGINE
Installation Inspection
The installation is the opposite of the removal pro- Check impeller for cracks or other damage. Replace
cedure. impeller if damaged.
CAUTION: To prevent leaking, take care that
the gasket is exactly in groove when you rein- Installation
stall the water pump housing. The installation is the opposite of the removal pro-
Tightening sequence for screws on water pump cedure. Pay attention to the following detail.
housing is as per following illustration (criss-cross). CAUTION: Be careful not to damage impeller
wings during installation.
WATER PUMP SHAFT

3 Removal
1 2 Remove:
– water pump housing no. 3
– impeller no. 4
4 – magneto housing cover
R400motr231B (refer to MAGNETO SYSTEM)
– retaining ring no. 6 with appropriate pliers
WATER PUMP IMPELLER CAUTION: Never use the retaining ring a second
time. Always install a new one.
Removal – water pump gear no. 7
Remove:
1 2
– water pump housing no. 3
– impeller no. 4.
1
R400motr141A 3
1. Retaining ring
2. Water pump gear
R400motr140A
3. Thrust washer
1. Impeller
CAUTION: Water pump shaft no. 5 and impeller

no. 4 have right-hand threads. Remove by turn-
ing counterclockwise and install by turning
clockwise.
VMR2004_128_03_05A.FM 03-05-7
Section 03 ENGINE
NOTE: The water pump gear is held by a needle pin

no. 8 on the water pump shaft.
1
R400motr144A 1
1. Water pump shaft with rotary seal
R400motr142A
1. Water pump gear
– needle pin no. 8 and thrust washer no. 9.
R400motr145A 1 2
1. Oil seal behind the rotary seal
2. Rotary seal bore
Extract the water pump shaft with rotary seal

no. 5 together with oil seal no. 10 from inside
magneto housing cover with a pusher.
CAUTION: Be careful not to damage the surface of
R400motr143A 2 1 the rotary seal bore in magneto housing cover.
1. Needle pin
2. Thrust washer
CAUTION: When removing water pump shaft,

always replace rotary seal with water pump shaft
no. 5 and oil seal no. 10 (behind rotary seal).
03-05-8 VMR2004_128_03_05A.FM
Section 03 ENGINE
1 3
R400motr146A 1
1. Special area for oil seal removal R400motr147A 2
1. Oil seal for the water pump shaft
Inspection 2. Oil seal pusher (P/N 529 035 757)
3. Handle for insertion jig (P/N 420 877 255)
Inspect water pump gear for wear and damage on
the snap mechanism to the needle pin. Replace if It is recommended to install the water pump shaft
damaged. assembly using the water pump ceramic seal in-
staller (P/N 529 035 766).
Water pump shaft with rotary seal must rotate free-
ly. Otherwise, replace it. NOTE: The water pump shaft assembly has to be
pushed using the outside area of the rotary seal.
NOTE: When removing water pump shaft, always
replace together retaining ring, oil seal, water pump
shaft with rotary seal with new parts.
Installation
However, pay attention to the following.
NOTE: Never use oil in the press fit area of the oil
seal and rotary seal.
Push water pump shaft oil seal in place by using the
oil seal pusher (P/N 529 035 757).
R400motr150A 1
1. Surface to push water pump shaft assembly in place
CAUTION: Never use a hammer for the rotary

seal installation. Only use a press to avoid dam-
aging the ceramic component.
VMR2004_128_03_05A.FM 03-05-9
Section 03 ENGINE
R400motr148A 1
1. Water pump shaft with rotary seal
2. Water pump ceramic seal installer (P/N 529 035 766)
V07C0PA
NOTE: For installation use the torque values in the
1. Radiator inlet hose
exploded view. Ensure to use multi-purpose grease
for oil seal no. 10 and engine oil in water pump
shaft bore/shaft.
Tighten screws in the following sequence.
3
1 2
4
R400motr231B
PRESSURE CAP
Check if radiator cap no. 11 pressurizes the sys-
tem. If not, install a new 110 kPa (16 PSI) cap (do V07C0QA 1
not exceed this pressure).
1. Radiator outlet hose
RADIATOR – overflow hose no. 12

– mounting bolts no. 17.
Removal
Drain cooling system.
Remove:
– front facia and both inner fenders (refer to BODY)
– radiator inlet no. 14 and radiator outlet no. 16
hoses
03-05-10 VMR2004_128_03_05A.FM
Section 03 ENGINE
Removal
Remove:
– LH inner fender (refer to BODY)
– coolant tank support bolt no. 19
V07C0RA 1
V07C0SA
1. Radiator mounting bolts
Unplug temperature sender connector no. 18 – overflow hose no. 12

then remove the radiator no. 13. – coolant tank no. 15.
Inspection Empty coolant tank.
Check radiator air passage for clogging or damage. Installation
Remove insects, mud or other obstructions with The installation is the reverse of the removal pro-
compressed air or low pressure water. cedure.
Check for any coolant leakage from radiator and
hoses. COOLING FAN
Installation Test
For installation, reverse the removal procedure. Pay NOTE: No key required for this test.
attention to the following detail.
Unplug the temperature sender connector.
Fill up the radiator. Refer to the COOLANT RE-
PLACEMENT PROCEDURE, at the beginning of Install a jumper wire end in connector. Replace the
this section. cooling fan no. 20 if it does not work.
COOLANT TANK Removal

Remove both inner fenders. Refer to BODY.
Overflow Coolant Tank Unplug cooling fan connector.
The coolant expands as the temperature (up to Remove bolts no. 21.
100 - 110°C (212 - 230°F)) and pressure rise in the Remove the cooling fan.
system. If the limiting system working pressure
cap is reached 110 kPa (16 PSI), the pressure relief Installation
valve in the pressure cap is lifted from its seat and
allows coolant to flow through the overflow hose For the installation, reverse the removal procedure.
into the overflow coolant tank no. 15.
VMR2004_128_03_05A.FM 03-05-11
Section 03 ENGINE
TEMPERATURE SENDER
Test
Remove temperature sender no. 18, see below
for procedure.
Put the temperature sender in water and heat wa-
ter.
Using a multimeter, check the resistance from
temperature sender. Temperature sender should
open when water temperature reaches the follow-
ing degree.
WATER TEMPERATURE 85°C (185°F)
Change temperature sender if resistance does not

change when water temperature is equal or over
specification.
Removal
Drain coolant.
Remove the LH inner fender (refer to BODY).
Unplug temperature sender connector.
V07C0TA 1
1. Temperature sender connector
Unscrew temperature sender no. 18.
Installation
cedure, pay attention to the following details.
Check O-ring and change if necessary.
CAUTION: Do not apply any product on the
threads or on the O-ring.
03-05-12 VMR2004_128_03_05A.FM
Section 03 ENGINE
Subsection 06 (REWIND STARTER)
REWIND STARTER 0
5
3
4
7
15
2
8 Nm 8
(71 lbfin) 9
Molykote PG54 10
11
12
13
14
Molykote PG54
Molykote PG54
Molykote G-N
Loctite 603
6.5 Nm
(58 lbfin)
Loctite 243
25 Nm
(18 lbfft)
R400motr218S
VMR2004_129_03_06A.FM 03-06-1
Section 03 ENGINE
GENERAL – Untie knot holding rewind starter grip and re-

move grip.
During assembly/installation, use the torque values
and service products as in the exploded views.
complete procedure.
 WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (ex.: locking tabs, elastic stop R400motr220A 2 1
nuts, self-locking fasteners, etc.) must be in- 1. Starter housing
stalled or replaced with new ones where 2. Rewind starter grip
specified. If the efficiency of a locking device
– Finally untie other knot and slowly release rope
is impaired, it must be renewed.
into starter housing to release spring tension.
CAUTION: Hold rope sheave reactive to spring
REWIND STARTER tension while releasing the rope into starter
housing.
Removal
Remove RH side panel and engine cover.
Remove rewind starter mounting bolts no. 15 and
pull rewind starter.
To release tension from torsion spring no. 2: 1
– First pull grip no. 6 and tie a knot more than 20 cm
(8 in) below it.
R400motr221A 2
1. Direction to release spring tension
2. Rope sheave
Disassembly
 WARNING
Spring tension has to be released prior to with-
draw the rewind starter sheave.
R400motr219A 1
1. Rope
03-06-2 VMR2004_129_03_06A.FM
Section 03 ENGINE
To remove rope no. 5 from rewind starter mecha- At assembly, position spring no. 2 outer end into
nism: spring guide notch. Use appropriate ring to push
– First remove flat washer no. 11 and screw spring into starter housing as illustrated.
no. 12, locking spring no. 10, locking spring
washer no. 9, pawl lock no. 8 and pawl no. 7.  WARNING
NOTE: Use two flat screwdrivers to withdraw Since the spring is tightly wound inside the
locking spring washer no. 9. guide it may fly out when rewind is handled.
Always handle with care.
– Remove sheave no. 3 from starter housing no. 1.
 WARNING
Torsion spring is tightly wound inside the
guide. Handle with care and always wear safety
goggles and hand gloves.
A
– Disengage key no. 4 and pull out rope no. 5.
R400motr223A 1 2 3
TYPICAL
1. Outer end into guide notch
R400motr222A
2. Apply Molykote PG 54 inside spring guide
3. Ring for spring installation
TYPICAL — GENTLY TAP ON KEY A. 82 + .2 mm (3.23 + .008 in)
NOTE: Due to dust accumulation, rewind starter

 WARNING must be periodically cleaned, inspected and relu-
Never remove spring out of starter housing ex- bricated.
cept if spring is damaged. Torsion spring is CAUTION: It is of the utmost importance that
spring loaded, so handle with care and always the rewind starter spring(s) be lubricated peri-
wear safety goggles and hand gloves. odically using specific lubricants. Otherwise,
rewind starter component life will be short-
Assembly ened and/or rewind starter will not operate
properly under very cold temperatures.
Pay attention to the following details.
 WARNING
Always install new spring into starter housing.
Torsion spring is spring loaded, so handle with
care during installation. Always wear safety
VMR2004_129_03_06A.FM 03-06-3
Section 03 ENGINE
Lubricate spring assembly with Molykote PG 54 To adjust rope tension:

(P/N 420 899 763) and position into starter housing Wind rope on sheave and place rope sheave into
as illustrated. starter housing making sure that the sheave hub
notch engages in the rewind spring hook.
 WARNING
To prevent spring from flying out of the guide,
it is mandatory to secure rope sheave in
place. Always handle with care and use safety
Position pawl no. 7, pawl lock no. 8 and locking

spring washer no. 9.
Install locking spring no. 10.
R400motr224A 1
TYPICAL
1. Apply Molykote PG 54 in spring area
CAUTION: The use of standard multi-purpose

grease could result in rewind starter malfunc-
tion.
To install a new rope no. 5, insert rope into sheave
orifice and lock it with the key no. 4 as illustrated.
1 2
R400motr227A 1 3 4 2
TYPICAL
B
1. Locking spring
2. Pawl
3. Pawl lock
4. Locking spring washer
A
Install washer no. 11 and torque screw no. 12.
R400motr225A
TYPICAL
1. Punch
2. Key
A. Maximum 14 mm (.55 in)
B. Rope overstand 20 to 25 mm (.787 to .984 in)
R400motr229A 1 2
1. Washer
2. Screw
03-06-4 VMR2004_129_03_06A.FM
Section 03 ENGINE
Rotate rope sheave clockwise until rope end is ac- Pass rope through starter grip, tie a knot in the rope
cessible through starter housing orifice. end.
Pull rope out of the starter housing and temporarily
hold it.
NOTE: It is recommended to use a hose clamp to
fix rope in place. A knot can get too thight.
R400motr230A
TYPICAL
Insert rope end down and pull the starter grip over
1
the knot.
Installation
R400motr226A 2
TYPICAL Pay attention to the following details.
1. Turn clockwise
2. Position to fix rope in place Prior to reinstalling rewind starter on engine, clean
threads from Loctite deposits.
Thread starter rope no. 5 through rope guide when
applicable. NOTE: Before torquing mounting bolts no. 15, ap-
ply Loctite 243 on threads.
Prior to installing starter grip on new rope, it is first
necessary to fuse the rope end with a lit match.
STARTING PULLEY
Removal
1 Remove rewind starter.
Remove screw no. 13 and starting pulley no. 14
from crankshaft MAG side.
Installation
CAUTION: Take care to have the starting pulley
well mounted on crankshaft end.
Apply Loctite 243 on threads and torque the screw
R400motr228A to 25 N•m (18 lbf•ft).
TYPICAL
1. Fuse end of starter rope
VMR2004_129_03_06A.FM 03-06-5
Section 03 ENGINE
MAGNETO SYSTEM 0
10 Nm
(89 lbfin) 1
Anti-seize lubricant
10 Nm
(89 lbfin) 10
10 Nm Multi-purpose
(89 lbfin) grease
15
25 Nm 25 Nm
(18 lbfft) (18 lbfft)
Multi-purpose 5 2
grease
Loctite 243
7 10 Nm Loctite
(89 lbfin) 5910
4
Multi-purpose
grease
10 Nm
(89 lbfin) 3
11
10 Nm
25 Nm 8 (89 lbfin)
(18 lbfft) 5
Loctite 243
180 Nm
12 (133 lbfft)
6 9 14
30 Nm Loctite 5910
10 Nm
(22 lbfft) (89 lbfin)
13
R400motr01T
VMR2004_130_03_07A.FM 03-07-1
Section 03 ENGINE
GENERAL
The engine removal is necessary to work on mag-
neto components except for the CPS (Crankshaft
Position Sensor) and oil seal.
Always perform the electric tests before removing
or installing whatever component.
and service products as in the exploded views. 1 2
complete procedure.
 WARNING
V07C0JA
strictly be adhered to. 1. Unscrew these screws
2. Remove these screws
nuts, self-locking fasteners, cotter pin, etc.) – screws nos. 3, 4 and 5
where specified. If the efficiency of a locking 3 2 1
MAGNETO HOUSING COVER

Removal
Remove engine from vehicle.
Remove disconnect unit.
Lock crankshaft at TDC (refer to CYLINDER AND
HEAD).
Remove:
– rewind starter (refer to REWIND STARTER) R400motr02A
– water pump cover (refer to COOLING SYSTEM) 1. Gasket ring

2. Screw M6
– electric starter screws no. 1 3. CPS (Crankshaft Position Sensor)
– screws no. 2 holding output shaft cover in place – magneto housing cover no. 6.
NOTE: Only remove the two front screws no. 2. NOTE: Lift the magneto housing cover from the
To ease lifting the magneto cover it is recommend- provided area using two flat screwdrivers prying
ed to loosen the screws behind. equally at the same time.
03-07-2 VMR2004_130_03_07A.FM
Section 03 ENGINE

IMPORTANT: When beginning the application of
the crankcase sealant, the assembly and the first
torquing should be done within 10 minutes. It is
suggested to have all you need on hand to save time.
NOTE: It is recommended to apply this specific
sealant as described here to get an uniform applica-
tion without lumps. If you do not use the roller meth-
od, you may use your finger to uniformly distribute
the sealant (unlike the Drei Bond sealing compound,
using a finger will not affect the adhesion).
Use the silicone-based Loctite 5910 (P/N 293 800
081) on mating surfaces.
R400motr03A 1
NOTE: The sealant curing time is similar to the
1. Special area for removal of magneto housing cover Loctite 518 without using the Primer N.
CAUTION: Do not use Loctite 515 or 518 to seal
crankcase. Do not use Loctite Primer N with the
Loctite 5910. Using these products or non silicone-
based sealant over a previously sealed housing
with Loctite 5910 will lead to poor adhesion and
1 possibly a leaking housing. These products are
chemically incompatible. Even after cleaning,
the Loctite 5910 would leave incompatible mi-
croscopic particles.
Use a plexyglass plate and apply some sealant on
it. Use a soft rubber roller (50 - 75 mm (2 - 3 in))
(available in arts products suppliers for printmak-
ing) and roll the sealant to get a thin uniform coat
on the plate (spread as necessary). When ready,
R400motr04A
apply the sealant on magneto mating surfaces.
1. Special area for removal of magneto housing cover
Inspection
Check magneto housing cover for cracks or other
Installation
NOTE: Clean all metal component in a non-ferrous
metal cleaner. Use Bombardier gasket remover
(P/N 413 708 500), or suitable equivalent. To re-
move remaining Loctite 5910 on the contact sur-
face, use a copper brush.
 WARNING
Wear safety glasses and work in a well venti- F12R17A
lated area when working with strong chemical
products. Also wear suitable non-absorbent Do not apply in excess as it will spread out inside
gloves to protect your hands. crankcase.
VMR2004_130_03_07A.FM 03-07-3
Section 03 ENGINE
NOTE: Do not use Loctite Primer N with this seal-

1
ant. The sealant curing time is similar to the Loc-
tite 518 without using the Primer N, which is 4 to
24 hours.
CAUTION: Apply Loctite 5910 all around the
crankcase MAG slit surface except the areas de-
scribed below. 2
1
2 1
3 3
R400motr08A 1
1 2 1. Screws M6 x 45
2. Screws M6 x 45 with sealing ring
3. Screws M8 x 65
R400motr06A
Tightening sequence for screws on magneto hous-
1. Mating surface on the magneto housing cover ing cover is as per following illustration.
2. No need to apply Loctite 5910
CAUTION: Ensure the sealing ring is present on 7 9 5 13 11

the crankcase mag side. Use oil seal protector
(P/N 529 035 935) to avoid damaging the oil seal
during reinstallation of the magneto housing
cover. 15
3 16
17 1
18
4
2
3
10 8 6 12 14
1 R400motr05A
OIL SEAL
2
Remove rewind starter (refer to REWIND STARTER).
R400motr07A
1. Oil seal protector Inspection

2. Magneto housing cover
3. Crankshaft MAG side Check the oil seal no. 7 on the magneto housing
cover. If brittle, hard or damaged, replace it.
Refer to the following illustration for proper instal-
lation of screws. Removal
CAUTION: Never use the gasket ring on screw NOTE: The oil seal no. 7 can be removed even if
no. 4 a second time. Always install a new one. the cover is not removed.
Pry out oil seal with a screwdriver.
CAUTION: Be careful not to damage the oil seal
bore when using a screwdriver.
03-07-4 VMR2004_130_03_07A.FM
Section 03 ENGINE
Installation CAUTION: Use the oil seal protector (P/N 529

035 935) to avoid damaging the oil seal during
With Magneto Housing Cover Removed installation.
Using the oil seal installer (P/N 529 035 759) and
the inserting jig handle (P/N 420 877 650), install STATOR
the oil seal in its location.
NOTE: Never use oil in the press fit area of oil seal. Removal
Remove:
3
– magneto housing cover no. 6
– screws nos. 8 and 9
– stator no. 11.
2
3 4
1
R400motr10A
1. Oil seal
1
2. Oil seal installer (P/N 529 035 759)
3. Handle for insertion jig (P/N 420 877 650)
Reinstall other removed parts in the reverse order.

CAUTION: Always use the oil seal protector R400motr11A
(P/N 529 035 935) to avoid damaging the oil seal

1. Stator
during magneto housing cover installation. 2. Stator screws
3. Holding strip
Without Magneto Housing Cover Removed 4. Holding strip screw
Using a suitable tube, with the proper diameter,

install the oil seal as per following illustration.
Inspection
Check stator condition. If damaged replace it.
For electrical inspection, refer to CHARGING SYS-
TEM.
2
1 Installation
CAUTION: When installing the stator take care
that the cable is in place (guide for the wire).
R400motr09A 3
1. Oil seal
2. Oil seal protector
3. Tube
VMR2004_130_03_07A.FM 03-07-5
Section 03 ENGINE
NOTE: There is only one position for the stator Inspection

(notch in the magneto housing cover).
Check the CPS condition and replace it if necessary.
1 To test the sensor refer to IGNITION SYSTEM.
Installation
2 ROTOR
Removal
Lock crankshaft with locking bolt (P/N 529 035 617).
Refer to CRANKSHAFT/BALANCER SHAFT.
Remove:
– magneto housing cover no. 6
R400motr13A
– nut no. 12 retaining rotor no. 14
1. Thread for cable holding strip
2. Notch for stator – serrated washer no. 13.
CPS (Crankshaft Position Sensor)

The CPS is located on the top of magneto housing
cover, behind the exhaust pipe support. 1
2
Removal
Lift up the console (refer to BODY) then unplug
the CPS connector. 3
Remove the RH side panel.

Unscrew the CPS screw no. 10.
1 2
R400motr14A
1. Nut
2. Serrated washer
3. Rotor
Install magneto puller (P/N 529 035 748) and crank-

shaft protector (P/N 420 876 557) then remove rotor.
NOTE: Use grease to place protector on crank-
shaft end prior to screw on the magneto puller.
Inspection
Check woodruff key and keyway on the crankshaft
and the serrated washer for wear or damages. Re-
place as necessary.
Installation
R400motr12A
1. Crankshaft position sensor However, pay attention to the following.
2. Screw
CAUTION: When installing the rotor, take care
Remove the CPS no. 15. that the tapers are clean. Serrated washer no. 13
has to be put in place correctly.
03-07-6 VMR2004_130_03_07A.FM
Section 03 ENGINE
Subsection 08 (LUBRICATION SYSTEM)
LUBRICATION SYSTEM 0
10 Nm 5
(89 lbfin) Engine oil
Engine oil
27 Multi-purpose grease
16 12 Nm Loctite 243

Engine oil (106 lbfin)
15 Engine
oil 1
19 20
26 14
10 Nm
(89 lbfin) 23 21
12
22 18
2
13
17
3 24
30 Nm
(22 lbfft) 25
6
7
8
9
Engine oil 10
10 Nm 11
(89 lbfin)
R400motr108S
VMR2004_131_03_08A.FM 03-08-1
Section 03 ENGINE
GENERAL 1 2
Prior to change the oil, ensure vehicle is on a level
surface.
Oil and oil filter must be replaced at the same time.
Oil change and oil filter replacement should be
done with a warm engine.
 WARNING
The engine oil can be very hot. Wait until en-
gine oil is warm.

fer to SELF-LOCKING FASTENERS and LOCTITE R400motr109A
1. Oil pressure switch
complete procedure. 2. Electrical starter
 WARNING NOTE: Oil pressure switch works between 30 kPa

(4 PSI) and 60 kPa (9 PSI).
strictly be adhered to. The engine oil pressure should be within the follow-
ing values.
nuts, self-locking fasteners, cotter pin, etc.) PRESSION/RPM 1300 RPM 6000 RPM
where specified. If the efficiency of a locking 70 kPa 350 kPa
MINIMAL
device is impaired, it must be renewed. (10 PSI) (51 PSI)
350 kPa 500 kPa
Dispose oil and filter as per your local environmen- NOMINAL
(51 PSI) (73 PSI)
tal regulations.
550 kPa 700 kPa
MAXIMAL
ENGINE OIL PRESSURE TEST (80 PSI) (102 PSI)
NOTE: The engine oil pressure test should be done If the engine oil pressure is out of specifications,
with a warm engine and the recommended oil. check the points described in TROUBLESHOOTING
Remove the oil pressure switch no. 1 in the area section.
of the cylinder head (exhaust side), mounted on To install oil pressure switch, reverse the removal
the crankcase MAG side and install the oil pres- procedure.
sure gauge (P/N 529 035 652).
03-08-2 VMR2004_131_03_08A.FM
Section 03 ENGINE
OIL CHANGE
Removal
Place a drain pan under the engine magnetic drain
plug area.
Clean the magnetic drain plug area.
Unscrew magnetic drain plug no. 3 then remove
dipstick no. 4.
CAUTION: Pay attention not to lose the O-ring
no. 5 on dipstick.
3
R400motr110A 1 2
1. Magnetic drain plug
1 2. Gasket ring
3. Engine MAG side
System Capacity
2 Refer to TECHNICAL DATA.
OIL FILTER
Removal
Remove:
– engine oil (refer to OIL CHANGE)
– oil filter screws
V07C0LA
– oil filter cover
1. Dipstick – oil filter.
2. O-ring
Wait a while to allow oil to flow out of oil filter.
Inspection
Oil condition gives information about the engine
condition. See TROUBLESHOOTING section.
Clean the magnetic drain plug from metal shav-
ings and dirt. Presence of debris gives an indica-
tion of failure inside the engine. Check engine to
correct the problem.
Change gasket ring on magnetic drain plug if dam-
aged.
Installation R400motr111A 4 3 2 1
1. Oil filter screws
The installation is the reverse of removal proce- 2. Oil filter cover
dure. 3. O-ring
4. Oil filter
CAUTION: Never use the gasket ring no. 2 a sec-
ond time. Always replace by a new one.
VMR2004_131_03_08A.FM 03-08-3
Section 03 ENGINE
Inspection OIL STRAINER

Check oil filter cover O-ring, change it if necessary.
Removal
Check and clean the oil filter inlet and outlet area
for dirt and other contaminations. Remove:
– engine oil (refer to OIL CHANGE)
– air box (refer to AIR INTAKE SILENCER)
– disconnect unit bolts from engine
– exhaust support bolts
– upper engine support bolts.
Install the lifting engine tool (P/N 529 035 898).
Remove:
– front and rear engine mounting bolts
– front engine mounting bracket
– CVT outlet and inlet hoses
– exhaust nuts
– carburetor from grommet.
R400motr112A 2 1
Lift engine and disconnect the rear propeller shaft.
1. Inlet bore from the oil pump to the oil filter
2. Outlet bore to the engine oil providing system Remove:
– screws no. 11 retaining oil strainer cover no. 10
Installation
The installation is the opposite of the removal pro- 2
cedure. Pay attention to the following details.
Apply oil on rubber seal of oil filter to ensure proper
installation.
Install O-ring on oil filter cover.
R400motr114A 2 1
1. Oil strainer cover
2. 5 screws
R400motr113A
1. O-ring in place
03-08-4 VMR2004_131_03_08A.FM
Section 03 ENGINE
– oil collector no. 8 and O-ring no. 7

– oil strainer no. 6.
1 2
R400motr116A 2 1 3
1. Oil inlet to the oil pump
2. Oil return from the oil pressure regulator system
3. Oil return from the engine oil circulation
R400motr115A
Installation
1. Oil collector with O-ring
2. Oil strainer For installation, reverse the removal procedure.
Torque oil strainer cover screws as per following se-
Cleaning and Inspection quence.
Clean oil strainer with a part cleaner then use an
air gun to dry it.
 WARNING
Always wear eye protector. Chemicals can 1
cause a rash break out in and an injury to your
eyes. 5
Inspect O-ring no. 7 and rubber ring no. 9. 4

If O-ring and/or rubber ring is (are) brittle, cracked 3
or hard, replace the defective part(s).
Clean both contact surfaces of oil strainer cover. 2
Check and clean the oil inlet and outlet area for dirt
and other contaminations.
R400motr114B
Refill engine at the proper level with the recom-

mended oil. Refer to TECHNICAL DATA for capacity.
Start engine and let idle for a few minutes. Ensure
oil filter and magnetic drain plug areas are not leak-
ing.
Stop engine. Wait a while to allow oil to flow down
to crankcase then check oil level. Refill as necessary.
VMR2004_131_03_08A.FM 03-08-5
Section 03 ENGINE
ENGINE OIL PRESSURE Inspection

REGULATOR Inspect valve piston for scoring or other damages.
The oil pressure regulator is located on the engine Check compression spring for free length.
MAG side (behind magneto housing cover).
COMPRESSION SPRING FREE LENGTH
NEW NOMINAL 64 mm (2.519 in)
SERVICE LIMIT 62 mm (2.441 in)
Replace both parts if important wear or damage

are present.
Clean bore and threads in the oil pump housing
from metal shavings and other contaminations.
Installation
OIL PUMP
R400motr130A 1 The oil pump is located on the engine MAG side
1. Oil pressure regulator plug
(refer to ENGINE OIL PRESSURE REGULATOR).
NOTE: The oil pressure regulator system works Removal

when the oil pressure exceeds 500 kPa (73 PSI).
Remove:
Removal – engine from vehicle
(refer to REMOVAL AND INSTALLATION)
Remove:
– water pump housing
– vehicle from vehicle (refer to COOLING SYSTEM)
(refer to REMOVAL and INSTALLATION)
– magneto housing cover
– water pump housing (refer to MAGNETO SYSTEM)
(refer to COOLING SYSTEM)
NOTE: The following steps to remove the gears
– magneto housing cover no. 13 and no. 16 are not necessary to replace
(refer to MAGNETO SYSTEM) only the oil pump.
– oil pressure regulator plug no. 20, compression – retaining ring no. 14 then drive gear no. 13
spring no. 19 and valve piston no. 18.
CAUTION: Never use the retaining ring a second
 WARNING time. Always replace by a new one.
Oil pressure regulator plug on oil pump housing NOTE: Drive gear is snapped on a needle pin. This
is spring loaded. needle pin passes through the balancing shaft.
– needle pin no. 12
– pin no. 15
– intermediate gear no. 16
R400motr117A 3 2 1
1. Valve piston
2. Compression spring
3. Oil pressure regulator plug
03-08-6 VMR2004_131_03_08A.FM
Section 03 ENGINE
1 2
R400motr121A 1
1. Dowel pins
R400motr118A
1. Intermediate gear – oil pump gear no. 25

2. Pin
NOTE: Oil pump gear is snapped on needle pin.
– screws no. 26 This needle pin passes through the oil pump shaft.
– oil pump cover no. 23 Use screwdrivers to remove this gear.
4 2 3
1
R400motr119A 1
1. 4 screws
2. Oil from the pump to the oil filter in the magneto housing cover R400motr122A
3. Oil pump cover
4. Oil seal to crankcase MAG side 1. Flat screwdrivers
NOTE: To remove oil pump system, lift the dowel
pins no. 22 a bit. The oil pump housing with oil
pump shaft assembly will be easier to remove.
CAUTION: Pay attention not to drop the dowel
pins inside the engine.
R400motr120A
1. Oil pump system
VMR2004_131_03_08A.FM 03-08-7
Section 03 ENGINE
2
3 2
1
R400motr125A
1
1. Oil pump shaft assembly
R400motr123A
2. Oil pump housing
1. Oil pump gear
2. Dowel pins Inspection
3. Suction side of the oil pump
4. Outlet from the engine oil pressure regulator valve Inspect oil pump shaft assembly, housing and cov-
– needle pin no. 24 er for marks or other damages.
– oil pump shaft assembly no. 21 Replace O-ring no. 27 if brittle or hard. This O-ring
is located on the oil pump housing.
– oil pump housing no. 17.
Check inner rotor for corrosion pin-holes or other
damages. If so, replace oil pump shaft assembly.
Ensure to also check oil pump housing and cover.
If damaged, replace the complete oil pump as-
sembly.
1
R400motr126A
R400motr124A 2 1 3
1. Pittings on the teeth
1. Oil inlet to the oil pump (leads to strainer on engine bottom)
2. Oil return from the oil pressure regulator system
3. Bore for dowel pin support Using a feeler gauge, measure the clearance be-
tween inner and outer rotor.
03-08-8 VMR2004_131_03_08A.FM
Section 03 ENGINE
C
2
1
A
1
R400motr127A R400motr128B
1. Outer rotor 1. Oil pump outer rotor surface

2. Inner rotor 2. Dial indicator
OUTER AND INNER ROTOR CLEARANCE Difference between pump housing and outer rotor
mm (in) should not exceed 0.1 mm (.004 in). If so, replace
SERVICE LIMIT
replace the complete oil pump assembly.
A NOTE: When the axial clearance of the oil pump
shaft assembly increases, the oil pressure de-
B 0.25 mm (.009 in) creases.
C Check the inside of oil pump housing and its cover
If clearance between inner and outer rotor ex- for scoring or other damages. If so, change the
ceeds the tolerance, replace oil pump shaft as- complete oil pump assembly.
sembly. Ensure to also check oil pump housing
and cover. If damaged, replace the complete oil Installation
pump assembly. For installation, reverse the removal procedure.
If clearance between outer rotor and its bore in oil Tightening oil pump housing screws as per follow-
pump exceeds the tolerance, replace the complete ing sequence.
oil pump assembly.
Using a dial indicator, measure side wear as shown. 1 4
2
3
R400motr119B
Install the O-ring no. 27 on oil pump cover.

CAUTION: Never apply any sealing compound
on split surfaces of oil pump.
1
R400motr128B
Final Test
1. Oil pump housing surface After engine is completely reassembled, start en-
2. Dial indicator gine and make sure oil pressure is within specifi-
cations.
VMR2004_131_03_08A.FM 03-08-9
Section 03 ENGINE
Subsection 09 (CYLINDER AND HEAD)
CYLINDER AND HEAD 0

NOTE: For cylinder head, cylinder and piston removal, it is not necessary to remove engine from vehicle.
7 Nm
(62 lbfin)
2 1 16 12 Nm
11 (106 lbfin)
3 13
15
14
Loctite 34
243 35
400 engine Engine 16
5 type only oil 33
6
7 38 25 Nm
8 Engine
9 10 Nm 39 (18 lbfft)
(89 lbfin) oil
4
30 Nm Loctite243 30
(22 lbfft) 26
Engine
24 oil 10 Nm
25 (89 lbfin)
10 28
Engine 10 Nm
oil (89 lbfin)
29
Loctite 243
16 32
16 Engine oil
11 38
34 36
12 39 Loctite
243
13 14 23
12 Nm 35 33 8 Nm Engine
(106 lbfin) 20 oil
(71 lbfin)
19 31
Engine oil 10 Nm 37
(89 lbfin) 27
Anti-seize 21
18 0.4 Nm 60 Nm
lubricant (44 lbfft)
40 22 (3.5 lbfin) See
17 procedure
4.5 Nm inside
(40 lbfin)
R400motr49T
VMR2004_132_03_09A.FM 03-09-1
Section 03 ENGINE
41 Engine
oil
42
46
44
Engine
oil
43 45
43
Engine
oil
R400motr50S
03-09-2 VMR2004_132_03_09A.FM
Section 03 ENGINE
GENERAL Intake port/air filter contaminated (clogged) with

dirt, sand, etc. (leads to worn valves, piston rings
NOTE: When diagnosing an engine problem, always and finally to leak of power).
perform a cylinder leak test. This will help pin-point a
CAUTION: In case of piston rings and/or valve
problem. Refer to the instructions included with your
replacement, always clean the whole engine
leak tester and LEAK TEST section for procedures.
and change oil and oil filter.
Always place the vehicle on level surface.
NOTE: For a better understanding, the many SPARK PLUG
illustrations are taken with engine out of vehicle. To
perform the following instructions, it is not necessary Removal
to remove engine from vehicle.
Unplug the spark plug wire.
Always disconnect BLACK (-) cable from the battery,
Clean spark plug area before disassembly.
then RED (+) cable before working on the engine.
Unscrew spark plug.
 WARNING
Always disconnect battery or starter cables
exactly in the specified order, BLACK (-) cable
first.
Even if the removal of many parts is not necessary

to reach another part, it is recommended to remove
these parts in order to check them.
complete procedure.
1
 WARNING
R400motr51A
1. Spark plug on engine PTO side

strictly be adhered to. Inspection
Locking devices (ex.: locking tabs, elastic stop Check spark plug condition (refer to IGNITION
nuts, self-locking fasteners, cotter pin, etc.) SYSTEM).
must be installed or replaced with new ones NOTE: To check spark, place connected spark
where specified. If the efficiency of a locking plug with threads against crankcase to simulate
device is impaired, it must be renewed. electrical ground and crank the engine.
When disassembling parts that are duplicated in the
engine, (e.g.: valves), it is a strongly recommended to
Installation
note their position (PTO, MAG side) and to keep them For installation, reverse the removal procedure.
as a “group”. If you find a defective component, it Pay attention to the following details.
would be much easier to find the cause of the failure Check spark plug gap (refer to TECHNICAL DATA).
among its group of parts (e.g.: you found a worn valve
guide. A bent spring could be the cause and it will be Screw spark plug. Torque spark plug to 20 N•m
easy to know which one among the springs is the (15 lbf•ft). Reinstall the spark plug wire.
cause to replace it if you grouped them at disassem-
bly). Besides, since used parts have matched togeth- THERMOSTAT
er during the engine operation, they will keep their Refer to COOLING SYSTEM.
matched fit when you reassemble them together
within their “group”.
VMR2004_132_03_09A.FM 03-09-3
Section 03 ENGINE
VALVE COVER Installation

Removal
Install the valve cover screws in a criss-cross se-
Remove: quence.
– valve cover screws no. 1
VALVE ADJUSTMENT
2
Lock crankshaft at the TDC compression position
1 (refer to CRANKSHAFT/BALANCER SHAFT, see
CRANKSHAFT LOCKING PROCEDURE).
Remove valve cover (refer to VALVE COVER above).
Hold adjusting screw no. 14 and loosen locking
nut no. 13.
Using feeler gauge, check the valve clearance.
3 2 1
R400motr52A
1. Valve cover screws

2. Water temperature switch
– valve cover no. 2 and profile sealing ring no. 3.
2 1
R400motr54A
1. Adjustment screws
2. Locking nuts
3. Feeler gauge
VALVE CLEARANCE
0.11 to 0.19 mm
R400motr53A EXHAUST
(.0043 to .0075 in)
1. Valve cover
2. Profile sealing ring 0.06 to 0.14 mm
INTAKE
(.0024 to .0055 in)
Inspection
Check the profile sealing ring on the valve cover if NOTE: Use mean value of exhaust/intake to en-
it is brittle, cracked or hard. If so, replace the profile sure a proper valve adjustment.
sealing ring. Hold the adjusting screw at the proper position
and torque the locking nut.
Repeat the procedure for each valve.
Before installing valve cover, recheck all valve ad-
justments.
03-09-4 VMR2004_132_03_09A.FM
Section 03 ENGINE
CHAIN TENSIONER Installation

Removal However, pay attention to the following.
 WARNING Screw the plunger until it touches the chain guide.

Install a spring end in plunger groove and the other
Chain tensioner is spring loaded.
in the plug groove. Screw plug.
CAUTION: Do not forget to place the O-ring
 WARNING no. 22 on chain tensioner plug.
Never perform this operation immediately af-
ter the engine has been run because the ex- CHAIN TENSIONER HOUSING
haust system can be very hot. Wait until ex-
haust system is warm or cold. Removal
Remove: Remove:
– chain tensioner plug no. 17 – chain tensioner
– O-ring no. 22 – screw no. 19
– spring no. 18 – chain tensioner housing no. 20 with O-ring
– chain tensioner plunger no. 21. no. 23.
2
R400motr56A 1
1. Chain tensioner screw
2. Chain tensioner housing
R400motr55A 4 3 2 1
Inspection
1. Chain tensioner plug
2. O-ring Check the housing for cracks or other damages.
3. Spring Replace it if necessary.
4. Chain tensioner plunger
Check if O-ring no. 23 is brittle, cracked or hard.
Inspection Replace as necessary.
Check chain tensioner plunger for free movement
and/or scoring. Installation
Check if possible chain guides for wear. Replace as Reverse the removal procedure.
necessary.
Check if O-ring no. 22 is brittle, cracked or hard.
Replace as necessary.
Check spring condition. Replace if broken or worn.
VMR2004_132_03_09A.FM 03-09-5
Section 03 ENGINE
DECOMPRESSOR 1 2 3
330 Engines
This engine is not equipped with a decompressor
system. Therefore parts no. 5 to no. 8 are not
present and camshaft screw no. 4 is shorter.
R400motr57A
1. Camshaft screw
2. Decompressor washer
3. Centrifugal weight
1
Inspection
R400motr232A
Check decompressor shaft for service limit, replace
1. Camshaft timing gear if out of specifications.
2. Camshaft screw
2 1
400 Engines
A
C
Removal
Remove: B
– valve cover
– camshaft screw no. 4
R400motr58A
– decompressor washer no. 5
1. Decompressor shaft
– centrifugal weight no. 6 together with torsion 2. Groove for centrifugal weight
A. Measure here the bearing seat to cylinder head
spring no. 7 and spacer no. 8 B. Measure top end (contact to camshaft lobe exhaust)
C. 7 mm (.276 in)
– decompressor shaft no. 9.
03-09-6 VMR2004_132_03_09A.FM
Section 03 ENGINE
DECOMPRESSOR SHAFT MEASUREMENT A 1

NEW MINIMUM 5.578 mm (.219 in)
NEW MAXIMUM 5.590 mm (.220 in)
SERVICE LIMIT 5.450 mm (.215 in)
DECOMPRESSOR SHAFT MEASUREMENT B
Check torsion spring, edge and bearing bore of

centrifugal weight for visible wear. If so, replace
them together.
R400motr60A
1
1. Position of torsion spring end
Engage the edge of centrifugal weight into the de-

compressor shaft groove then put the parts in place.
R400motr59B 3
2. Edge of centrifugal weight
3. Bearing bore
Installation
cedure, but pay attention to the following details.
Position the end of torsion spring properly in the
centrifugal weight location. R400motr61A 1
1. Decompressor shaft groove
CAUTION: Take care before and after cover instal-

lation that the centrifugal system moves (slides)
easily.
VMR2004_132_03_09A.FM 03-09-7
Section 03 ENGINE
CAMSHAFT TIMING GEAR Installation

Removal Pay attention to the following details.
Remove: Clean mating surface and threads of camshaft pri-
– valve cover or to assemble camshaft timing gear.
– chain tensioner
Using the camshaft locking tool (P/N 529 035 926),
lock the camshaft at TDC compression position to
prevent timing chain stretching.
2 3 1 1
R400motr63A
1. Mating surface on camshaft

R400motr62A
2. Threads for camshaft screw
1. Camshaft locking tool Camshaft timing gear must be at TDC position be-
2. Camshaft screw fore installing the timing chain.
3. Camshaft timing gear
Install camshaft timing gear so that the timing gear
Lock crankshaft at the TDC compression position tabs are located into the flat zone of the camshaft.
to have the crankshaft position defined for reas- The printed marks on the camshaft timing gear
sembly (refer to CRANKSHAFT/BALANCER have to be parallel to the cylinder head base. See
SHAFT, see CRANKSHAFT LOCKING PROCEDURE). the following illustration for a proper positioning.
– decompressor (400 engine type only)
– camshaft timing gear no. 10.
NOTE: Secure timing chain no. 24 with a retaining
wire. 2
4
Inspection
3
Check camshaft timing gear for wear or deterioration.
1
If gear is worn or damaged, replace it as a set
(camshaft timing gear and timing chain).
For crankshaft timing gear, refer to CRANKSHAFT/ 5
BALANCER SHAFT.
R400motr233A
1. Printed marks on camshaft timing gear

2. Cylinder head base
4. Timing gear tab
5. Decompressor shaft bore
03-09-8 VMR2004_132_03_09A.FM
Section 03 ENGINE
CAUTION: Crankshaft and camshaft must be

locked on TDC position to place camshaft timing
gear and timing chain in the proper position.
Double-check position of timing gear with cam- 3
shaft locking tool (P/N 529 035 926)
2 3 1
1
2
R400motr65A
1. Cylinder head
2. Allen screws
3. Camshaft retaining plate
R400motr62A – rocker arm shafts no. 11

1. Camshaft locking tool – rocker arm assembly (exhaust side no. 12 and
2. Camshaft screw intake side no. 15) with adjustment screws
no. 14 and nuts no. 13
When the camshaft timing gear and the timing
chain are installed, remove the crankshaft locking 3 4 5
bolt as well as the camshaft locking tool.
Reinstall all other removed parts.
ROCKER ARM
1
Removal
Lock crankshaft at the TDC compression position,
refer to CRANKSHAFT/BALANCER SHAFT, see
CRANKSHAFT LOCKING PROCEDURE.
Remove:
– valve cover
– chain tensioner
– camshaft timing gear no. 10 R400motr66A 2
– Allen screws no. 25 and camshaft retaining plate 1. Rocker arm shaft
2. Rocker arm (exhaust side)
no. 26 3. Rocker arm (intake side)
4. Adjusting screw
5. Locking nut
VMR2004_132_03_09A.FM 03-09-9
Section 03 ENGINE
– thrust washers no. 16. Check adjustment screws for free movement,
CAUTION: Pay attention not to lose thrust wash- cracks and/or excessive play.
ers or drop them into the timing chain compart-
ment.
1 2 1
3
1
R400motr69A
1. Free movement of adjustment screw top

R400motr67A 4
Rocker Arm Shaft
1. 2 thrust washers
2. Rocker arm (exhaust side) Check for scored friction surfaces; if so, replace parts.
3. Cylinder head — spark plug side
4. Big taper to PTO side Measure rocker arm shaft diameter.
Inspection
Rocker Arm
Inspect each rocker arm for cracks and scored friction
surfaces. If so, replace rocker arm assembly.
Check the rocker arm rollers for free movement, R400motr70A A
wear and excessive radial play. Replace rocker A. Measure rocker arm shaft diameter here
arm assembly if necessary.
ROCKER ARM SHAFT DIAMETER
2 1
Any area worn excessively will require parts

replacement.
A
R400motr68A Installation
1. Rocker arm (exhaust side) NOTE: Use the same procedure for exhaust or in-
2. Roller take rocker arm.
A. Bore for rocker arm shaft
Apply engine oil on rocker arm shaft.
Measure rocker arm bore diameter. If diameter is
out of specification, change the rocker arm assem- Install the rocker arm shafts with the chamfered
bly. edge first and use following procedure:
– Insert a rocker arm pin through rocker arm pin
ROCKER ARM BORE DIAMETER bore.
NEW MINIMUM 12.036 mm (.4739 in) – Install a thrust washer no. 16 then the proper
rocker arm nos. 12 or 15 depending if you work
NEW MAXIMUM 12.050 mm (.4744 in) on intake or exhaust side.
03-09-10 VMR2004_132_03_09A.FM
Section 03 ENGINE
– Push in rocker arm shaft no. 11 until its chamfer NOTE: Before removing cylinder head, blow out
reaches the end of rocker arm bore. remaining coolant by air pressure. During cylinder
head removal, the remaining coolant in cylinder
head could overflow into the engine and a little
quantity of coolant could drop into the engine. In
this case, the engine oil will be contaminated.
Disconnect:
– spark plug wire
– temperature switch connectors.
Remove:
– both side panels and both inner fenders
(refer to BODY)
– exhaust pipe spring
– exhaust pipe nuts
– radiator inlet hose
R400motr66B 1 2 3
– carburetor clamp (cylinder head side only)
1. Rocker arm shaft
2. Thrust washer (MAG side) – chain tensioner (see CHAIN TENSIONER above)
3. Thrust washer (PTO side)
– valve cover and profile sealing ring
– Place the other thrust washer no. 16 and push (see VALVE COVER above)
rocker arm shaft to end position. – camshaft timing gear
Install the other rocker arm by using the previous – cylinder head screws no. 28
procedure.
– cylinder head screws no. 27 retaining cylinder
Install the camshaft retaining plate no. 26. head and cylinder to cylinder base.
Install all other removed parts.
TIMING CHAIN
Refer to CRANKSHAFT/BALANCER SHAFT, see
TIMING CHAIN.
CYLINDER HEAD
1
Removal
Lock crankshaft at TDC compression position, re-
fer to CRANKSHAFT/BALANCER SHAFT, see
CRANKSHAFT LOCKING PROCEDURE.
Drain coolant (refer to COOLING SYSTEM).
R400motr71A 2
1. Cylinder head screws M6
VMR2004_132_03_09A.FM 03-09-11
Section 03 ENGINE
Pull up cylinder head no. 29. Installation

Remove: For installation, reverse the removal procedure.
– chain guide no. 30 Pay attention to the following details.
– gasket no. 31 (discard). Ensure dowel pins are in place.
Install a new gasket no. 31.
First, torque cylinder head screws no. 27 in criss-
cross sequence to 20 N•m (15 lbf•ft) then finish
tightening by applying the recommended torque
4 indicated in the exploded view.
2 Torque cylinder head screws no. 28 with the rec-
ommended values in the exploded view.
R400motr72A 3
1
1. Cylinder head
2. Timing chain
3. Chain guide
4. Head gasket
Inspection
Check for cracks between valve seats, if so, replace
cylinder head. R400motr71A 2
Check mating surface between cylinder and cylin- 1. Cylinder head screws M6
der head for contamination. If so, clean both sur-
faces. Check chain guide no. 30 for movement.
Clean oil support through the cylinder head from CAUTION: Chain guide has to be fixed between
contamination. cylinder and cylinder head.
1 1
2 3
R400motr73A
2
1. Oil port to lubricate camshaft lobes intake/exhaust
2. Oil supply to camshaft bearing journal MAG side
3. Oil supply to camshaft bearing journal PTO side R400motr74A
1. Chain guide (fixed between cylinder and cylinder head)

2. Chain tensioner guide (mounted in crankcase)
Remove crankshaft locking bolt then reinstall plug

with sealing ring.
03-09-12 VMR2004_132_03_09A.FM
Section 03 ENGINE
CAMSHAFT Inspection
Check each lobe and bearing journal of camshaft
Removal for scoring, scuffing, cracks or other signs of wear.
The camshaft can be removed with the cylinder Measure camshaft bearing journal diameter and
head installed. lobe height using a micrometer.
Remove:
C B
– valve cover (see VALVE COVER above)
A
– chain tensioner (see CHAIN TENSIONER above) D
– camshaft timing gear

(see CAMSHAFT TIMING GEAR above)
– camshaft retaining plate no. 26
3
R400motr76A
A. Camshaft lobe (exhaust valves)

B. Camshaft lobe (intake valves)
C. Camshaft bearing journal MAG side
1 D. Camshaft bearing journal PTO side
CAMSHAFT LOBE — EXHAUST VALVES
NEW MINIMUM 32.027 mm (1.2609 in)

2
NEW MAXIMUM 32.047 mm (1.2617 in)
R400motr65A
1. Cylinder head
SERVICE LIMIT 32.000 mm (1.2598 in)
2. Allen screws
3. Camshaft retaining plate CAMSHAFT LOBE — INTAKE VALVES
– rocker arms (see ROCKER ARM above) NEW MINIMUM 32.343 mm (1.2733 in)
– camshaft no. 32.
NOTE: Rotate camshaft so that intake/exhaust
lobe shows to upper side of cylinder head to ease SERVICE LIMIT 32.300 mm (1.2717 in)
removal of the camshaft.
CAMSHAFT BEARING JOURNAL — MAG SIDE
2 NEW MINIMUM 34.959 mm (1.3763 in)

3
CAMSHAFT BEARING JOURNAL — PTO SIDE

1

R400motr75A
1. Area for camshaft lobes

2. Camshaft
3. Camshaft retaining plate
VMR2004_132_03_09A.FM 03-09-13
Section 03 ENGINE
Measure clearance between both ends of cam-

shaft and cylinder head. 2
R400motr75B
A 1. Camshaft retaining plate position

2. Slot retaining camshaft
3. Direction of movement
For other parts, refer to proper installation proce-

R400motr77A dure.
A. Cylinder head — camshaft bore MAG side
B. Cylinder head — camshaft bore PTO side VALVE SPRING
CAMSHAFT BORE — MAG SIDE Removal
MEASURED IN DIAMETER
Remove:
NEW MINIMUM 35.000 mm (1.3780 in) – rocker arms (see ROCKER ARM above)
NEW MAXIMUM 35.025 mm (1.3789 in) – cylinder head (see CYLINDER HEAD above).
SERVICE LIMIT 35.040 mm (1.3795 in) Compress valve spring no. 33; use valve spring
compressor clamp (P/N 529 035 724) and valve
CAMSHAFT BORE — PTO SIDE spring compressor cup (P/N 529 035 725).
MEASURED IN DIAMETER

 WARNING
Always wear safety glasses when disassem-
NEW MAXIMUM 22.021 mm (.8670 in) bling valve springs. Be careful when unlock-
ing valves. Components could fly away be-
SERVICE LIMIT 22.040 mm (.8677in) cause of the strong spring preload.
Replace parts that are not within specifications.
Installation
Install camshaft in the opposite way of the remov-
al then place the camshaft retaining plate in the
slot.
03-09-14 VMR2004_132_03_09A.FM
Section 03 ENGINE
1 3 2 Inspection
Check valve spring for visible damages. If so, replace
valve spring.
Check valve spring for free length and straightness.
R400motr78A
1. Valve spring compressor clamp (P/N 529 035 724)

2. Valve spring compressor cup (P/N 529 035 725)
R400motr80A A
3. Valve cotter A. Valve spring length
VALVE SPRING FREE LENGTH
NEW NOMINAL 40.81 mm (1.607 in)
Replace valves springs if not within specifications.
Installation
Colored area of the valve spring must be placed on
R400motr79A top.
LOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OF NOTE: Valve cotter must be properly engaged in
THE VALVE valve stem grooves.
Remove valve cotters no. 34.
Withdraw valve spring compressor, valve spring 2
retainer no. 35 and valve spring no. 33.
R400motr81A
1. Position of the valve spring

2. Valve cotters
VMR2004_132_03_09A.FM 03-09-15
Section 03 ENGINE
VALVE Inspection
Valve Stem Seal
Removal
Inspection of valve stem seals is not needed because
Remove valve spring. new seals should always be installed whenever
Push valve stem then pull valves no. 36 (intake) cylinder head is removed.
and no. 37 (exhaust) out of valve guide no. 40. Valve
Inspect valve surface, check for abnormal stem
2 1 wear and bending. If out of specification, replace by
a new one.
VALVE OUT OF ROUND

NEW NOMINAL
EXHAUST
0.005 mm (.0002 in)
INTAKE
R400motr82A
SERVICE LIMIT
1. Intake valve 31 mm
2. Exhaust valve 27 mm
EXHAUST
Remove valve stem seal no. 38 with special pliers 0.06 mm (.0024 in)
INTAKE
such as Snap-ON YA 8230.
Valve Stem and Valve Guide Clearance

Measure valve stem and valve guide in three places
using a micrometer and a small bore gauge.
NOTE: Clean valve guide to remove carbon depos-
its before measuring.
Change valve if valve stem is out of specification
or has other damages such as wear or friction sur-
face.
A
R610motr125A
R400motr83A
A. Valve stem diameter
03-09-16 VMR2004_132_03_09A.FM
Section 03 ENGINE
VALVE STEM DIAMETER

Ensure to seat valves properly. Apply some lapping
compound to valve face and work valve on its seat
NEW MINIMUM with a lapping tool (see VALVE GUIDE PROCE-
DURE below).
EXHAUST 4.956 mm (.1951 in)
Measure valve face contact width.
INTAKE 4.966 mm (.1955 in) NOTE: The location of contact area should be in
NEW MAXIMUM
center of valve seat.
Measure valve seat width using a caliper.
EXHAUST 4.970 mm (.1957 in)
VALVE SEAT CONTACT WIDTH
INTAKE 4.980 mm (.1960 in)
NEW
SERVICE LIMIT
1.25 to 1.55 mm
EXHAUST EXHAUST
(.049 to .061 in)
4.930 mm (.1941 in)
INTAKE 1.15 to 1.35 mm
INTAKE
(.045 to .053 in)
Replace valve guide out of cylinder head if valve
guide is out of specification or has other damages SERVICE LIMIT
such as wear or friction surface (see VALVE
GUIDE PROCEDURE below). EXHAUST 2 mm (.078 in)
INTAKE 1.8 mm (.07 in)

VALVE GUIDE DIAMETER
SERVICE LIMIT If valve seat contact width is too wide or has dark
spots, replace the cylinder head.
EXHAUST
5.050 mm (.1988 in)
INTAKE
A B
Valve Face and Seat
2
3
V01C1HA
1
A. Valve face contact width
B. Valve seat contact width
R400motr84A
1. Valve seat
2. Exhaust valve contaminated area
3. Valve face (contact surface to valve seat)
Check valve face and seat for burning or pittings

and replace valve or cylinder head if there are signs
of damage.
VMR2004_132_03_09A.FM 03-09-17
Section 03 ENGINE
Installation 2
CAUTION: Make sure the thrust washer no. 39
is installed before installing valve stem seal 1
no. 38.
Apply engine oil on valve stem and install it.
CAUTION: Be careful when valve stem is passed
through sealing lips of valve stem seal.
1 2
R400motr86A
1. Valve guide remover

2. Valve guide
Inspection
Always replace valve stem seals whenever cylin-
der head is removed.
R400motr85A Clean the valve guide bore before reinstalling the
valve guide into cylinder head.
1. Thrust washer
2. Sealing lips of valve stem seal
Installation
To ease installation of cotters, apply oil or grease
on them so that they remain in place while releas- For installation, reverse the removal procedure.
ing the spring. Pay attention to the following details.
After spring is installed, ensure it is properly Use valve guide installer (P/N 529 035 853) to in-
locked by tapping on valve stem end with a soft stall valve guide no. 40.
hammer so that valve opens and closes a few
times.
CAUTION: An improperly locked valve spring 1
will cause engine damage.
VALVE GUIDE PROCEDURE

Removal
Remove:
– cylinder head (see CYLINDER HEAD above) 2
– valve spring (see VALVE SPRING above) R400motr87A
– valves (see VALVE above). 1. Valve guide installer

2. Valve guide
NOTE: Clean valve guide area from contamination
before removal. NOTE: Apply anti-seize lubricant (P/N 293 800
Using valve guide remover (P/N 529 035 924), 070) on valve guide prior to install it into the cylin-
remove valve guide no. 40 with a hammer. der head.
03-09-18 VMR2004_132_03_09A.FM
Section 03 ENGINE
CAUTION: Push valve guide no. 40 in the cold NOTE: Ensure to turn reamer in the right direc-
cylinder head as per following illustration. tion. Use cutting oil and make brakes to clean
reamer/valve guide from metal shavings.
Apply some lapping compound to valve face and
work valve on its seat with a lapping tool.
3 A
2
1
2
A
1
R400motr87B
1. Thrust surface of cylinder head

2. Valve guide
A. Measurement from thrust surface to valve guide top
R400motr89A
VALVE GUIDE MEASUREMENT A 1. Valve seat

2. Valve face (contact surface to valve seat)
NEW MINIMUM 14.00 mm (.5512 in) 3. Turn valve while pushing against cylinder head
A. Valve seat angle 45°
NEW MAXIMUM 14.40 mm (.5669 in) NOTE: Ensure to seat valves properly. Apply
marking paste to ease checking contact pattern.
Valve guide to be adjusted in diameter by using a
reamer. Repeat procedure until valve seat/valve face fits
together.
VALVE GUIDE DIAMETER
NEW MINIMUM
CYLINDER
EXHAUST Removal
5.006 mm (.1971 in) Lock crankshaft at TDC compression position, re-
INTAKE
fer to CRANKSHAFT/BALANCER SHAFT, see
NEW MAXIMUM CRANKSHAFT LOCKING PROCEDURE.
EXHAUST
Using the camshaft locking tool (P/N 529 035 926),
5.018 mm (.1976 in) lock the camshaft at TDC compression position to
INTAKE prevent timing chain stretching.
Remove:
– chain tensioner
1 (see CHAIN TENSIONER above)
– decompressor
– camshaft timing gear
A
– cylinder head (see CYLINDER HEAD above).
R400motr88A
1. Valve guide
A. Valve guide diameter
VMR2004_132_03_09A.FM 03-09-19
Section 03 ENGINE
Pull cylinder no. 41. CYLINDER TAPER IN DIAMETER

Discard cylinder gasket no. 42.
4
Distance between measurements should not ex-

ceed the service limit mentioned above.
1 Cylinder Out of Round
Measure cylinder diameter in piston axis direction
from top of cylinder. Take another measurement
2 90° from first one and compare.
3 NOTE: Take the same measuring points like de-
scribed in CYLINDER TAPER above.
R400motr90A
1. Cylinder
2. Piston assembly
3. Cylinder base gasket
4. Camshaft timing chain
Inspection B
Cylinder A
Check cylinder for cracks, scoring and wear ridges
on the top and bottom of the cylinder. If so, replace
cylinder.
R400motr92A
Cylinder Taper A. Perpendicular to crankshaft axis

Measure cylinder bore and if it is out of specifications, B. Parallel to crankshaft axis
replace cylinder and piston ring set no. 46.
CYLINDER OUT OF ROUND
Measure cylinder bore at 3 recommended posi-
tions. See the following illustration. NEW MAXIMUM 0.015 mm (.0006 in)

3
C CAUTION: Always replace gasket no. 42 before
1 installing the cylinder.
A
Installation
B
Apply engine oil in the bottom area of the cylinder
2
R400motr91A
bore and also on the band of the piston ring
compressor tool.
1. First measuring of diameter
2. Second measuring of diameter
3. Third measuring of diameter MODELS PISTON RING COMPRESSOR
A. 7 mm (.276 in) from cylinder bottom
B. 68 mm (2.68 in) OUTLANDER 330 529 035 977
C. 32 mm (1.260 in)
OUTLANDER 400 529 035 919
03-09-20 VMR2004_132_03_09A.FM
Section 03 ENGINE
Remove one piston circlip no. 43 and discard it.
1
3 1
2 R400motr94A
R400motr93A
1. Piston circlip
1. Timing chain
2. Piston ring compressor tool
3. Piston NOTE: The removal of both piston circlips is not
4. Cylinder necessary to remove piston pin.
NOTE: Put timing chain through the chain pit then Push piston pin no. 44 out of piston.
put the cylinder in place.
Install cylinder head and the other parts in accor-
dance with the proper installation procedures.
1
PISTON
Removal 2
Remove:
– cylinder head (see CYLINDER HEAD above)
– cylinder (see CYLINDER above). R400motr95A
Place a rag under piston and in the area of timing 1. Piston

chain compartment. 2. Piston pin
Detach piston no. 45 from connecting rod.

 WARNING
Piston circlips are spring loaded.
VMR2004_132_03_09A.FM 03-09-21
Section 03 ENGINE
Inspection
Piston
Inspect piston for scoring, cracking or other dam-
ages. Replace piston and piston rings if necessary.
Using a micrometer, measure piston at 8 mm 2 1
(.315 in) perpendicularly (90°) to piston pin.
F00B09A
1. Use the micrometer to set the cylinder bore gauge

2. Dial bore gauge
A
R400motr96A
1. Measuring perpendicularly (90°) to piston pin

A. 8 mm (.315 in)
The measured dimension should be as described

in the following table. If not, replace piston.
PISTON MEASUREMENT
NEW NOMINAL
81.950 to 81.966 mm
OUTLANDER 330
(3.2264 to 3.2270 in)
1
90.950 to 90.966 mm
OUTLANDER 400
(3.5807 to 3.5813 in)
F00B0AA
Piston/Cylinder Clearance TYPICAL

1. Indicator set to 0 (zero)
Adjust and lock a micrometer to the piston dimension.
Position the dial bore gauge 20 mm (.787 in) above
1 cylinder base, measuring perpendicularly (90°) to
piston pin axis.
Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder wall
clearance.
PISTON/CYLINDER CLEARANCE
NEW NOMINAL
0.057 to 0.087 mm
OUTLANDER 330
(.0022 to .0034 in)
F00B08A
0.027 to 0.057 mm
OUTLANDER 400
1. Micrometer set to the piston dimension (.0011 to .0022 in)
With the micrometer set to the dimension, adjust SERVICE LIMIT
a cylinder bore gauge to the micrometer dimen-
sion and set the indicator to 0 (zero). ALL MODELS 0.010 mm (.004 in)
03-09-22 VMR2004_132_03_09A.FM
Section 03 ENGINE
NOTE: Make sure used piston is not worn. See

PISTON MEASUREMENT above.
If clearance exceeds specified tolerance, replace
cylinder.
NOTE: Make sure the cylinder bore gauge
indicator is set exactly at the same position as with
the micrometer, otherwise the reading will be
false.
Piston Pin A
1
Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracking or other
R400motr98A
damages.
Measure piston pin. See the following illustration 1. Connecting rod small end
A. Connecting rod small end diameter
for the proper measurement positions.
Replace crankshaft if diameter of connecting
rod small end is out of specifications. Refer to
CRANKSHAFT/BALANCER SHAFT for removal
procedure.
Installation
R400motr30A A Apply engine oil on the piston pin.
A. Piston pin diameter Insert piston pin into piston and connecting rod.
CAUTION: Take care that piston will be installed
PISTON PIN DIAMETER with the punched arrow on piston top to the
NEW MINIMUM 19.996 mm (.7872 in) exhaust side.
Replace piston pin if diameter is out of specifications. 2

Piston Pin/Connecting Rod Bushing Clearance
Measure inside diameter of connecting rod. 1
CONNECTING ROD SMALL END DIAMETER

R400motr99A
1. Arrow should indicate to the exhaust side
SERVICE LIMIT 20.060 mm (.7898 in) 2. Area of timing chain compartment
Use the piston circlip installer (P/N 529 035 921) to

assemble the new piston circlip as per following
procedure:
VMR2004_132_03_09A.FM 03-09-23
Section 03 ENGINE
CAUTION: Always replace disassembled pis-

ton circlip(s) by new ones. Place a rag on cylin-
der base to avoid dropping the circlip inside the
engine.
– Place circlip no. 43 in sleeve as per following
illustration.
1
R400motr102A
2
CORRECT POSITION OF THE PISTON CIRCLIP
PISTON RINGS
Removal
R400motr100A Remove:
1. Circlip – cylinder head
2. Sleeve
3. Assembly jig from piston clip installer – cylinder
– Push taper side of assembly jig until circlip reach- – piston pin.
es middle of sleeve.
Inspection
– Align sleeve with piston pin axis and push as-
sembly jig until circlip engages in piston. Ring/Piston Groove Clearance
Using a feeler gauge measure each ring/piston
3 4 groove clearance. If the clearance is too large, the
piston and the piston rings should be replaced.
2 1 RING/PISTON GROOVE CLEARANCE
5 NEW MINIMUM
UPPER
0.03 mm (.0012 in)
COMPRESSION RING
LOWER
0.02 mm (.0008 in)
COMPRESSION RING
R400motr101A
OIL SCRAPER RING 0.01 mm (.0004 in)
1. Arrow should indicate to the exhaust side
2. Hold piston while pushing circlip in place NEW MAXIMUM
3. Sleeve
4. Assembly jig UPPER
5. Direction to push circlip 0.070 mm (.0028 in)
COMPRESSION RING
NOTE: Take care that the hook of the piston circlip LOWER
is positioned properly. 0.060 mm (.0026 in)
COMPRESSION RING
OIL SCRAPER RING 0.045 mm (.0018 in)
SERVICE LIMIT
ALL 0.15 mm (.0059 in)
03-09-24 VMR2004_132_03_09A.FM
Section 03 ENGINE
Install the oil scraper ring first, then the lower com-
1
pression ring with the word “N and TOP “ facing
2 up, then the upper compression ring with the word
“N and TOP“ facing up.
1
R400motr103A
1. Piston 2
2. Feeler gauge
Ring End Gap

3
RING END GAP A31C2NA
NEW MINIMUM 1. Upper compression ring

2. Lower compression ring
3. Oil scraper ring
UPPER
0.20 mm (.008 in)
COMPRESSION RING CAUTION: Ensure that top and second rings are
not interchanged.
LOWER
0.20 mm (.008 in) NOTE: Use a ring expander to prevent breakage
COMPRESSION RING
during installation. The oil ring must be installed by
OIL SCRAPER RING 0.20 mm (.008 in) hand.
NEW MAXIMUM Check that rings rotate smoothly after installation.
Space the piston ring end gaps 120° apart and do
UPPER
0.40 mm (.014 in) not align the gaps with the piston pin bore or the
COMPRESSION RING
thrust side axis.
LOWER
0.40 mm (.014 in)
COMPRESSION RING A
OIL SCRAPER RING 0.70 mm (.028 in) A A
SERVICE LIMIT
ALL 1.5 mm (.059 in)
Measure position for ring end gap in the area of 8

to 16 mm (.315 to .630 in) from top of cylinder. 1
NOTE: In order to correctly position the ring in the
cylinder, use piston as a pusher.
Using a feeler gauge, check ring end gap. Replace 2
ring if gap exceeds above described specified tol-
erance.
Installation A31C2OA
1. DO NOT align ring gap with piston thrust side axis

For installation, reverse the removal procedure. 2. DO NOT align ring gap with piston pin bore axis
Pay attention to the following details. A. 120°
NOTE: First install spring and then rings of oil

scraper ring.
VMR2004_132_03_09A.FM 03-09-25
Section 03 ENGINE
Subsection 10 (CRANKSHAFT/BALANCER SHAFT)
CRANKSHAFT/BALANCER SHAFT 0
CRANKCASE
10 Nm
(89 lbfin)
10 Nm
(89 lbfin)
25 Nm MAG
(18 lbfft) Loctite 5910
PTO
25 Nm
(18 lbfft)
9
10
2
1 Engine 10 9
oil
Loctite 5910
Loctite
5 5331
11
Multi-purpose
grease
R400motr15T
VMR2004_133_03_10A.FM 03-10-1
Section 03 ENGINE
CRANKSHAFT/BALANCER SHAFT
8
Engine oil
4
Engine oil
6 20 Nm
(15 lbfft)
7 Finish with
70° angle
torque
Engine oil
R400motr16S
03-10-2 VMR2004_133_03_10A.FM
Section 03 ENGINE
GENERAL Use a screwdriver to check if groove in crankshaft

is aligned with the hole.
complete procedure.
 WARNING
Locking devices (ex.: locking tabs, elastic
stop nuts, self-locking fasteners, etc.) must
be installed or replaced with new ones where
1
CRANKSHAFT LOCKING
PROCEDURE R400motr235A
1. Screwdriver
Removal Lock crankshaft with crankshaft locking bolt (P/N
Unplug spark plug cable then remove the spark plug. 529 035 617).
Remove valve cover (refer to CYLINDER AND HEAD).
To place piston at TDC, pull rewind starter to rotate
crankshaft until piston is at TDC compression po-
sition. 2
Remove screw no. 1 and sealing washer no. 2.
R400motr236A
3
1. Crankshaft locking bolt
2. Front output shaft area
2
Install camshaft locking tool (P/N 529 035 926).
1
R400motr234A
NOTE: At piston TDC, the printed marks on the
camshaft timing gear have to be parallel to cylinder
1. Screw head base as per following illustration.
2. Sealing washer
3. Output shaft on front side of vehicle
VMR2004_133_03_10A.FM 03-10-3
Section 03 ENGINE
2 3 1 4 CHAIN TENSIONER PLUNGER PROTRUSION

18.5 mm to 20 mm
SERVICE LIMIT
(.71 in to .79 in)
If protrusion exceeds service limit, replace timing

chain, camshaft timing gear, chain guide and chain
tensioner guide at the same time.
Check timing chain on camshaft timing gear for ex-
cessive radial play.
Check chain condition for wear and rollers condition.
R400motr20A
1. Printed mark on camshaft timing gear

2. Cylinder head base
3. Camshaft timing gear R610motr201A 1
4. Camshaft locking tool
1. Timing chain
NOTE: The Outlander 330 is not equipped with a
If chain is excessively worn or damaged, replace it
decompressor system.
as a set (camshaft timing gear and timing chain).
TIMING CHAIN Removal
Inspection Remove:
Distance between chain tensioner guide and end – engine from vehicle
of chain tensioner housing is a general information (refer to REMOVAL AND INSTALLATION)
about the valve train (chain) condition. – valve cover, chain tensioner and camshaft tim-
ing gear (refer to CYLINDER AND HEAD)
2 1 3
– magneto cover and rotor
(refer to MAGNETO SYSTEM)
– output shaft (refer to GEARBOX).
If the chain is not changed, note the operation di-
A rection to reinstall it in the same way.
Installation
The installation is essentially the reverse of the re-
moval procedure but, pay attention to the follow-
ing details.
Ensure to perform proper valve timing. Lock crank-
shaft and camshaft at ignition TDC (refer to CYL-
INDER AND HEAD).
R400motr21A
Install chain then, adjust chain tension (refer to
1. Timing gear CYLINDER AND HEAD).
2. Chain tensioner guide
3. Chain tensioner plunger CAUTION: Improper valve timing will damage
A. Chain tensioner plunger protrusion
engine components.
03-10-4 VMR2004_133_03_10A.FM
Section 03 ENGINE
TIMING CHAIN GUIDE CRANKCASE

Removal To reach the balancer shaft and the crankshaft, it
is necessary to separate the crankcase.
Remove:
The procedures to remove, inspect and install the
– engine from vehicle balancer shaft and the crankshaft are explain fur-
(refer to REMOVAL AND INSTALLATION) ther in this section. For all gearbox parts refer to
– magneto and rotor (refer to MAGNETO) GEARBOX).
– bearing screw at the bottom of chain guide.
Removal
Pull the chain guide downward to remove it.
Remove:
Inspection – engine from vehicle
Check chain tensioner guide for wear, cracks or other
damages. Replace if necessary. – magneto housing cover and rotor
Installation NOTE: Oil pump removal from crankcase MAG
Clean bearing screw threads then apply Loctite 243 side not necessary, but recommended to see con-
on the screw threads. dition of oil pump (refer to LUBRICATION SYS-
TEM).
Install the guide in crankcase housing then torque
bearing screw to 10 N•m (89 lbf•in). – output shaft (refer to GEARBOX)
– timing chain (see TIMING CHAIN above)
3 1 2
– cylinder head and cylinder
(refer to CYLINDER AND HEAD)
– drive pulley (refer to CVT, see DRIVE PULLEY).
Measure axial clearance between the crankshaft
no. 3 and crankcase PTO no. 5 with a feeler gauge.
R400motr48A
1. Chain tensioner guide

2. Bearing screw
3. Crankcase MAG side
Reinstall all removed parts in accordance with the

proper installation procedures. R400motr22A
1. Feeler gauge
CRANKSHAFT AXIAL CLEARANCE

MINIMUM (new) 0.1 mm (.0039 in)
MAXIMUM (new) 0.4 mm (.0157 in)
VMR2004_133_03_10A.FM 03-10-5
Section 03 ENGINE
If measurement is out of specification, inspect NOTE: Hit with a soft hammer to ease lifting crank-
butting faces of crankshaft and crankcase (MAG/ case MAG.
PTO side) for excessive wear. Remove balancer shaft and crankshaft (see BAL-
Remove: ANCER SHAFT and CRANKSHAFT above).
– timing chain
Inspection
– intermediate gear
NOTE: To check some parts, it is recommended to
– retaining ring and drive gear. remove all components in both crankcase housing.
2 3 1 Clean crankcase from contaminations and blow
the oil supply lines with compressed air.
 WARNING
Use safety goggles to avoid injury to your eyes.
Check plain bearings no. 9 and no. 10 for scorings

or other damages.
Measure plain bearing inside diameter. Replace if
the measurement is out of specification.
3 2 1
R400motr23A
1. Timing chain
2. Intermediate gear
3. Drive gear
Disassembly
Remove screws retaining crankcase MAG. 4
R400motr41A
1. MAG plain bearing without groove

2. Oil bore
3. Split of the plain bearing halves
4. Cylinder base direction
A. Plain bearing inside diameter to be measured in area of oil bore
R400motr40A
19 SCREWS
Split crankcase housings.
03-10-6 VMR2004_133_03_10A.FM
Section 03 ENGINE
3 2 1 1
A
R400motr45A 2 3
R400motr42A
PUSH PLAIN BEARINGS OUTSIDE
1. PTO plain bearing without groove 1. Plain bearing remover/installer
2. Oil bore 2. Plain bearing
3. Split of the plain bearing halves 3. Crankcase PTO
4. Cylinder base direction
A. Plain bearing inside diameter to be measured in area of oil bore To install the plain bearing turn the plain bearing
remover/installer up side down.
PLAIN BEARING INSIDE DIAMETER (MAG/PTO)
NOTE: Use crankcase support MAG (P/N 529 035
SERVICE LIMIT 42.070 mm (1.6563 in) 916) and crankcase support PTO (P/N 529 035 754)
when removing or pushing plain bearing in place.
Check oil seal no. 11 if brittle, hard or otherwise
damaged. Replace if necessary. 2 1
NOTE: The oil seal is removed easily with a flat
screwdriver.
Plain Bearing Removal Procedure

CAUTION: Always support crankcase housings
properly when ball bearings, needle bearings
or plain bearings are removed. Crankcase hous-
ing damages may occur if this procedure is not
performed correctly.
NOTE: Always use a press for removal or installa-
tion of plain bearing halves.
Remove plain bearings no. 9 and no. 10 with the
plain bearing remover/installer (P/N 529 035 917). R400motr43A
1. Crankcase support MAG (P/N 529 035 916)

2. Crankcase MAG side
VMR2004_133_03_10A.FM 03-10-7
Section 03 ENGINE
2 2 1 3 4
R400motr44A 1
1. Crankcase support PTO (P/N 529 035 754)
2. Crankcase PTO side R400motr42B
NOTE: Mark oil bore position on crankcase to align 1. Mark on crankcase and oil bore position
2. Split between bearing halves
new plain bearing with crankcase thrust surface. 3. Perpendicular axle to cylinder base
4. Crankcase PTO
2 1 3 4
CAUTION: Push plain bearings MAG/PTO cor-
rectly in place to ensure oil supply to crankshaft
(oil bore and split between plain bearing halves).
R400motr41B
1. Mark on crankcase and oil bore position

2. Split between bearing halves R400motr46A
3. Perpendicular axle to cylinder base
4. Crankcase MAG PUSH PLAIN BEARINGS INSIDE
1. Plain bearing installer
03-10-8 VMR2004_133_03_10A.FM
Section 03 ENGINE
Install a new oil seal no. 11 with the crankshaft oil

2 3
seal installer (P/N 529 035 760).
R400motr24A 1 5
1. Crankshaft
2. Balancer shaft
3. Connecting rod
R400motr47A 4. Rotate crankshaft for balancer shaft removal
5. Groove for fixation at TDC
1. Crankcase PTO oil seal
2. Crankshaft oil seal installer
3. Insertion jig handle Inspection
Check balancer shaft and replace if damaged.
Assembly
Check ball bearings on MAG and PTO side for ex-
The assembly of crankcase is the reverse of re- cessive play and smooth operation. Replace if nec-
moval procedure. However, pay attention to the essary (see GEARBOX for proper procedure).
following details.
If the gear on the balancer shaft is damaged, re-
Clean oil passages and make sure they are not place balancer shaft.
clogged. Check gears on the crankshaft and replace crank-
Before closing the crankcase, refer to GEARBOX shaft if necessary (refer to CRANKSHAFT below).
to perform an inspection of gearbox parts and find
the proper procedure to clean mating surfaces, ap- Installation
ply Loctite 5910 and close crankcase with the For installation, reverse the removal procedure.
proper torquing sequence. Pay attention to following detail.
Align the dot on crankshaft gear with the balancer
BALANCER SHAFT shaft gear dot.
Removal
Split crankcase housing (refer to CRANKCASE
above).
Remove the crankshaft locking bolt.
Align the dot of crankshaft gear with the balancer
shaft gear dot then remove balancer shaft no. 4.
R400motr25A 1
1. Punched marks located in the gears
VMR2004_133_03_10A.FM 03-10-9
Section 03 ENGINE
CRANKSHAFT Connecting Rod Big End Axial Play

Using a feeler gauge, measure distance between
Removal butting face of connecting rod and crankshaft coun-
Remove: terweight. If the distance exceeds specified toler-
ance, replace the crankshaft.
– balancer shaft (see BALANCER SHAFT above)
– crankshaft no. 3. 1 2
R400motr28A
1. Crankshaft
2. Feeler gauge
R400motr26A 1 2
CONNECTING ROD BIG END
1. Crankshaft
2. Crankcase PTO
Inspection MAXIMUM (new) 0.352 mm (.014 in)
Replace crankshaft if the gears are worn or other- SERVICE LIMIT 0.5 mm (.02 in)
wise damaged.
Connecting Rod/Piston Pin Clearance
Measure piston pin. Compare to inside diameter of
connecting rod no. 6.
2
1
R400motr29A
1. Bore gauge
R400motr27A 1 2 2. Connecting rod
1. Balancer gear
2. Crankshaft timing gear
03-10-10 VMR2004_133_03_10A.FM
Section 03 ENGINE
R400motr30A A
2
A. Piston pin diameter in the area of the bushing
CONNECTING ROD SMALL END DIAMETER

PISTON PIN DIAMETER

R400motr32A
1. Micrometer
2. Crankpin area for bushings
PISTON PIN BORE CLEARANCE
To measure the connecting rod big end diameter,
SERVICE LIMIT 0.080 mm (.0035 in) use the OLD screws no. 7.
If the connecting rod small end diameter is out of Install the OLD bushings no. 8 as they were mount-
specification, replace connecting rod. ed initially.
Connecting Rod Big End Radial Play Do the torque procedure as described further.
NOTE: Prior to remove connecting rod from the
crankshaft, mark big end halves together to en-
sure a correct reinstallation (cracked surface fits in
only one position).
Remove connecting rod no. 6 from crankshaft no. 3.
CAUTION: Always replace connecting rod screws
no. 7 if removing the connecting rod. It is recom-
mended to replace bushings no. 8, if connecting A
rod is installed.
R400motr33A
A. Connecting rod big end bushing
1 CRANKSHAFT PIN DIAMETER

R400motr31A MINIMUM (new) 40.009 mm (1.575 in)
1. Connecting rod screw
MAXIMUM (new) 40.025 mm (1.576 in)
Measure crankpin. Compare to inside diameter of SERVICE LIMIT 39.980 mm (1.574 in)
connecting rod big end.
VMR2004_133_03_10A.FM 03-10-11
Section 03 ENGINE
CONNECTING ROD BIG END DIAMETER CRANKSHAFT MAG/PTO DIAMETER

SERVICE LIMIT 40.100 mm (1.579 in) MINIMUM (new) 42.024 mm (1.6545 in)
CONNECTING ROD BIG END CLEARANCE
CRANKSHAFT MAG RADIAL CLEARANCE
Crankshaft Radial Play MAG/PTO Side
Measure crankshaft on MAG/PTO side. Compare
to inside diameter of MAG/PTO bushing (refer to
GEARBOX). Installation
Pay attention to following details.
2 Use NEW bushings no. 8, when connecting rod
big end diameter is out of specification.
1
Put bushings correctly in place and clean the split
surface on both sides (cracked area) carefully.
R400motr34A 2
1. Micrometer
2. Crankshaft area for MAG bushing
1
R400motr36A
1. Half bushing of connecting rod big end

2. Split surface of the connecting rod
3. Nose of bushing in line with connecting rod groove
Torque NEW connecting rod screws no. 7 as per

following procedure:
– Install screws with half of recommended torque
in the exploded view. Do not apply any thread
R400motr35A locker product.
1. Micrometer – Torque with the recommended values in the ex-
2. Crankshaft area for PTO bushing ploded view.
– Finish tightening the screws with an additional
70° turn using an angle torque wrench.
03-10-12 VMR2004_133_03_10A.FM
Section 03 ENGINE
CAUTION: Failure to strictly follow this proce-

dure may cause screw to loosen and lead to
engine damage. The bushing tapered end must
be against the counterweight. Besides, as the
“crankpin” screw has been stretched from the
previous installation, it is very important to use
a new screw at assembly.
R400motr25A 1
1. Punched marks located in the gears
After reinstalling of crankcase MAG, measure axial

clearance of crankshaft with a feeler gauge on the
PTO side between PTO crankcase and crankshaft
thrust surface.
CAUTION: Install crankshaft locking bolt (P/N 529
035 617) right away to put crankshaft in TDC
position before installing the camshaft and
R400motr37A
rockers (refer to CYLINDER AND HEAD).
1. Angle torque wrench
R400motr39A 1 2
1. Crankshaft locking bolt (P/N 529 035 617)
R400motr38A 2. Engagement groove for TDC position of the piston
1. Insertion of balancer shaft NOTE: Always degrease tapers on both sides of
Align the marks of crankshaft and balancer shaft. the crankshaft before reinstalling rotor or CVT.
CAUTION: Make sure the woodruff key on crank-
shaft MAG is present and correctly in place.
VMR2004_133_03_10A.FM 03-10-13
Section 03 ENGINE
Subsection 11 (GEARBOX)
GEARBOX 0
OUTPUT SHAFT AND TRANSMISSION
Engine oil
4
3
2
Engine
27 oil
11
12 29
1 20 Engine
Engine 18
13 oil
21 oil
19
4 14 28
6 7 22
23 Engine
Engine 15
5 oil 17 oil
9
Engine
oil 16
10
Loctite 243 24
10 Nm 8 Different gear Engine 26
(89 lbfin) transmission oil 25
between
Outlander 400
and 330
R400tran31S
VMR2004_134_03_11A.FM 03-11-1
Section 03 ENGINE
CRANKCASE
10 Nm
(89 lbfin) 25 Nm
Multi-purpose Anti-seize (18 lbfft)
grease lubricant 30
Loctite
5910 32
10 Nm
(89 lbfin) 31 Multi-purpose
grease
10 Nm
59 (89 lbfin)
25 Nm
(18 lbfft) Loctite
243
37 Engine
oil 41 10 Nm Loctite
10 Nm (89 lbfin) 5910
25 Nm (89 lbfin)
(18 lbfft) 36 45
Multi-purpose
25 Nm 38 grease
54
Loctite (18 lbfft) 42
5910
35 40 44
43 58
Engine 56
34 oil
Loctite 57
33 5910 39
25 Nm
(18 lbfft) 48 50
55
46 49 51
Loctite
5331
47
Multi-purpose 52
grease 8 Nm 53
(71 lbfin)
Loctite
243
R400motr239S
03-11-2 VMR2004_134_03_11A.FM
Section 03 ENGINE
GENERAL 2 1
To remove gearbox, the engine removal is necessary.
complete procedure.
 WARNING
stalled or replaced with new ones where
R400motr195A
is impaired, it must be renewed. 1. Output shaft
2. Dial indicator
To remove oil seals no. 32, no. 47, no. 58 and

no. 59, the engine removal/disassembly is NOT OUTPUT SHAFT AXIAL CLEARANCE
necessary (see OIL SEALS below). SERVICE LIMIT 0.30 mm (.012 in)
OIL SEALS If the output shaft axial clearance is out of specifi-

cation, perform the bevel gear adjustment proce-
Removal dure (see BEVEL GEAR ADJUSTMENT below).
NOTE: To remove oil seals no. 47 and/or no. 58, it is
necessary to remove drive and/or driven pulley (ies). OUTPUT SHAFT
Remove oil seals no. 32, no. 47, no. 58 and no. 59 Removal
with a small flat screwdriver.
Remove:
CAUTION: Avoid scoring crankshaft MAG end
and/or shift shaft and/or main shaft during oil – disconnect unit bolts
seal removal. NOTE: The oil seal no. 32 is easily replaced with-
out disassembly of the bearing cover no. 31. Use
Inspection the output shaft oil seal installer (P/N 529 035 941)
Check bearings behind each oil seal for contami- for installation of the oil seal.
nation and/or metal shavings.
Check oil seal running surface of main shaft, crank-
shaft MAG and shift shaft for grooves. Replace if
necessary (see GEARBOX below).
Installation
The installation is the reverse of removal procedure.
Use a suitable ring to push oil seals in place.
CAUTION: Oil seal must be installed with seal-
ing lip toward engine.
Measure output shaft axial clearance prior to re- R400motr242A 2 1
move output shaft no. 1. This measure will indi- 1. Output shaft oil seal installer
cate if bevel gear adjustment is necessary. 2. Insertion jig handle
VMR2004_134_03_11A.FM 03-11-3
Section 03 ENGINE
– bearing cover screws no. 30 CAUTION: Use a soft hammer to remove output
shaft from crankcase MAG side.
3 1
– O-ring no. 4 and bearing no. 5
NOTE: Both bearings on output shaft have a tran-
sition fit.
R400motr196A 2
1. Remaining screw M8
2. Bearing cover
3. Output shaft spline R400trans04A 2 1
– bearing cover no. 31 including oil seal no. 32 1. O-ring
2. Bearing with writing to the outside
– O-ring no. 4 and bearing no. 3
R400trans03A 1 2 R400trans05A 2 1
1. Bearing cover 1. O-ring
2. Oil seal ring (apply Loctite 5910) 2. Bearing with writing to the outside
– magneto housing and rotor – shim no. 2.

– output shaft
03-11-4 VMR2004_134_03_11A.FM
Section 03 ENGINE
R400trans06A 1 2
R400trans07A 1
1. Shim
2. Output shaft gear 1. Soft hammer
2. Push output shaft as per following illustration.

Inspection
Check output shaft for cracks and other visible dam-
ages.
CAUTION: Always replace output shaft no. 1 and
bevel gear shaft no. 21 at the same time.
Check output shaft bearings for excessive play
and smooth operation. Replace if necessary.
Replace oil seal no. 32 if brittle, hard or damaged.
Replace O-rings no. 4 if brittle, hard or damaged.
Clean crankcase split surface and especially the
bearing areas from metal particles or other con-
tamination.
R400trans08A
Installation WAY TO PUSH THE BEVEL GEARS TOGETHER

3. Install bearing cover no. 30 and measure axial
gap between bearing and output shaft gear with
Adjust axial play as per following procedure: a feeler gauge.
1. Use soft hammer to put bearing no. 3 exactly
in place against crankcase MAG side.
R400trans09A
VMR2004_134_03_11A.FM 03-11-5
Section 03 ENGINE
4. Remove output shaft again and rebuild it with

proper shim.
5. Take measured thickness and choose shim as
per the following table.
MEASURED THICKNESS SHIM THICKNESS

0.79 to 0.88 mm 0.70 mm
(.0311 to .0346 in) (.0276 in)
0.89 to 0.98 mm 0.80 mm
(.0350 to .0386 in) (.0315 in)
0.99 to 1.08 mm 0.90 mm
(.0390 to .0425 in) (.0354 in) R400trans11A
1.09 to 1.18mm 1.00 mm MEASURE AXIAL CLEARANCE OF BEVEL GEAR

(.0429 to .0465 in) (.0394 in)
Remove:
1.19 to 1.28 mm 1.10 mm
(.0469 to .0504 in) (.0433 in) – cylinder head and cylinder
1.29 to 1.38 mm 1.20 mm – timing chain
(.0508 to .0543 in) (.0472 in) – drive and intermediate gear of water and oil pump
1.39 to 1.48 mm 1.30 mm
(.0547 to .0583 in) (.0512 in) 3 2
1.49 to 1.58 mm 1.40 mm
(.0587 to .0622 in) (.0511 in)
6. Finish with ball bearing cover no. 31.
CRANKCASE
Disassembly
Remove:
– engine from vehicle
– magneto housing cover and rotor
– output shaft. R400motr197A 1
Measure the axial clearance of bevel gear with a 1. Timing chain
feeler gauge. 2. Intermediate gear
3. Drive gear
NOTE: Bevel gear axial clearance should be mea-
sured before crankcase housings separation.
BEVEL GEAR AXIAL CLEARANCE
03-11-6 VMR2004_134_03_11A.FM
Section 03 ENGINE
– screws retaining crankcase housing.

1 1 4 2 3
R400motr200A
POSITION FOR BIG FLAT SCREWDRIVER
Inspection
1 1 2 1 1
R400motr198A NOTE: To check some parts, it is recommended to
1. 14 screws M6 x 45 remove all components in both crankcase halves.
2. 2 screws M6 x 85
3. 2 screws M8 x 65 Clean crankcase from contaminations and blow
4. 1 screw M6 x 16 the oil supply lines with compressed air.
Place the crankcase housings on a wood stand, MAG
side upwards.  WARNING
Lift crankcase housing no. 35 with 2 screwdrivers. Use safety goggles to avoid injury to your eyes.
Check bearings nos. 38, no. 42, no. 43 and

no. 45 as well as needle bearings no. 36 and
no. 37 for excessive play and smooth operation.
Replace if necessary.
Check plain bearings no. 39 and no. 40 for scor-
ings or other damages.
Measure plain bearing inside diameter. Replace if
the measurement is out of specification (refer to
CRANKSHAFT/BALANCER SHAFT, see CRANK-
CASE).
R400motr199A
Bearing Removal Procedure
POSITION FOR BIG FLAT SCREWDRIVER
 WARNING
Clean oil, outside and inside, from housing.
CAUTION: Make sure to support crankcase hous-

ings properly when ball bearings, needle bear-
ings or plain bearings are removed; otherwise,
crankcase housings could be damaged.
VMR2004_134_03_11A.FM 03-11-7
Section 03 ENGINE
To remove bevel gear needle bearing no. 36 and Ball bearings no. 38 and no. 45 can be easily re-
main shaft needle bearing no. 37, use a punch. moved with a suitable pusher from outside in.
The oil seals no. 46, no. 49, no. 60 and no. 61 are
removed easily with a flat screwdriver.
NOTE: To remove oil seals no. 34, no. 49, no. 60
and no. 61, the engine removal/disassembly is NOT
necessary (see OIL SEAL PROCEDURE above).
For ball bearing no. 47, remove screw no. 43 then
push bearing from outside in with a punch.
1 2
R400trans12A 1 2
1. Bevel gear needle bearing
2. Punch
2 1
R400trans14a
tra
1. Screw M6
2. Main ball bearing PTO side
Use needle bearing remover (P/N 529 035 756) to

remove needle bearing no. 48.
R400trans13A
1. Main shaft needle bearing location

2. Punch
Remove plain bearings no. 39 and no. 40 with the

proper plain bearing remover (refer to CRANKSHAFT/
BALANCER SHAFT).
To remove ball bearings no. 42 and no. 43, use a
blind hole bearing puller.
R400motr201a
R610outi03A
03-11-8 VMR2004_134_03_11A.FM
Section 03 ENGINE
Bearing Installation Procedure

1 2 3
Unless otherwise instructed, never use hammer
to install ball bearings, needle bearings or plain
bearings. Use press machine only.
 WARNING
Clean oil, outside and inside, from housing.
Install plain bearings no. 40 and no. 41 with the

proper plain bearing installer (refer to CRANKSHAFT/
BALANCER SHAFT).
NOTE: Place crankcase housings on a wood stand,
MAG side upwards before installing needle bear-
ings no. 38 and no. 39.
NEEDLE BEARING INSTALLER

R400motr203A
Main shaft bearing 529 035 762
1. Bevel gear needle bearing
Bevel gear bearing 529 035 763 2. Needle bearing installer
3. Insertion jig handle
Starter drive bearing 529 035 943
Install needle bearing no. 46 using needle bearing
installer (P/N 529 035 934) and insertion jig handle
Install needle bearing no. 37 with the needle bear-
(P/N 420 877 650).
ing installer (P/N 529 035 762) and insertion jig
handle (P/N 420 877 650).
1 2 3
R400motr241A
1. Starter drive needle bearing PTO side

R400motr202A 2. Needle bearing installer
1. Main shaft needle bearing CAUTION: Ball bearings have to be installed with
2. Needle bearing installer
3. Insertion jig handle closed bearing cage to the engine outside.
Install needle bearing no. 36 using needle bearing Use a suitable installer for installing ball bearings
installer (P/N 529 035 763) and insertion jig handle no. 38, no. 42, no. 43 and no. 45.
(P/N 420 877 650).
VMR2004_134_03_11A.FM 03-11-9
Section 03 ENGINE
Install new oil seals with the proper installer.

3 2 1
OIL SEAL INSTALLER
Crankshaft oil seal 529 035 760
Balancer shaft oil seal 529 035 933
Main shaft oil seal 529 035 934
3 2 1
R400motr206A
1. Main shaft oil seal PTO side

2. Oil seal installer
Assembly
The assembly of crankcase is essentially the re-
verse of removal procedure. However, pay atten-
R400motr204A
tion to the following details.
1. Crankcase oil seal PTO side Clean oil passages and make sure they are not
2. Oil seal installer clogged.
Clean all metal components in a solvent.
Crankcase mating surfaces are best cleaned using
a combination of the chisel gasket remover (P/N
413 708 500) and a brass brush. Brush a first pass
in one direction then make the final brushing per-
pendicularly (90°) to the first pass cross (hatch).
CAUTION: Do not wipe with rags. Use a new clean
hand towel only.
IMPORTANT: When beginning the application of
the crankcase sealant, the assembly and the first
torquing should be done within 10 minutes. It is sug-
gested to have all you need on hand to save time.
NOTE: It is recommended to apply this specific
sealant as described here to get a uniform applica-
tion without lumps. If you do not use the roller meth-
R400motr205 1 4 2 3 od, you may use your finger to uniformly distribute
1. Balancer shaft oil seal PTO side the sealant (unlike the Drei Bond sealing compound,
2. Oil seal installer using a finger will not affect the adhesion).
4. Bore for engine blow-by Use the silicone-based Loctite 5910 (P/N 293 800
081) on mating surfaces.
NOTE: The sealant curing time is similar to the
Loctite 518 without using the Primer N.
03-11-10 VMR2004_134_03_11A.FM
Section 03 ENGINE
CAUTION: Do not use Loctite 515 or 518 to seal

crankcase. Do not use Loctite Primer N with the
Loctite 5910. Using these products or non silicone-
based sealant over a previously sealed crankcase
with Loctite 5910 will lead to poor adhesion and
possibly a leaking crankcase. These products are
chemically incompatible. Even after cleaning, the
Loctite 5910 would leave incompatible microscop-
ic particles.
Use a plexiglas plate and apply some sealant on it.
Use a soft rubber roller (50 - 75 mm (2 - 3 in))
(available in arts products suppliers for printmak-
ing) and roll the sealant to get a thin uniform coat
on the plate (spread as necessary). When ready,
apply the sealant on crankcase mating surfaces.
R400motr215A 2 1 3
1. O-ring
2. Distance sleeve
3. Main shaft end PTO side
Torque crankcase screws by hand as per following

sequence. Repeat procedure, retightening all screws
to 10 N•m (89 lbf•in).
17 16 15 14 9 5 7 3 1 2
F12R17A
Do not apply in excess as it will spread out inside

crankcase.
NOTE: Do not use Loctite Primer N with this seal-
ant. The sealant curing time is similar to the Loc-
tite 518 without using the Primer N, which is 4 to
24 hours.
CAUTION: Do not forget to place O-ring no. 28 in- 18 19 8 4 6 10 11 12 13
R400motr207A
cluding distance sleeve. Chamfered bore of dis-
tance sleeve has to face the engine.
VMR2004_134_03_11A.FM 03-11-11
Section 03 ENGINE
GEARBOX – shift fork shaft no. 11
1
General
The only difference between gearbox of the Out-
lander 400 to 330 is the transmission ratio of gears
no. 22 and no. 29 (high range gear).
During and after gearbox disassembly, inspect the
condition of each part closely. In particular, check for:
– gear teeth damage
– worn or scoured bearing surfaces
– worn or scoured shift fork
– worn or scoured shift fork shaft
– rounded engagement dogs and slots
R400trans16A
– bent shift forks
1. Shift fork shaft
– bent shift fork shaft
– shift fork no. 12.
– worn shift fork engagement pins
– worn tracks on shift drum 1
– worn shift fork engagement groove
– worn splines on shafts and gears.
Removal
Remove output shaft.
Separate crankcase.
Remove:
– balancer shaft
– parking lever no. 7
– shift shaft no. 6
R400trans17A
1. Shift fork (engaged in main shaft gear)
Disengage shift fork no. 13 from shift drum no. 9.
R400trans15A 2 1
1. Parking lever
2. Shift shaft
03-11-12 VMR2004_134_03_11A.FM
Section 03 ENGINE
– gear selection no. 22, thrust washer no. 23, re-

1 2
verse gear no. 25, needle bearing no. 24 and
shim no. 26
– distance sleeve no. 14, thrust washer no. 15, in-
termediate gear no. 16, needle bearing no. 17
and intermediate gear shaft no. 18.
NOTE: It is not necessary to remove index lever
no. 8. Check index lever for visible damage and if
it moves freely. Replace if necessary.
Inspection
Check both shift forks for visible damage, wear or
bent shift fork claws.
Measure the shift fork claw thickness.
R400motr208A
SHIFT FORK CLAW THICKNESS
1. Shift fork engagement pin
2. Shift drum MINIMUM (new) 4.800 mm (.189 in)
Insert a flat screwdriver in the slot of index lever MAXIMUM (new) 4.900 mm (.193 in)
no. 8. Turn screwdriver counterclockwise and re-
move shift drum. SERVICE LIMIT 4.750 mm (.187 in)
R400trans18A 1 2
R400trans19A 1
1. Index lever
2. Shift drum 1. Micrometer
A. Shift fork claw thickness
Remove:
Check shift drum tracks for scoring or heavy wear
– shift fork no. 13 like rounded engagement slots.
– bevel gear shaft no. 21 with low range gear as- Check index washer on shift drum for scoring or
sembly visible damages.
– main gear no. 27
– O-ring no. 28 including distance sleeve from
main shaft on engine PTO side
– main shaft with high range gear assembly
VMR2004_134_03_11A.FM 03-11-13
Section 03 ENGINE
Replace isolating washer no. 10 if there are signs

1 A 2
of wear or visible damages.
1 2
R400motr211A
1. Main gear
2. Caliper
A. Gap for engagement of shift fork
R400motr210A 3 Check main shaft for wear.

1. Track for the low/reverse gear shift fork
2. Track for the high gear shift fork MAINSHAFT
3. Isolating washer on the shift drum
SERVICE LIMIT
Check shift shaft no. 6 for worn splines and gears.
MAG SIDE 17.990 mm (.708 in)
Parking lever no. 7 for cracks or other damages.
Index lever with roller no. 8 must have free move- PTO SIDE 24.950 mm (.982 in)
ment.
Measure the gap of shift fork engagement groove. 2 1
NOTE: Both gears no. 22 and no. 27 have same
gap width and same service limit.
GAP OF SHIFT FORK ENGAGEMENT GROOVE

R400trans20A
1. Mag side
MAXIMUM (new) 5.10 mm (.201 in) 2. PTO side
SERVICE LIMIT 5.20 mm (.205 in) Check bevel gear shaft.
BEVEL GEAR SHAFT

SERVICE LIMIT
PTO SIDE 24.990 mm (.984 in)
03-11-14 VMR2004_134_03_11A.FM
Section 03 ENGINE
Install:
1
– intermediate gear shaft no. 18, needle bearing
no. 17, intermediate gear no. 16, thrust washer
no. 15 and distance sleeve no. 14
– shim no. 26, needle bearing no. 24, reverse
gear no. 25, thrust washer no. 23 and gear se-
lection no. 22
– main shaft with high range gear assembly
– O-ring no. 28 including distance sleeve on main
shaft end PTO side
CAUTION: Place O-ring no. 28 including distance
sleeve right away. Chamfered bore of distance
R400trans21A
sleeve has to face the engine.
1. PTO side
Check all bearings, bearing points, tooth flanks,

taper grooves and annular grooves. Annular grooves
must have sharp edges.
Replace gears only together with the correspond-
ing meshing gears.
NOTE: Always replace circlips and use special pli-
ers to install them.
Check all shims for wear. Always replace shim by
a new one with the same thickness, when reas-
sembling the gearbox with existing output shaft
no. 1 and bevel gear shaft no. 21.
R400motr215A 2 1 3
1. O-ring
2. Distance sleeve
3. Main shaft end PTO side
– main gear no. 27

2
– bevel gear shaft no. 21 with low range gear as-
sembly
NOTE: If a new bevel gear assembly no. 1 and
3 no. 21 is used, it is necessary to make the shim
1
adjustment. See below. If the existing bevel gear
R610motr183A
is used, it is mandatory to use new shims no. 19,
1. Thrust washer for adjusting the bevel gear crankcase on CVT side no. 26 with same thickness and also new axial
2. Area where wear signs appear
3. Adjustment thickness of the washer needle bearing no. 20
– shift forks no. 13 and no. 12.
Installation
Put shift forks in place and afterward insert pin
For installation, reverse the removal procedure. no. 11 with the chamfer on top for a better instal-
Pay attention to the following details. lation of crankcase MAG side.
NOTE: Run all gears before installing the crank-
case MAG.
VMR2004_134_03_11A.FM 03-11-15
Section 03 ENGINE
Insert a flat screwdriver in the slot of index lever Bevel Gear Adjustment
no. 8. Turn screwdriver counterclockwise and in-
Use following course of calculation to adjust bevel
stall shift drum on park position as per the follow-
gear in place between crankcase PTO and MAG.
ing illustration.
NOTE: Only necessary if the output shaft axial
clearance of the bevel gear is out of specification.
Measure following items and enter measurement
in the following list:
LETTER MEASUREMENT 1 MEASUREMENT 2
A 2 mm (.0787 in) 2 mm (.0787 in)
F
R400trans22A 1 2
1. Park position (flat area on index washer) G
2. Index lever
H
Insert shift shaft no. 6 with mark in line to first tooth
on shift drum. I
R400trans23A 1 2
1. Mark on shift shaft
2. First tooth on shift drum
Install parking lever no. 7.
03-11-16 VMR2004_134_03_11A.FM
Section 03 ENGINE
B H
C G F
D(E) I(J)
Crankcase mating surface
Output shaft mating surface

R400trans27S
VMR2004_134_03_11A.FM 03-11-17
Section 03 ENGINE
Measure shim on MAG side: • C = Distance between butting face (MAG side)
NOTE: Clean mating surface of crankcase before to mating surface of crankcase MAG.
measurement. Refer to crankcase assembly pro-
cedure.
• A = 2 mm (.0787 in) nominal thickness of axial
needle bearing no. 20.
• B = Distance between butting face and theoret-
ical center of bevel gear taper. K is defined by
manufacturer and written on surface of bevel
gear PTO end.
Use following course of calculation to find out val-
ue B.
B = (K/100) + 37.8
NOTE: Value K is a number between - 10 and + 10
and equals the (±) deviation to the nominal value
of 37.8 mm (1.488 in) in hundreth of a millimeter. R400trans25A 2 1
For example, number K = - 3 equals - 0.03 mm 1. Depth gauge — measurement C
(- 0.0012 in) to the nominal value of 37.8 mm. 2. Butting face inside of crankcase MAG
B = (-3/100) + 37.8 = 37.77 • D = Theoretical shim thickness.

• E = Shim selected in accordance with D.
Use following course of calculation to get the the-
oretical thickness D for washer no. 19.
D=B-C-A
NOTE: Take theoretical value D and choose shim
E (MAG side shim) from the below table.
2
CALCULATED THICKNESS SHIM NUMBER
(D) (E)
1.20 mm to 1.29 mm
120
(.0472 to .0508 in)
1
1.30 mm to 1.39 mm
130
(.0512 to .0547 in)
R400tran24B
1.40 mm to 1.49 mm
1. Bevel gear 140
2. Area of written number K to find out value B (.0551 to .0587 in)
1.50 mm to 1.59 mm
150
(.0591 to .0626 in)
1.60 mm to 1.69 mm
160
(.0630 to .0665 in)
1.70 mm to 1.79 mm
170
(.0669 to .0705 in)
1.80 mm to 1.89 mm
180
(.0709 to .0744 in)
NOTE: For example, if the measured thickness is

1.53 mm (.0602 in), choose the shim 150. The shim
number 150 represents a value equal at 1.50 mm
(.0591 in).
03-11-18 VMR2004_134_03_11A.FM
Section 03 ENGINE
Measure shim on PTO side:

NOTE: Clean mating surfaces of crankcase before
measurement. Refer to crankcase assembly pro-
cedure.
• F = Distance between mating surface (crank-
case PTO) to ball bearing inner race.
R400trans29A
• I = Theoretical shim thickness.

• J = Shim selected in accordance with I.
Use following course of calculation to get the the-
oretical thickness I for washer no. 27.
I=F+G-H-A-E
NOTE: Take theoretical value I and choose shim J
(PTO side shim) from the below table.
R400trans26A 2 1 3 CALCULATED THICKNESS SHIM NUMBER

(I) (J)
1. Ball bearing inner race
2. Mating surface of crankcase PTO 1.22 mm to 1.31 mm
3. Depth gauge 120
(.0480 to .0516 in)
• G = Distance between mating surface of crank- 1.32 mm to 1.41 mm
case MAG and butting face. 130
(.0519 to .0555 in)
1.42 mm to 1.51 mm
140
(.0559 to .0594 in)
1.52 mm to 1.61 mm
150
(.0598 to .0634 in)
1.62 mm to 1.71 mm
160
(.0638 to .0673 in)
1.72 mm to 1.81 mm
170
(0.0677 to .0713 in)
1.82 mm to 1.91 mm
180
(.0717 to .0752 in)
NOTE: For example, if the measured thickness is

1.53 mm (.0602 in), choose the shim 150.
NOTE: Bevel gear axial clearance of 0.02 to 0.11 mm
(.00079 to .00433 in) is included in the above table.
R400trans28A 1
1. Butting surface
• H = Distance between butting faces of bevel gear

shaft.
VMR2004_134_03_11A.FM 03-11-19
Section 03 ENGINE
Example Installation
LETTER MEASUREMENT 1
A 2 mm (.0787 in) CAUTION: Don’t forget thrust washer no. 15 and
B 37.760 mm (1.487 in) no. 22.
First install intermediate gear then main shaft and
C 34.040 mm (1.340 in) afterward the bevel gear.
D 1.72 mm (.068 in)
3 1 4 2
E 170
F 51.800 mm (2.039 in)
G 39.080 mm (1.539 in)
H 85.680 mm (3.373 in)
I 1.500 mm (.059 in)
J 140
Shim on MAG side:

The measure A is 2 mm (.0787 in).
R400trans30A
Note the measure indicates on bevel gear in the
1. Intermediate gear
box B. Example: 37.760 mm (1.487 in). 2. Main shaft
3. Thrust washer after main gear on bevel gear
Measure the distance C then indicates its value in 4. Thrust washer between distance sleeve and reverse gear
the box C. Example: 34.040 mm (1.340 in).
Install the shift drum.
B-C-A=D
(37.760 - 34.040 - 2 = 1.72 mm). 1 8
In accordance with the appropriate table, you need 7
5
a shim number 170.
Shim on PTO side:
Measure the distance F. Indicate this value in the
box F. Example: 51.800 mm (2.039 in).
Measure the distance G. Note this value in the 6
box G. Example: 39.080 mm (1.539 in). 2
Measure the distance between both butting sur- 3 4
R400motr212A
face of bevel gear shaft. This is the value H. Exam-

1. Parking stop location
ple: 85.680 mm (3.373 in). 2. Reverse stop location
3. Neutral stop location
F+G-H-A-E=I 4.
5.
High gear stop location
Low gear stop location
(51.800 + 39.080 - 85.680 - 2 - 1.70 = 1.50 mm). 6. Contact to stop location for neutral/park position
7. Contact to reverse stop location
NOTE: The shim number 170 represents a value 8. Pin to align isolating and index washer
equal at 1.70 mm (.0669 in). If a shim 160 was re- NOTE: Run all gears as a final function check be-
quired, its value would be 1.60 mm (.0630 in). fore reassembling crankcase MAG.
In accordance with the appropriate table, you need
a shim number 140.
03-11-20 VMR2004_134_03_11A.FM
Section 03 ENGINE
SHIFTING INDICATOR SWITCH

Test
Prior to remove parts from vehicle and/or engine
perform general test as per following procedure:
– Unplug connector from vehicle wire harness.
R400motr213A 1 2 3
1. Blue wire for contact to parking gear
2. Brown wire for contact to reverse gear
3. Green/yellow wire for contact to neutral gear
Remove screw(s) retaining shifting indicator switch

wire(s).
Unscrew the shifting indicator switches no. 55.
4 1 2 3 5
R400motr216A
NOTE: Remove the shifting indicator switches
1. Blue wire for contact to parking gear one at a time.
2. Brown wire for contact to reverse gear
3. Green/yellow wire for contact to neutral gear
4. Shifting indicator connector to dash board Test
5. Oil pressure area
Check if shifting indicator switches work properly
– Put vehicle in park, reverse or neutral position and as per following procedure:
use a multimeter to measure the electric passage
– Put shift drum in park, reverse or neutral position.
from connector (specific cable) to engine ground.
– Use a multimeter to measure electric passage
NOTE: For example, shift gear to park position
and measure from blue cable of connector to en- from specific shifting indicator switch to engine
gine ground. ground.
In case of an electrical failure check wire harness Check wiring harness as per following procedure:
no. 54 and/or shifting indicator switch no. 55 (see Install a pin in the connector.
TEST below).
NOTE: The engine removal is not necessary to
reach the shifting indicator switches.
To reach the shifting indicator switches, remove:
– CVT cover
– driven pulley.
Removal
NOTE: Clean area from dirt and belt dust before
removing parts.
Remove: R610motr196A
– screw no. 57
– protection sheet no. 56. – Place one probe of multimeter on the pin and
the other on the opposite side of wire harness
NOTE: Clean area from dirt and belt dust before (specific cable).
removing shifting indicator switch(es).
VMR2004_134_03_11A.FM 03-11-21
Section 03 ENGINE
NOTE: The alligator clip is recommended. Inspection

Replace wire harness no. 54 if damaged, brittle, Check if starter drive pinion is free of movement.
hard or otherwise damaged.
NOTE: Centrifugal weights avoid disengaging of
If the shifting indicator switch and its harness are the pinion while starting the engine.
good, check the vehicle harness and/or indicator
lights. 3
2
Installation
If all switches are removed, take care to put back
wires at the proper location.
Take care do not damage shifting indicator switch-
es threads during installation.
R400motr217A 1
STARTER DRIVE PINION 1. Starter drive pinion
2. Starting position (spring released)
Removal 3. Gear is engaged drive pulley fixed half (spring loaded)
Remove: Replace needle bearing no. 46 if damaged (see

CRANKCASE above).
– drive pulley (refer to CVT)
Check starter drive pinion cover for crack and clean
– screw no. 53 retaining starter drive pinion cover
it before reinstallation.
NOTE: Do not lose shims no. 50, no. 52 and/or
Check bore inside starter drive pinion cover if dam-
spring no. 49 during removal of starter pinion cover.
aged, worn or otherwise damaged. Replace as
– starter drive pinion cover no. 51 necessary.
– starter drive pinion no. 48.
Installation
3 NOTE: Apply multi-purpose grease inside starter
drive pinion cover.
4
5
1
6
R400motr240A
1. Starter drive pinion cover

2. Starter drive pinion
3. Screw
4. Shim
5. Shim
6. Spring
03-11-22 VMR2004_134_03_11A.FM
Section 03 ENGINE
Subsection 12 (CVT)
CVT 0
NOTE: This is a lubrication free system except drive pulley one-way clutch.
Anti-seize lubricant
35 32
29
34 33 30
25
20 27
27 24 4 31
Degrease
28
9 16
15 23 26
22
21 60 Nm 3
Anti-seize (44 lbfft)
lubricant 17 10
18
12
76
6 Nm 13
(44 lbfin) 8
19
14
11
5
100 Nm
(74 lbfft)
1
7 Nm
(62 lbfin)
R400motr238S
VMR2004_135_03_12A.FM 03-12-1
Section 03 ENGINE
Subsection 12 (CVT)
GENERAL CAUTION: These pulleys have metric threads.

Do not use imperial thread puller. Always tight-
NOTE: For a better understanding, the following en puller by hand to ensure that the drive pulley
illustrations are taken with engine out of vehicle. has the same type of threads (metric vs impe-
To perform the following instructions, it is not nec- rial) before tightening completely.
essary to remove engine.
This CVT is lubrication free. Never lubricate any com- BELT REPLACEMENT
ponents except drive pulley one-way clutch.
During assembly/installation, use the torque values Removal
and service products as in the exploded views. Remove:
Clean threads before applying a threadlocker. Refer – LH engine side panel
to SELF-LOCKING FASTENERS and LOCTITE AP-
– LH footwell.
PLICATION at the beginning of this manual for com-
plete procedure. Unscrew clamps retaining CVT cover hoses.
Remove:
 WARNING – screws no. 1 with mounted rubber bushings CVT
Torque wrench tightening specifications must cover no. 2 and gasket no. 3.
where specified. If the efficiency of a locking
 WARNING
Never touch CVT while engine is running. Nev-
er drive vehicle when CVT cover is removed.
 WARNING R400motr155A 3 1 2 4
Any drive pulley repairs must be performed by
an authorized Bombardier ATV dealer. Sub- 1. CVT cover
2. Gasket
component installation and assembly toler- 3. Intake for air cooling
ances require strict adherence to procedures 4. Air outlet
detailed. NOTE: Remove the center top screw last. This
screw supports the cover during removal.
 WARNING Open driven pulley with the driven pulley expand-
Never use any type of impact wrench at drive er (P/N 529 035 747).
pulley removal and installation.
 WARNING
The clutch assembly is a precisely balanced
unit. Never replace parts with used parts from
another clutch assembly.
03-12-2 VMR2004_135_03_12A.FM
Section 03 ENGINE
Subsection 12 (CVT)
Screw tool in the threaded hole of driven pulley

and tighten to open the pulley.
R400motr158A 1
1. Drive belt
A. Belt width
Installation
R400motr156A 2 1 For installation, reverse the removal procedure.
1. Driven pulley expander
2. Fixed half of driven pulley The maximum drive belt life span is obtained when
To remove belt no. 4, slip the belt over the top edge the drive belt has the proper rotation direction. In-
of sliding half, as shown. stall it so the arrow printed on belt is pointing to-
wards the back of the vehicle.
NOTE: Put a small amount of Loctite 5910 in the
groove of CVT cover to ease installation of CVT
2 cover with gasket no. 3.
Install the center top screw of cover in first.
Install the other screws then torque them in a criss-
cross sequence.
DRIVE PULLEY
1
R400motr157A
1. Screw in of driven pulley expander

2. Removal direction for belt
Inspection
Inspect belt for cracks, fraying or abnormal wear.
Check drive belt width. Replace if it is out of spec-
ification (see table below).
DRIVE BELT WIDTH R400motr159A 2 1 3
NEW NOMINAL 32.00 mm (1.260 in) 1. Belt
2. Drive pulley
3. Driven pulley
VMR2004_135_03_12A.FM 03-12-3
Section 03 ENGINE
Subsection 12 (CVT)
Removal of Drive Pulley

Remove belt no. 4.
NOTE: To remove drive pulley, two procedures can
be followed.
 WARNING
Drive pulley screw has a left-hand thread.

– Remove the spark plug (refer to CYLINDER AND
HEAD).
– Put piston at TDC and lock crankshaft with crank-
shaft locking bolt (P/N 529 035 617).
R400motr161A 1 3 2
2
1. Clutch holding tool (P/N 529 006 400)
2. Drive pulley sliding half
3. Area to place holding tool hook
CAUTION: Prior to removing the drive pulley,

mark sliding half and governor cup together to
ensure correct reinstallation. There are only 4
levers mounted out of 6 possible positions for
1 the Outlander 400 execution. On the Outlander
330, there are 3 levers mounted out of 6 possi-
R400motr236A ble positions.
1. Crankshaft locking bolt
2. Output shaft (front side)
1 2

– Block drive pulley with clutch holding tool (P/N 529
006 400).
R400motr164A
1. Mark on drive pulley sliding half

2. Mark on governor cup
03-12-4 VMR2004_135_03_12A.FM
Section 03 ENGINE
Subsection 12 (CVT)
Remove drive pulley screw no. 5, spring washer Disassembly of Drive Pulley
no. 6 and thrust washer no. 7.
Governor Cup
Carefully lift governor cup no. 10 until slider shoes
no. 11 come at their highest position into guides.
Sliding Half
Unscrew lock nut no. 12 and remove centrifugal
lever pivot bolt no. 13.
NOTE: Outlander 400 shows 4 lever pivot bolt and
Outlander 330 only 3 levers.
Remove centrifugal lever no. 14.
R400motr162A 4 3 2 1
1. Drive pulley screw
2. Spring washer
3. Thrust washer
4. Drive pulley sliding half
R400motr165A 1 3 2
 WARNING 1. Lock nut
2. Centrifugal lever pivot bolt
Sliding half of drive pulley is spring loaded. 3. Centrifugal lever
Push the sliding half no. 8 of the drive pulley by hand Fixed Half
then remove the screw completely.
Slowly release sliding half.
 WARNING
Always wear safety glasses to remove spring
Screw clutch puller (P/N 529 035 746) in fixed half sleeves.
no. 9 then withdraw fixed pulley.
R400motr163A 2 1
1. Clutch puller
2. Fixed half
VMR2004_135_03_12A.FM 03-12-5
Section 03 ENGINE
Subsection 12 (CVT)
Pull one-way clutch no. 15 slowly until the half of

spring sleeves no. 16 is visible.  WARNING
This procedure must be performed in a well-
ventilated area.
CAUTION: To avoid damage, make sure clean-

er does not contact the crankshaft seal.
Remove all hardened oil deposits that have baked
on crankshaft and pulley tapered surfaces with
coarse or medium steel wool and/or sand paper
no. 600.
CAUTION: Do not use any other type of abrasive.
Reclean mounting surfaces with paper towel and
4
cleaning solvent.
Wipe off the mounting surfaces with a clean, dry
paper towel.
CAUTION: Mounting surfaces must be free of any
oil, cleaner or towel residue.
R400motr166A 2 3 1
1. One-way clutch
2. Fixed half
3. Spring sleeve area
4. Direction of removal
Hold both spring sleeves with fingers and release

them when one-way clutch is out of engagement.
1 2
R400motr168A 1
1. Taper of fixed half
R400motr167A 2 1 Only use petrol base cleaner when cleaning bush-
1. Spring ings no. 17 and no. 18.
2. Spring sleeve
CAUTION: Do not use acetone to clean bushing.
Cleaning of Drive Pulley
Inspection of Drive Pulley
Clean pulley faces and shaft with fine steel wool and
dry cloth. Drive Pulley
Using a paper towel with cleaning solvent, clean Drive pulley should be inspected annually.
crankshaft tapered end and the taper inside of the Governor Cup
fixed half of the drive pulley, crankshaft threads
and threads of drive pulley screw no. 5. Check governor cup for cracks or other visible dam-
ages. Replace if necessary.
03-12-6 VMR2004_135_03_12A.FM
Section 03 ENGINE
Subsection 12 (CVT)
Roller
Check each roller no. 19 for roundness of external
diameter.
NOTE: Replace governor cup if the roller does not
move freely.
Measure the roller diameter. If a roller is out of spec-
ification, replace governor cup. 1
ROLLER DIAMETER
MAXIMUM (new) 13.90 mm (.547 in) R400motr170A
SERVICE LIMIT 13.20 mm (.519 in) 1. Contact surface to the roller
Centrifugal Lever Pivot Bolt  WARNING

Measure diameter of centrifugal lever pivot bolt Whenever replacing centrifugal levers, al-
no. 13, replace if it is out of specification. ways replace all levers at the same time. Oth-
erwise, the drive pulley will be unbalanced
A (because of lever differences).
Slider Shoe
Check slider shoes no. 11 for visible wear and re-
place if damaged.
R400motr169A 1 NOTE: If necessary, use a screwdriver to remove
1. Centrifugal lever pivot bolt slider shoes.
A. Measure diameter here
CENTRIFUGAL LEVER PIVOT BOLT DIAMETER

Centrifugal Lever
Check bushing diameter in the centrifugal lever
no. 14 for wear. If a centrifugal lever must be re-
placed, replace all levers at the same time.
CENTRIFUGAL LEVER BORE DIAMETER
R400motr171A 1
Replace centrifugal lever no. 14 with screws no. 13 1. Slider shoe
and lock nuts no. 12 if the contact surfaces show Sliding Half
heavy visible wear.
Check sliding half for cracks and sliding contact
surface for excessive wear. Replace sliding half if
necessary.
VMR2004_135_03_12A.FM 03-12-7
Section 03 ENGINE
Subsection 12 (CVT)
Measure centrifugal lever pivot bolt bores. Replace

A
sliding half if bores are out of specification or dam-
aged.
R400motr172A
R400motr174A 1
A. Centrifugal lever pivot bolt bore diameter 1. Bushing on governor cup side
A. Bore diameter of bushing
CENTRIFUGAL LEVER PIVOT BOLT BORE SLIDING HALF LARGE BUSHING

DIAMETER
Replace sliding half if bushings no. 17 and/or no. 18
Measure bushing diameters of sliding half.
is(are) out of specification. Visually inspect coatings.
Use a dial bore gauge to measure bushing diame-
ter. Measuring point must be at least 5 mm (1/4 in) Fixed Half
from bushing edge. Check fixed half contact surface to the governor
cup for scorings and other damages. If so, replace
fixed half.
R400motr173A 1
1. Bushing on fixed half side
A. Bore diameter of bushing
SLIDING HALF SMALL BUSHING

MINIMUM (new) 55.000 mm (2.165 in)
MAXIMUM (new) 55.020 mm (2.166 in) R400motr175A 1
SERVICE LIMIT 55.200 mm (2.173 in) 1. Visually check here
03-12-8 VMR2004_135_03_12A.FM
Section 03 ENGINE
Subsection 12 (CVT)
Check for any marks on fixed half plate. Replace if Measure length of spring sleeve no. 16 and check
necessary. if edges on top of the spring sleeve are excessive-
Check ring gear teeth for excessive wear or other ly worn. If out of specifications, replace both
damage. Replace fixed half if necessary. spring sleeves and springs at the same time.
 WARNING SPRING SLEEVE LENGTH
Fixed half and ring gear are balanced together. SERVICE LIMIT 9 mm (.276 in)
Always replace both parts together otherwise
severe injury and/or damages may occur. Assembly of Drive Pulley
For assembly, reverse the disassembly procedure.
Spring Pay attention to following details.
Measure spring free length and squareness. If spring NOTE: Lubricate spring sleeve no. 16 prior to re-
is out of specification, replace by a new. install the one-way clutch.
SPRING FREE LENGTH CAUTION: Centrifugal lever no. 14 and rollers
no. 19 must move easily after installation.
Insert slider shoes into governor cup to properly
slide in guides.
CLUTCH SPRING SQUARENESS
SERVICE LIMIT 4 mm (.157 in) Installation of Drive Pulley
One-Way Clutch Pay attention to the following details.
Check bearings no. 20 for excessive play and
smooth operation. Replace one-way clutch if nec-
 WARNING
essary. Do not apply anti-seize or any lubricant on
crankshaft and drive pulley tapers.
CAUTION: Be careful not to damage the inside
of one-way clutch no. 15 during bearing removal.
 WARNING
Never use any type of impact wrench at drive
pulley removal and installation.
Clean mounting surfaces as described in CLEAN-

ING above.
Install drive pulley on crankshaft extension.
Install spring washer no. 6 with its concave side
towards drive pulley then install drive pulley screw
no. 5.
3
 WARNING
1 Never substitute spring washer and/or screw
R400motr176A 2 with jobber ones. Always use Bombardier gen-
1. One-way clutch uine parts for this particular case.
2. Bearings
3. Drive pulley sliding half side
Install clutch holding tool (P/N 529 006 400) and
BUSHING BORE DIAMETER torque screw to 100 N•m (74 lbf•ft).
MAXIMUM (new) 39.990 mm (1.574 in)  WARNING

MAXIMUM (new) 40.085 mm (1.578 in) Drive pulley screw has a left-hand thread.
VMR2004_135_03_12A.FM 03-12-9
Section 03 ENGINE
Subsection 12 (CVT)
2 1 1 2
R400motr177A

2. Drive pulley removal/installation area R400motr178A

DRIVEN PULLEY 2. Driven pulley fixed half
Removal of Driven Pulley Second possible procedure:

Remove: – Block driven pulley with clutch holding tool
(P/N 529 006 400) then remove the driven pul-
– belt no. 4 (see BELT REPLACEMENT above) ley bolt no. 21 and the washer no. 22.
– driven pulley.
1
3 2 1
R400motr180A
2
1. Fixed half of driven pulley
2. Sliding half of driven pulley R400motr179A
3. Spring
NOTE: Two procedures can be carried out to re- 2. Driven pulley fixed half
move driven pulley.
– Block driven pulley fixed half with clutch holding
tool (P/N 529 035 771) then remove the driven
pulley bolt no. 21 and the washer no. 22.
03-12-10 VMR2004_135_03_12A.FM
Section 03 ENGINE
Subsection 12 (CVT)
Disassembly of Driven Pulley CAUTION: To avoid damage, make sure clean-

er does not contact the countershaft seal.
Fixed Half
Remove retaining ring no. 23 and lift torque gear 1
no. 24.
NOTE: The following procedure is not necessary
except if ball bearing or shaft must be removed.
Refer to INSPECTION before proceeding.
Heat ball bearing area up to 100°C (212°F) before
removing ball bearing.
Use a soft hammer to push shaft no. 25 with bear-
ing no. 26 out of fixed half.
1 2
R400motr182A 2
1. Main shaft support
2. Sealing lip of countershaft oil seal
Inspection
Sliding Half
Check bushings no. 27 for cracks, scratch and for
free movement when assembled to sliding half.
Using a dial bore gauge, measure bushing diame-
ter. Measuring point must be at least 5 mm (1/4 in)
from bushing edge.
This bushing is not replaceable. Replace sliding
R400motr181A half if bushings no. 27 are out of specification. Vi-
1. Soft hammer sually inspect coatings.
2. Shaft
1
Remove shaft from ball bearing.
Cleaning of Driven Pulley

To remove a dust deposit from cam or shaft, use
a dry cloth.
Clean pulley faces and shaft with fine steel wool
and dry cloth.
Use pulley flange cleaner (P/N 413 711 809) to
clean driven pulley.
Clean the CVT crankcase area from contamination.
Using a paper towel with cleaning solvent to clean
main shaft end and the inside of the shaft no. 25.
 WARNING R400motr183A
1. Bushings
This procedure must be performed in a well-
ventilated area.
VMR2004_135_03_12A.FM 03-12-11
Section 03 ENGINE
Subsection 12 (CVT)
BUSHING BORE DIAMETER Cam

Check cam no. 29 for visible damage and wear limit
with a caliper.
2
Fixed Half
Check ball bearing for free play and smooth oper-
ation. Replace if necessary.
Check shaft for heavy wear or visible damage. Re-
place if necessary.
If the shaft is removed, measure bushing diameter 1
A
with a dial bore gauge. Measuring point must be
at least 5 mm (1/4 in) from bushing edge.
This bushing is not replaceable. Replace fixed half
if bushing no. 28 is out of specification. Visually
inspect coatings. R400motr185A
BUSHING BORE DIAMETER 1. Contact surfaces for power train

2. Caliper
MAXIMUM (new) 30.000 mm (1.181 in) A. Width to be measured due to wear on contact surface
MAXIMUM (new) 30.020 mm (1.182 in) WIDTH ON TOP SURFACE

SERVICE LIMIT 30.200 mm (1.189 in) SERVICE LIMIT 6.000 mm (.236 in)
Check torque gear no. 24 for visible damage and

1 3 2
wear limit with a caliper.
A
B
R400motr186A
R400motr184A
1. Caliper
2. Sliding half
A. Measurement inside 3. Contact surface
B. Measurement outside A. Wear to be measured
WEAR ON TEETH BOTH SIDES WEAR ON CONTACT SURFACE

SERVICE LIMIT 7.500 mm (.295 in) SERVICE LIMIT 2.000 mm (.079 in)
03-12-12 VMR2004_135_03_12A.FM
Section 03 ENGINE
Subsection 12 (CVT)
Spring
3
Measure spring free length and squareness. If spring
is out of specification, replace by a new.
SPRING FREE LENGTH
1
2
CLUTCH SPRING SQUARENESS
Assembly of Driven Pulley

Pay attention to following details. R400motr188A
Heat ball bearing area up to 100°C (212°F) before 1. Shaft

ball bearing installation. 2. Fixed half
3. Press machine
NOTE: Place new ball bearing in a freezer for 10 min-
utes before installation. Install torque gear no. 24 then secure it with re-
taining ring no. 23.
Install ball bearing no. 26 with the writing on top
and push only on the outer ring.
R400motr187 1 R400motr189A 2 1
1. Ball bearing 1. Retaining ring
2. Torque gear
CAUTION: Do not use a hammer, use a press
machine only.
VMR2004_135_03_12A.FM 03-12-13
Section 03 ENGINE
Subsection 12 (CVT)
Installation of Driven Pulley Place spring no. 33 behind sliding half then align
driven pulley with cam.
1 2
Install sliding half no. 30 into fixed half no. 31.
Place O-ring no. 34 on main shaft splines and 3
move it with spacer no. 35 in end position.
CAUTION: Chamfer on inside diameter of the
spacer must face engine side.
3 1 2
R400motr192A
1. Cam
2. Spring
R400motr190A 3. Driven pulley
4. Location for pushing during screw installation
1. O-ring
2. Distance sleeve
3. Chamfered area of distance sleeve
Push the driven pulley by hand. Install the driven
pulley screw no. 21 and washer no. 22.
Install cam retainer no. 32 on main shaft end the
right way then install cam no. 29.  WARNING
NOTE: Place cam retainer no. 32 with printed Driven pulley is a spring loaded system.
mark ENGINE SIDE towards the engine.
CAUTION: Always place washer no. 22 at the
time of driven pulley installation.
R400motr193A 1 2
R400motr191A 2 1 3 1. Washer
1. Sharp edge of cam retainer to engine side 2. Driven pulley screw
2. Main shaft spline
3. Inscription NOTE: Driven pulley end-play is 0 (zero).
Torque driven pulley screw.
03-12-14 VMR2004_135_03_12A.FM
Section 04 FUEL SYSTEM
TABLE OF CONTENTS 0
FUEL CIRCUIT ........................................................................................................................ 04-02-1
GENERAL ........................................................................................................................... 04-02-2
FUEL LINES........................................................................................................................ 04-02-2
FUEL SYSTEM PRESSURIZATION ................................................................................... 04-02-2
FUEL GAUGE ..................................................................................................................... 04-02-3
FUEL TANK DRAINING ..................................................................................................... 04-02-3
FUEL TANK PROTECTORS ............................................................................................... 04-02-4
FUEL TANK ........................................................................................................................ 04-02-5
FUEL TANK STRAINER ..................................................................................................... 04-02-6
FUEL VALVE ...................................................................................................................... 04-02-7
FUEL PUMP ....................................................................................................................... 04-02-8
CARBURETOR ....................................................................................................................... 04-03-1

GENERAL ........................................................................................................................... 04-03-2
CARBURETOR ................................................................................................................... 04-03-2
THROTTLE CABLE ............................................................................................................. 04-03-5
CHOKE CABLE ................................................................................................................... 04-03-8
AIR INTAKE SILENCER.......................................................................................................... 04-04-1

GENERAL ........................................................................................................................... 04-04-2
AIR FILTER ......................................................................................................................... 04-04-2
AIR FILTER BOX CLEANING/ DRAINING ......................................................................... 04-04-3
AIR FILTER BOX ................................................................................................................ 04-04-3
VMR2004_154_04_01ATOC.FM 04-01-1
Subsection 02 (FUEL CIRCUIT)
FUEL CIRCUIT 0
5
10 Nm
(89 lbfin) 6 9
10
11
15
10 Nm
(89 lbfin)
14
14 12
10 Nm
(89 lbfin)
7 17 16 2 Nm
(18 lbfin)
10 Nm
(89 lbfin)
13
2
3 Intake adaptor
13 Carburetor
4
5.5 Nm
V07F0YS (49 lbfin)
VMR2004_136_04_02A.FM 04-02-1
GENERAL When replacing fuel lines, be sure to use hoses as

available from Bombardier parts department. This
 WARNING will ensure continued proper and safe operation.
Always disconnect battery exactly in the
specified order, BLACK (-) cable first. It is rec-
 WARNING
ommended to disconnect electrical connec- Use of improper fuel lines could compromise
tions prior to disconnecting fuel lines. fuel system integrity.
 WARNING FUEL SYSTEM PRESSURIZATION

When draining a fuel tank or whenever a fuel Fill up fuel tank no. 1.
line is disconnected, obstruct line with a hose
pincher (P/N 295 000 076) or equivalent de-
vice. Fuel is flammable and explosive under Unplug the impulse line no. 2 from fuel pump
certain conditions. Ensure work area is well no. 3.
ventilated. Do not smoke or allow open flames Install hose pinchers (P/N 295 000 076) on fuel
or sparks in the vicinity. pump outlet hose no. 4 at carburetor, as shown in
the following photo.
ues and service products as in the exploded views. 1
fer to SELF-LOCKING FASTENERS and LOCTITE AP-
plete procedure.
 WARNING
FUEL LINES V07F0GA 2

1. Install hose pincher on this hose
 WARNING 2. Impulse line location
Whenever working on fuel system, always Install on fuel tank, the special cap of leak testing
verify for water or dust infiltration in reser- kit (P/N 529 033 100).
voir. Replace any damaged, leaking or deteri-
orated fuel lines.
04-02-2 VMR2004_136_04_02A.FM
Using air pump from engine leak test kit (P/N 861
1
749 100) inject air into fuel tank. See next photo.
1
V07F0IA 3 2
1. Fuel gauge
2. Rear fender
3. Fuel gauge gasket
V07F0HA
1. Special cap on tank

Inspection
2. Air pump Check if fuel gauge gasket is brittle, hard or
Pressurize fuel system to 21 kPa (3 PSI). That pres- cracked. Replace if necessary.
sure must not drop during 3 minutes. Check if the float moves freely between its sup-
If pressure drops, locate fuel leak(s) and repair/ ports.
replace leaking component(s).
Installation
To ease locating leak(s) at fuel tank vent fitting,
fuel gauge or fuel cap spray soapy water on com- The installation is the reverse of the removal pro-
ponents; bubbles will indicate leak location(s). cedure.
FUEL GAUGE FUEL TANK DRAINING

NOTE: The fuel gauge no. 5 shows an approxi-
mate amount of the fuel in tank.
 WARNING
Never perform this operation when the en-
Removal gine and/or the exhaust system is/are hot.
Pull out fuel gauge no. 5 from fuel tank. At the Turn fuel valve no. 7 OFF.
same time, remove the fuel gauge gasket no. 6.
Remove:
– seat, RH side panel and console (refer to BODY)
– air box (refer to AIR INTAKE SILENCER).
VMR2004_136_04_02A.FM 04-02-3
Install hose pincher (P/N 295 000 076) on reserve FUEL TANK PROTECTORS
fuel hose no. 8.
Removal
LH Fuel Tank Protector
Remove screw under LH fuel tank protector.
1 2
V07F0JA 1
1. Reserve fuel hose
V07F0LA 3
Disconnect the reserve fuel hose from fuel valve.
1. Fuel tank
Bring the reserve fuel hose on the right side of 2. Fuel tank protector
engine and put it between footrest and frame. 3. Remove this screw
Remove screw retaining both protectors then lift

up the LH protector to unlatch the upper tab.
V07F0KA
Place an approved fuel container under engine

then bring the reserve fuel hose into the container. V07F0MA 3 1 2
Remove the hose pincher to drain the fuel tank. 1. LH protector
2. RH protector
NOTE: To accelerate fuel tank draining and ensure 3. Tab
complete draining, remove cap no. 9.
Pull the protector out through the left hand side of
vehicle.
04-02-4 VMR2004_136_04_02A.FM
RH Fuel Tank Protector Removal

Remove screw under RH fuel tank protector. Drain fuel tank no. 1 (see the procedure above).
Remove:
– rear fender (refer to BODY)
– CVT outlet deflector (refer to CVT)
– LH fuel tank protector
– screws nos. 10, 11 and 12
– LH side panel.
Pinch and unplug the main fuel hose no. 13 from
fuel valve no. 7.
V07F0NA 2 1
1. Rear propeller shaft
2. Remove this screw
Remove screw retaining both protectors to the

frame.
Callout
V07F16A 1
1. Fuel hose
Pull out the fuel tank through the LH side of vehicle.
 WARNING
During fuel tank removal, do not pull main and
reserve grommets and/or fittings out of fuel
tank because a small amount of gas is still con-
tained in the fuel tank.
V07F0OA 1 2
Inspection
1. LH protector
2. RH protector Visual
Pull the protector out through the right hand side Inspect fuel tank for any damage or cracks which
of vehicle. may result in fuel leaks. If so, replace tank with
new one.
Installation
To install protectors, reverse the removal proce- Pressure Test
dure. Refer to FUEL SYSTEM PRESSURIZATION for
complete detailed procedure.
FUEL TANK
Installation
NOTE: To ease reinstallation, mark all hoses be-
fore removing them. Insert the fuel tank into the frame.
VMR2004_136_04_02A.FM 04-02-5
Install screw no. 11 (behind the engine) with a spac- Removal

er, a washer and an elastic nut. Do not torque yet.
Drain and remove fuel tank, see above for the
Install the LH bottom screw no. 12 with a spacer, a proper procedures.
washer and an elastic lock nut. Do not torque yet.
Manually pull grommet no. 14 out of fuel tank.
NOTE: In the case that grommet is too tight, use
a flat screwdriver and carefully pull out grommet,
as shown in the next photo.
V07F0PA
On right side of vehicle, install the last screw V01N02A

no. 10 with a washer, a spacer and an elastic nut.
TYPICAL — USE SCREWDRIVER ONLY IF GROMMET IS TOO
TIGHT
Inspection
Ensure that fuel tank strainer no. 15 and fuel line
are clean and not damaged, as per following photo.
1 2
V07F0QA
Torque all fuel tank screws.

Install all removed parts in accordance with the
proper instructions described in each sections.
Refuel tank and ensure there are no leaks by per-
forming fuel system pressurization as described in
the FUEL SYSTEM PRESSURIZATION section.
A31I03A
FUEL TANK STRAINER TYPICAL

1. Fuel tank strainer
2. Fuel line
NOTE: The fuel tank has two fuel hose strainers.
Use the following procedure for both fuel lines.
04-02-6 VMR2004_136_04_02A.FM
Installation Unscrew valve nut no. 16.

NOTE: To ease grommet insertion, apply BOM-
BARDIER LUBE (P/N 293 600 016).
Position grommet on fuel line, as shown in the
next photo then insert grommet in tank hole.
V07F0SA
UNSCREW VALVE NUT

V01N03A 2 1 Unplug all hoses from fuel valve.
TYPICAL Remove fuel valve.
1. Grommet properly positioned for tank insertion
2. Fitting recess
Installation
Once grommet is inserted in tank hole, push fitting
Reinstall fuel valve by positioning rubber washer
until its recess properly sits in grommet.
no. 17 inside and nut outside vehicle. See next
Refuel tank and ensure there are no leaks. photo.
FUEL VALVE
Removal
NOTE: To ease reinstallation, mark all hoses be-
fore removing fuel valve no. 7.
Remove the LH side panel, refer to BODY.
Remove plastic cap from fuel valve.
V07F0TA 2 1
1. Rubber washer
2. Fuel valve nut
V07F0RA 1
1. Plastic cap
VMR2004_136_04_02A.FM 04-02-7
Plug all hoses at the proper position; check on fuel Install a hose pincher (P/N 295 000 076) on main
valve for location. fuel line no. 13.
1
V07F0UA
V07F0WA 2
FUEL PUMP 1. Main fuel line from fuel valve
2. Hose pincher
Removal
Unscrew fuel pump.
Remove CVT inlet hose.
Unplug all hoses from fuel pump then remove it
Callout from vehicle.
Inspection
Check fuel pump operation as follows:
– Connect a clean plastic tubing to the fuel inlet
nipple. Using pump from leak test kit (P/N 529
021 800), apply pressure and vacuum. The inlet
valve should release with pressure and hold un-
der vacuum.
– Repeat the same procedure at the fuel outlet
nipple. This time the outlet valve should hold
with pressure and release under vacuum.
V07F0VA 2 1
1. Upper engine support
2. CVT inlet hose
04-02-8 VMR2004_136_04_02A.FM
– Connect a clean plastic tubing to the impulse

nipple. Repeat the previous procedure at the
impulse nipple. This time the outlet valve
should hold pressure and vacuum.
1
V07F0XA 3 2
1. Fuel inlet nipple
2. Fuel outlet nipple
3. Impulse line location
Installation
The installation is the reverse of removal proce-
dure.
VMR2004_136_04_02A.FM 04-02-9
Subsection 03 (CARBURETOR)
CARBURETOR 0
Harness assembly
V07F0ZS
VMR2004_137_04_03A.FM 04-03-1
GENERAL Unscrew choke cable then remove the choke

plunger from the throttle body.
Before performing any job on the fuel system, al-
NOTE: Take care not to drop the choke plunger. If
ways turn fuel valve to OFF position and discon-
so, check plunger for damages and replace if nec-
nect BLACK (-) cable from battery.
essary.
 WARNING On the RH side of vehicle, remove the throttle ca-
ble from carburetor. See THROTTLE CABLE fur-
Always disconnect battery exactly in the
ther in this section.
specified order, BLACK (-) cable first. It is rec-
ommended to disconnect electrical connec- Unscrew clamp retaining carburetor to the intake
tions prior to disconnecting fuel lines. adaptor.
Pull out carburetor.
CARBURETOR Cleaning and Inspection
CAUTION: Although some jets can be replaced The entire carburetor should be cleaned with a
by other jets from other carburetors, such mod- general solvent and dried with compressed air be-
ifications should not be performed. They can fore disassembly.
greatly affect engine calibration and can cause
severe damage to engine. Use only recom- CAUTION: Heavy duty carburetor cleaner may
mended jetting specific for this carburetor. be harmful to the float material and to the rub-
ber parts, O-rings, etc. Therefore, it is recom-
Removal mended to remove those parts prior to cleaning.
Carburetor body and jets should be cleaned in a
Remove air filter box (refer to AIR INTAKE SILENCER).
carburetor cleaner following manufacturer’s in-
Install hose pincher (P/N 295 000 076) on fuel structions.
pump outlet hose at carburetor.
 WARNING
Solvent with a low flash point such as gaso-
line, naphtha, benzol, etc., should not be used
as they are flammable and explosive.
Carburetor Float Level Adjustment

Correct fuel level in float chamber is vital toward
maximum engine efficiency. To check for correct
float level proceed as follows:
– Remove float bowl and gasket from carburetor.
– Make sure that float arm is symmetric, not dis-
torted.
With carburetor chamber upside down:
V07F05A – Measure height between bowl seat and the top
edge of float arm. Use float level gauge
Drain carburetor by unscrewing the drain screw (P/N 529 035 520).
underneath.
– Keep float level gauge perfectly vertical and in
Unplug all hoses from carburetor. line with main jet hole.
NOTE: To ease reinstallation, mark all hoses be- Ensure that both float level gauge tips are properly
fore unplugging. positioned on carburetor body and that “L” arm is
leaning on float while compressing valve spring.
04-03-2 VMR2004_137_04_03A.FM
Refer to following photos for proper float level Installation

gauge positioning and to TECHNICAL DATA for
To install carburetor on engine, inverse removal
proper level.
procedure. Pay attention to the following details:
– Inspect throttle and choke cable housing prior
to installation.
– Reinstall throttle and choke cables, at the same
time adjust the throttle cable, then install the
side cover. Refer to CARBURETOR ADJUST-
MENTS below in this section.
22
– Reinstall carburetor on vehicle.
When reinstalling carburetor on vehicle, pay atten-
A tion to the following:
CAUTION: The rubber flanges must be checked
for cracks and/or damage. At assembly, the rub-
1 ber flanges must be perfectly matched with the
air box, carburetor and engine or severe engine
damage will occur. Do not use screwdriver or
other tool to install the rubber flanges.
V01F0TA Make sure rubber flange recess is aligned with in-
take adaptor notch.
1. Gauge tips
2. “L” arm
A. Height
90°
V07F06A
TYPICAL
V01F0EA
Install clamps so that their tightening bolts are
staggered — not aligned.
GAUGE ALIGNED WITH MAIN JET
To adjust height, bend the contact tab of float arm

until the specified height is reached.
CAUTION: When adjusting lever, do not pry it.
This will apply pressure on needle and damage
valve seat/needle.
VMR2004_137_04_03A.FM 04-03-3
Align carburetor notch with the flange recess. Idle Speed Preliminary Adjustment
Adjust throttle screw to 1-1/2 turn or so that throt-
tle valve closes bypass hole by half, as shown in
the next photo.
V07F07A
TYPICAL
Carburetor notch aligned with the flange recess
Install air filter box. V04F0LA 1

1. Bypass hole closes to halfway
Carburetor Adjustments
Idle Speed Adjustment
1 2 Start engine and allow it to warm then adjust idle
speed to specifications by turning idle speed
screw clockwise to increase engine speed or
counterclockwise to decrease it.
NOTE: Use the digital induction tachometer
(P/N 529 014 500). Turn tachometer wire around
spark plug wire, about 4 or 5 turns, for the best
measure.
CAUTION: Do not attempt to set the idle speed
by using the pilot screw.
Refer to TECHNICAL DATA for idle speed specifi-
cations.
Pilot Screw Adjustment
NOTE: The pilot screw is factory pre-set. Warm
the engine to operating temperature.
Turn the pilot screw clockwise until you hear the
engine missing or decreasing idle speed, then turn
V07F08A 3 counterclockwise until the engine again misses or
BOTTOM VIEW decreases idle speed.
1. Idle speed screw Center the pilot screw exactly between these two
2. Pilot screw
3. Drain plug and screw extreme positions then unscrew the pilot screw
of 3/8 turn.
If idle speed changes after adjustment of the pilot
screw, readjust the idle speed screw.
04-03-4 VMR2004_137_04_03A.FM
Diaphragm Installation
Callout
Carefully replace diaphragm in its original position.
Make sure spring is located properly in carburetor
cover before screwing.
V07F0AA 1 2
1. Release tension on throttle lever
V07F09A
2. Cable end bushing
Separate cable end bushing from throttle cable

THROTTLE CABLE end, as shown in the next photo. Keep bushing.
Removal
Carburetor Side
 WARNING
Ensure the key is turned OFF, prior to perform-
ing the throttle cable adjustment.
NOTE: To ease reinstallation, take note the cable

routing.
Remove carburetor side cover.
Using thumb, release tension on throttle lever.
With long nose pliers, rotate cable end bushing so
that cable aligns with throttle lever recess, then lift V04F0UA
cable end. See next photo. REMOVE CABLE END BUSHING
VMR2004_137_04_03A.FM 04-03-5
Loosen throttle cable nut, as shown in the next photo.
V07I0GA 1 2 3 4
1. Cable protector
2. Throttle cable adjuster
3. Lock nut
V07F0BA 1 4. Throttle lever housing
1. Loosen this nut
Screw in the throttle cable adjuster.
Pull cable out from carburetor. Remove:
Throttle Lever Side – inner housing protector
Remove screws under throttle lever then open it.
1
V07I0HA 1
1. Inner housing protector
V07I0FA
– throttle cable from housing.

1. Remove these screws
Slide cable in clip slot and remove the end of cable
Separate housing. Slide rubber protector back to from clip.
expose throttle cable adjuster.
04-03-6 VMR2004_137_04_03A.FM
Insert the needle of lubricant can in the end of throt-

tle cable adjuster.
 WARNING
Always wear eye protection and gloves when
lubricating cables.
NOTE: Place a rag around cable adjuster to prevent

lubricant splash.
V07I0IA
Lubrication
The throttle cable must be lubricated with Bombardier
cable lubricant (P/N 293 600 041) only.
 WARNING V07I0JA
Using another lubricant could cause sticking

or stiffness of throttle lever/cable. Put lubricant until it passes through the cable.
Clean lubricant surplus in carburetor housing.
To lubricate the throttle cable, remove cable from
Spray lubricant inside throttle housing.
throttle lever side.
Reinstall carburetor cover and cable in throttle hous-
Slide rubber protector to expose throttle cable ad-
ing.
juster.
Adjust cable; see below.
Remove carburetor side cover.
Installation
Adjustment
 WARNING
Ensure the key is turned OFF, prior to perform
the throttle cable adjustment.
Slide rubber protector back to expose throttle ca-

ble adjuster.
Loosen lock nut then turn the adjuster to obtain
correct throttle lever free play.
NOTE: Measure throttle free play at the tip of throt-
V07F04A
tle lever.
Tighten lock nut and reinstall protector.
VMR2004_137_04_03A.FM 04-03-7
With the transmission lever on PARK position, start

engine. Check if the throttle cable is adjusted cor-
rectly by turning handlebar fully right then fully left.
If the engine RPM increase, readjust the throttle
lever free play.
CHOKE CABLE
Removal
NOTE: To ease reinstallation, take note of cable
routing.
Carburetor Side
Remove the LH side panel and the air filter box.
Unscrew choke plastic nut from carburetor.
V07F0DA
Pull choke cable to remove choke plunger from car-
buretor. Remove the retaining spring to remove the choke
Remove the choke plunger and its spring. cable from housing.
V07F0CA 2 1
V07F0EA
1. Choke plunger
2. Choke plunger spring 1. Retaining spring
2. Choke cable
Handlebar Side 3. Choke cable housing
Push the choke lever on FULL position.

Installation
Underneath multi-function switch, align the choke
cable end with the lever slot then remove the cable. The installation is the reverse of removal procedure.
04-03-8 VMR2004_137_04_03A.FM
Subsection 04 (AIR INTAKE SILENCER)
AIR INTAKE SILENCER 0

5.5 Nm
(49 lbfin)
Carburetor
10
11
2.5 Nm
7 (22 lbfin)
5.5 Nm
9 (49 lbfin)
Loctite 5900
Silicone
sealant
2.5 Nm
(22 lbfin)
2
3
5
4
2.5 Nm
V07C1SS (22 lbfin)
VMR2004_138_04_04A.FM 04-04-1
GENERAL Loosen clamp no. 2 and remove air filter no. 3.

plete procedure.
 WARNING
is impaired, it must be renewed. V07C0HA 1 2
TYPICAL
1. Clamp
AIR FILTER 2. Air filter
Removal Installation
CAUTION: Never remove or modify any compo- Properly reinstall removed parts in the reverse or-
nent in the air box. The engine carburation is cal- der of their removal.
ibrated to operate specifically with these com- NOTE: Apply air filter oil on air filter.
ponents. Otherwise, engine performance deg-
radation or damage can occur.
Remove seat and LH side panel.
Release clamps and remove air filter box cover no. 1.
1
V07C0GA
1. Release clamps
04-04-2 VMR2004_138_04_04A.FM
AIR FILTER BOX CLEANING/ NOTE: After air filter installation, you can find a
small quantity of air filter oil in the drain tube.
DRAINING
Remove air filter.
Periodically inspect air filter box drain tube no. 4
for liquid or deposits. NOTE: When liquid/deposits are found, the air filter
must be inspected/dried/replaced depending on its
condition.
3
Pour air filter cleaning solution (P/N 293 600 059
or an equivalent) into a bucket. Put the filter in to
soak.
While filter soaks, clean inside of air box.
Rince filter with warm water and let it dry com-
pletely.
When the filter is dried, re-oil with air filter oil (P/N
293 600 058 or an equivalent).
AIR FILTER BOX

2
1 4 Removal
Remove seat and console (refer to BODY).
On right side of vehicle, perform the following:
Unplug the carburetor vent hose.
Unscrew:
– carburetor clamp no. 6 on air filter box no. 7
– air filter box screws nos. 8 and 9.
2
V07C0FA
1. Air filter box

2. Drain tube
3. Clamp
4. CVT cover
NOTE: If vehicle is used in dusty area, inspect

more frequently than specified in MAINTENANCE
CHART.
If liquid/deposits are found, squeeze and remove the
clamp no. 5. Pull drain tube no. 4 out and empty it.
CAUTION: Do not start engine if liquid or de-
posit are found in the drain tube. If there is oil
in the air box, check engine oil level. Maybe oil
level is too high. V07C0XA 3 1
1. Carburetor vent hose
2. Carburetor clamp
3. Air filter box screws
VMR2004_138_04_04A.FM 04-04-3
Unplug engine blow-by hose no. 11 from air box.
V07C0YA 1 2
1. Engine blow-by hose
2. Air box
On LH side of vehicle, do the following:

Remove the LH side panel.
Unscrew air filter box screw no. 10.
V07C0ZA
Pull out air filter box.
Installation
CAUTION: Pay attention to fuel hoses and fit-
tings on fuel tank.
04-04-4 VMR2004_138_04_04A.FM
Section 05 ELECTRICAL
TABLE OF CONTENTS 0
OVERVIEW............................................................................................................................. 05-02-1
GENERAL OPERATION INFORMATION ........................................................................... 05-02-1
CHARGING SYSTEM......................................................................................................... 05-02-1
STARTING SYSTEM .......................................................................................................... 05-02-1
IGNITION SYSTEM............................................................................................................ 05-02-2
ACCESSORIES ................................................................................................................... 05-02-2
GENERAL TESTING/TROUBLESHOOTING INFORMATION .......................................... 05-02-2
FUSES LOCATION............................................................................................................. 05-02-3
SERVICING PACKARD CONNECTORS ............................................................................ 05-02-3
SERVICING DEUTSCH CONNECTORS ............................................................................ 05-02-4
IDENTIFICATION OF MAJOR CONNECTOR PINS .......................................................... 05-02-5
CHARGING SYSTEM............................................................................................................. 05-03-1

TESTING PROCEDURE ..................................................................................................... 05-03-1
STARTING SYSTEM.............................................................................................................. 05-04-1

BATTERY ............................................................................................................................ 05-04-1
TROUBLESHOOTING ........................................................................................................ 05-04-1
BATTERY TESTING ........................................................................................................... 05-04-1
REMOVAL........................................................................................................................... 05-04-1
CLEANING ......................................................................................................................... 05-04-2
INSPECTION ...................................................................................................................... 05-04-2
BATTERY STORAGE.......................................................................................................... 05-04-2
ACTIVATION OF A NEW BATTERY................................................................................... 05-04-2
INSTALLATION .................................................................................................................. 05-04-2
CABLE TERMINAL INSTALLATION .................................................................................... 05-04-2
STARTING SYSTEM TROUBLESHOOTING ..................................................................... 05-04-4
STARTING SYSTEM TESTS ............................................................................................. 05-04-5
GENERAL ........................................................................................................................... 05-04-5
ELECTRIC STARTER .......................................................................................................... 05-04-6
REMOVAL .......................................................................................................................... 05-04-6
INSTALLATION.................................................................................................................. 05-04-6
VMR2004_154_05_01ATOC.FM 05-01-1
IGNITION SYSTEM ................................................................................................................ 05-05-1

IGNITION SYSTEM TESTING PROCEDURE..................................................................... 05-05-1
GENERAL............................................................................................................................ 05-05-1
IGNITION SYSTEM TEST .................................................................................................. 05-05-3
IGNITION TIMING .............................................................................................................. 05-05-5
SPARK PLUG ...................................................................................................................... 05-05-5
DISASSEMBLY ................................................................................................................... 05-05-5
FOULING............................................................................................................................. 05-05-5
SPARK PLUG ANALYSIS ................................................................................................... 05-05-5
SPARK PLUG INSTALLATION ........................................................................................... 05-05-5
NGK SPARK PLUG SYMBOL EXPLANATION .................................................................. 05-05-6
INSTRUMENTS AND ACCESSORIES ................................................................................... 05-06-1

REMOVAL AND INSTALLATION......................................................................................... 05-06-1
12-VOLT AUXILIARY POWER OUTLET ............................................................................ 05-06-1
12-VOLT POWER OUTLET ................................................................................................. 05-06-1
HEADLAMP......................................................................................................................... 05-06-1
HEADLAMP BEAM AIMING .............................................................................................. 05-06-2
TAILLIGHT .......................................................................................................................... 05-06-3
IGNITION SWITCH ............................................................................................................. 05-06-3
ELECTRONIC MODULE...................................................................................................... 05-06-3
SPEEDOMETER .................................................................................................................. 05-06-4
WINCH ................................................................................................................................ 05-06-5
WINCH CONTROL SWITCH............................................................................................... 05-06-6
TESTS ................................................................................................................................. 05-06-6
12-VOLT AUXILIARY POWER OUTLET ............................................................................ 05-06-6
12-VOLT POWER OUTLET ................................................................................................. 05-06-6
HEADLAMP......................................................................................................................... 05-06-6
MULTI-FUNCTION SWITCH .............................................................................................. 05-06-7
SPEEDOMETER .................................................................................................................. 05-06-8
WINCH CONTROL SWITCH............................................................................................... 05-06-8
05-01-2 VMR2004_154_05_01ATOC.FM
Subsection 02 (OVERVIEW)
OVERVIEW 0
GENERAL OPERATION Voltage Regulator/Rectifier
INFORMATION A 3-phase full-wave shunt type voltage regulator/
rectifier receives the AC voltage and rectifies (con-
The electrical system consists of different sub- verts) it into DC. The voltage is also regulated to a
systems in which some are inter-related: maximum of 15.1 ± 0.5 volts (DC).
• charging system
• starting system Battery
• ignition system The battery supplies the entire vehicle. Therefore, DC
current only is used in the entire electrical system.
• accessories.
The following gives an outline of each components. STARTING SYSTEM
CHARGING SYSTEM When the ignition switch is turned on and start
button depressed, a signal is sent to the starting
It is the source of electrical energy to charge the bat- solenoid. The battery then supplies current to the
tery and keep it at a full state of charge. The magneto starter through the starting solenoid to turn the
is coupled to the engine and it transforms a magnetic engine.
field into electric current through a 3 phase, delta
“Y” wound stator on 18 poles. 6 4
The magneto supplies unregulated AC current (al-
ternative current) to the voltage regulator/rectifier.
3 4
V07G0BA 3 2
TYPICAL
1. Battery
2. Ignition switch
3. Start button
4. Electronic module
2 5. Starting solenoid
1 6. Electric starter
Engine can be started in any gear.

V07G0AA
Transmission must be in PARK or NEUTRAL or the
TYPICAL brake lever pulled in or brake pedal pressed, to al-
1. Magneto flywheel low engine starting.
2. Stator
3. Voltage regulator/rectifier However, an override mode allows to start the en-
4. Battery
gine with the transmission lever in any position
when holding any brake lever while pressing the
start button.
VMR2004_139_05_02A.FM 05-02-1
IGNITION SYSTEM Ignition Coil/Spark Plug

An CDI (Capacitor Discharge Ignition) system is The ignition coil receives its signal from the elec-
utilized. The ignition system is made up of the fol- tronic module. The ignition coil steps up the input
lowing components: voltage for the CDI system and the end result is
firing of the spark plug.
4 7
ACCESSORIES
6
The battery supplies the DC current to all accessories.
8
1
GENERAL TESTING/
TROUBLESHOOTING
INFORMATION
The following gives general electrical-related prob-
5 lems. For specific system-related problems, refer
V07G0CA 2 3 to proper system section.
TYPICAL It is possible that a component seems to operate
1. Battery in static condition but in fact, it is defective. In this
2. Ignition switch
3. Start button case, the best way to solve this problem is to re-
4. Electronic module move the original part and replace it with a known
5. Magneto flywheel
6. CPS (Crankshaft Position Sensor) good component.
7. Ignition coil
8. Spark plug IMPORTANT: When solving an electrical prob-
lem, the first thing to do is to check battery condi-
Battery/Ignition Switch tion as well as its cables and connections. Also
The ignition switch allows the battery to supply ensure the ignition switch is turned on. Check so-
current to the electronic module for the ignition lidity (close to battery) and related-circuit fuse con-
system. dition with an ohmmeter (visual inspection could
lead to false results). Also visually examine har-
Start Button ness and connections.
Besides enabling the starting system, the start but- CAUTION: It is recommended to always dis-
ton enables the ignition system. connect the battery when replacing any electric
or electronic parts.
Magneto Flywheel/CPS
The magneto flywheel features one projection
 WARNING
mark that is working with the CPS. The CPS sends Always disconnect BLACK (-) cable first and
the signals to the electronic module to be pro- reconnect last.
cessed for the ignition system.
To perform verifications, a good quality multimeter
such as Fluke 111 (P/N 529 035 868) should be used.
Pay particular attention to ensure that pins are not
out of their connectors or damaged. The trouble-
shooting procedures cover problems not resulting
from one of these causes.
05-02-2 VMR2004_139_05_02A.FM
CAUTION: Ensure all terminals are properly FUSES LOCATION

crimped on wires and connector housings are
properly fastened. replacing any electric or If a fuse is damaged, replace it with one of the
electronic part(s), always check electrical con- same rating.
nections. Make sure that they are tight and they CAUTION: Do not use a higher rated fuse as this
make good contact and are corrosion-free. The can cause severe damage.
voltage and current might be too weak to go
Fuses are located in the service compartment (be-
through dirty wire pins. Check the posts for
hind tool box).
signs of moisture, corrosion or if they look dull.
Clean pins properly and then coat them with sil- 1 3
icon-based dielectric grease or other appropri-
ate lubricant (except if otherwise specified)
when reassembling them. See connectors in-
formation below.
IMPORTANT: In a usual electric circuit, the bat-
tery supplies a switch which then supplies the
electric component. Therefore the switch opens
and closes the positive side of the circuit. Take this
into account when troubleshooting the electrical
system.
Pay attention to ground wires.
Checking for Shorts Between 2 Wires V07G02A 4 2

When checking continuity of a wire in a circuit, 1. Accessories (15 A)
wires should be checked for short circuit as fol- 2. Fan (20 A)
lows. 3. Main (20 A)
4. Charging system (30 A)
Make sure to isolate circuit by unplugging connec-
tors. SERVICING PACKARD
Let’s suppose that the circuit to be checked has a CONNECTORS
RED and a BLACK wire. Using an ohmmeter, mea-
sure the resistance between the RED and the To remove terminal from Packard connector hous-
BLACK wire. The resistance should be infinite ing, use Snap-on TT600-4 tool.
(0 L). Otherwise, there is a short circuit between
both wires. We must therefore identify and cor-
rect the fault.
F01B1JA
VMR2004_139_05_02A.FM 05-02-3
SERVICING DEUTSCH NOTE: Before extraction, push wire forward to re-

lieve pressure on retaining tab.
CONNECTORS
– Insert a 4.8 mm (.189 in) wide screwdriver blade
Waterproof Connector Housing inside the front of the contact cavity.
Female and Male Connector Housing – Pry back the retaining tab while gently pulling
wire back, until contact is removed.
To remove:
– Using long nose pliers, pull out the lock. 1
V01G0QA 1
FEMALE CONNECTOR HOUSING
1. Retaining tab
To install:
V01G0OA 1
– For insertion of signal contact, make sure the
FEMALE HOUSING
1. Female lock
lock is removed.
– Insert contact into appropriate circuit cavity and
push as far as it will go.
– Pull back on the contact wire to be sure the re-
tention fingers are holding the contact.
– After all required contacts have been inserted,
the lock must be installed.
CAUTION: Never apply dielectric grease on con-
tacts in plug connector. The use of dielectric
grease will make the seal swell and move out of
the connector. Do not lubricate.
V01G0PA 1
MALE HOUSING
1. Male lock
05-02-4 VMR2004_139_05_02A.FM
IDENTIFICATION OF MAJOR CONNECTOR PINS

DEUTSCH
85
A A B 2 87
1
87a
B B A 1 86 30 2
2
1
A A
A A
A
B B
C C B B
B
C
A
B
C C A 3
A 1
B 21
A C B 2
A C 3
B B
A B A C
C B
D A A B
C B D A B A
B C
A B
A B
D C A
B A B 4
C D 1
2
3
1
4 2
3
PACKARD
A A
B B
C
6
5
1 4 1
2 2
3 6 3
5
4
A
A
B B
A C
B A
C 12
D CB 11
D 1 10 1
FE 2
3 12
9
8
2
3
4 11 7 4
5 10 5
6 9 6
8
A 7
A
B CB
D
V01G0ES D
C FE
VMR2004_139_05_02A.FM 05-02-5
Subsection 03 (CHARGING SYSTEM)
CHARGING SYSTEM 0
TESTING PROCEDURE DYNAMIC TEST
NOTE: First, ensure that battery is in good condi- Current Test

tion prior to performing the following test using a Proceed as follows:
current inductive ammeter such as Snap-on MT – Start engine.
110.
– Lay an inductive ammeter on positive cable of
If the battery is regularly discharged, check main battery.
fuse (20 amp) condition.
– Bring engine to approximately 3500 RPM.
1 Depending on battery charge, current reading
should be approximately 5 amperes. If not, check
magneto output prior to concluding that voltage
regulator/rectifier is faulty.
Voltage Test
Proceed as follows:
– Start engine.
– Connect a multimeter to battery posts. Set mul-
timeter to Vdc scale.
– Bring engine to approximately 3500 RPM.
If multimeter reads over 15.1 ± 0.5 volts, voltage
V07G02B regulator/rectifier is defective. Replace it.
1. Main fuse NOTE: Whatever the voltmeter type used (peak
voltage or RMS), the voltage must not exceed
The voltage regulator/rectifier could be the culprit 15 V. A faulty voltage regulator/rectifier will allow
of a blown fuse. To check, simply disconnect the voltage to exceed 15 V as engine speed is in-
voltage regulator/rectifier from the circuit. creased.
If the fuse still burns, check for a defective wire.
NOTE: If the battery will not stay charged, the
CAUTION: Do not use a higher rated fuse as this problem can be any of the charging circuit compo-
can cause severe damage. nents. If these all check good, you would be accu-
rate in assuming the problem to be in the voltage
Voltage Regulator/Rectifier regulator/rectifier.
STATIC TEST: CONTINUITY If there is no charging at the battery with the pre-
1. Due to internal circuitry, there is no static test ceding voltage test, the following test can also be
available. performed.
NOTE: If the voltage regulator/rectifier is within
the specification, the wiring harness between the
voltage regulator/rectifier and battery is defective.
If the voltage regulator/rectifier is out of specifica-
tion and the stator tests good, the voltage regulator/
rectifier is defective.
VMR2004_140_05_03A.FM 05-03-1
Subsection 03 (CHARGING SYSTEM)
Stator STATIC TEST: INSULATION

STATIC TEST: CONTINUITY With the stator leads disconnected, insert either
meter test probe onto AC-1 and ground the other
1. Disconnect the magneto wiring harness connec- meter test probe to the engine or the stator iron
tor. With the recommended multimeter, place core and note the reading. There should be no con-
the 2 meter test probes onto the stator wire tinuity (infinity) between the stator insulated coils
leads AC-1 and AC-2 of the stator. The resis- and ground. If there is a reading, the stator coils
tance should be between 0.1 Ω and 1.0 Ω. and/or the wiring from the coils is grounded and
needs to be replaced/repaired respectively.
YL
YL
YL YL
YL
YL
V07G05A
TYPICAL V07G07A
2. Place either meter test probe into the remaining TYPICAL

stator lead (AC-3) and note the resistance (same DYNAMIC TEST
as step no. 1). If the readings are out of specifi-
cation, the stator will need to be replaced. 1. Unplug magneto wiring harness connector.
2. On magneto side, connect test probes of the
multimeter to two of the YELLOW wires.
3. Set multimeter to Vac scale.
4. Start engine. The obtained value should be be-
tween 10 and 12 Vac.
5. Repeat operation 3 times.
6. If the stator is out of specification, replace it.
YL
YL
YL
V07G06A
TYPICAL
05-03-2 VMR2004_140_05_03A.FM
Subsection 04 (STARTING SYSTEM)
STARTING SYSTEM 0
BATTERY Load Test
This is the best test of the batteries condition. Use
TROUBLESHOOTING a load testing device that has an adjustable load.
Apply a load of 3 times the ampere-hour rating of
SYMPTOM: DISCHARGED OR WEAK BATTERY the battery. At 14 seconds into the test, check bat-
CAUSE REMEDY tery voltage; if battery is in good condition, it will
have at least 10.5 Vdc.
1. Battery posts and/or Clean and coat with
cable terminal oxidized. dielectric grease.
REMOVAL
2. Loose or Check wiring and
bad connections. connector cleanliness,
Disconnect BLACK (-) cable first, then the RED (+)
damaged or short cable.
circuit.
 WARNING
3. Faulty battery Replace.
(does not keep a full Always respect this order for disassembly;
charge). disconnect BLACK (-) cable first. Electrolyte
or fuel vapors can be present in engine com-
4. Main system fuse burnt First check charging partment and a spark may ignite them and
or faulty voltage system. If it is in good possibly cause personal injuries.
regulator/rectifier.* condition replace fuse
or rectifier. Remove holding strap retaining battery to rack.
* To test charging system, refer to CHARGING 2 1
SYSTEM.
BATTERY TESTING
There are 2 types of battery tests: unloaded and
loaded. An unloaded test is made on a battery with-
out discharging current. It is the simplest and most
commonly used. However, be aware that the volt-
age test can be good, while the battery does not
have enough power to start the engine. A load test
gives a more accurate condition of the battery.
Unload Test
Check the charge condition using a multimeter.
With a multimeter, voltage readings appear instant- V07G03A
ly to show the state of charge. Always respect po-
TYPICAL
larity. A fully charged battery will have a reading of 1. Battery
12.6 Vdc minimum. 2. Holding strap
VMR2004_141_05_04A.FM 05-04-1
CLEANING INSTALLATION
Clean the battery casing, cables and battery posts Reinstall battery in vehicle. Install the holding strap.
using a solution of baking soda and water.
Remove corrosion (if so) from battery cable termi-  WARNING
nals and battery posts using a firm wire brush. Always connect RED (+) cable first then BLACK
Rinse with clear water and dry well. (-) cable.
INSPECTION CABLE TERMINAL INSTALLATION

Visually inspect battery casing for cracks or other
Carefully strip the wire approximately to 12 mm
damage. If casing is damaged, replace battery and
(1/2 in) in length, using a wire stripping tool or
thoroughly clean battery rack with water and bak-
sharp blade/knife.
ing soda.
Inspect battery rack mounting.
Inspect battery posts condition.
BATTERY STORAGE
If the battery is in storage or used infrequently,
disconnect the battery cables to eliminate drain
from electrical equipment. Charge the battery ev- A
ery two weeks.
A32E2QA
For extended storage, remove the battery from
vehicle and charge to 100%. Charge the battery A. 12 mm (1/2 in)
every month if stored at temperature below 16°C
NOTE: Make sure not to cut wire strands while
(60°F). If stored in a warm area, above 16°C (60°F),
stripping the wire.
charge every two weeks. Make sure battery is
stored out of reach of children. Install the appropriate terminal on the wire accord-
ing to the requirement. Refer to appropriate parts
Clean battery terminals and cable connections using
catalog.
a wire brush. Apply a light coat of dielectric grease
(P/N 293 550 004) on terminals.
Clean battery casing using a solution of baking
soda and water. Rinse battery with clear water and
dry well using a clean cloth.
ACTIVATION OF A NEW BATTERY

A32E2RA
 WARNING INSTALLATION OF TERMINAL

Never charge or boost battery while installed
Follow the instructions provided with the crimp plier
on vehicle.
(P/N 529 035 730) to select the proper position of
1. Connect a 2 A battery charger until the battery the tool.
is fully charged.
2. Disconnect battery charger.
3. Test battery state of charge. Use a multimeter.
NOTE: It is recommended to verify the battery
charge once a month. If necessary, fully charge bat-
tery.
05-04-2 VMR2004_141_05_04A.FM
NOTE: Different wires require different crimp plier

settings, so make sure to follow the instruction sup-
plied with the tool.
1 A32E2UA
PROPERLY CRIMPED WIRE
To verify, if the wire is properly crimped, hold the

wire with one hand and the terminal with the other
and pull with some force.
CAUTION: Never weld the wire to the terminal.
Welding can change the property of the wire
and it can become brittle and break.
2 Install the protective heat shrink rubber tube (P/N
A32E2SA
278 001 692) on the terminal. Heat the heat shrink
rubber tube using the heat gun so that it grasps
POSITIONING THE CRIMP PLIER
the wire and the terminal.
Step 1 : Press
Step 2 : Rotate CAUTION: Make sure that the protective heat
shrink rubber tube has been properly installed
After positioning the crimp plier, crimp the termi- and no part of wire is exposed.
nal already installed on wire.
A32E2TA
CRIMPING OF WIRE
VMR2004_141_05_04A.FM 05-04-3
STARTING SYSTEM TROUBLESHOOTING

SYMPTOM CAUSE REMEDY
Starter does not turn. Ignition switch is in the OFF position.
Turn switch to the ON position.
Burnt fuse. Check main fuse and wiring condition.
Transmission is not set to Park or Neu-
Set transmission to PARK or Neutral or
tral position. squeeze the brake lever or press on
brake pedal.
Poor contact of battery terminal(s) or Clean and tighten terminal(s).
ground cable connections.
Weak battery. Recharge battery.
Poor contact or open circuit of: Check and replace defective part.
start button, engine stop switch,
ignition switch or starting solenoid.
Park and/or Neutral switch(es) is(are) Check park and/or neutral switch(es)
defective. and wiring condition.
Engine mechanical problem Check and replace defective part.
(ensure that other electric
components are good).
Starter turns, but does not Poor contact of battery terminal(s). Clean and tighten terminal(s).
crank the engine. Poor battery ground cable connection. Clean and tighten.
Burnt or poor contact of solenoid Replace starting solenoid.
switch contact disc.
Poor contact of brush. Clean, verify or straighten commutator
and brush or replace electric starter.
Burnt commutator. Turn commutator in a lathe or replace
electric starter.
Worn commutator segments. Undercut mica or replace electric starter.
Shorted armature. Replace electric starter.
Weak brush spring tension. Replace electric starter.
Weak magnet. Replace electric starter.
Worn bushings. Replace electric starter.
Weak battery. Recharge or replace battery.
Starter turns, but overrunning Worn clutch pinion gear. Replace electric starter.
clutch pinion does not mesh Defective clutch. Replace electric starter.
with ring gear.
Poor movement of clutch on splines. Replace electric starter.
Worn clutch bushing. Replace electric starter.
Worn ring gear. Replace ring gear.
Starter motor keeps running. Shorted starting solenoid switch wind- Replace starter solenoid.
ing.
Melted solenoid contacts. Replace starter solenoid.
Sticking or defective starter clutch. Lubricate or replace electric starter.
05-04-4 VMR2004_141_05_04A.FM
STARTING SYSTEM TESTS Using a multimeter, measure the resistance be-

tween the following wires.
GENERAL POSITION WIRE RESISTANCE
First ensure the problem is not related to engine me- Switch to OFF 1 Ω max.
chanical components. If not, test the starting sys- BLACK and
tem. Switch to RUN BLACK/WHITE Infinite (0.L)
Causes of problems are not necessarily related to
starter but may be due to a burnt fuse, faulty bat- Replace multi-function switch if defective.
tery, start button, ignition switch, engine stop If switch and wiring test is good, continue the next
switch, starting solenoid, electrical cables, connec- tests.
tions or the electronic module.
Check these components before removing starter. Start Button
Consult the STARTING SYSTEM TROUBLE- If engine does not turn when pressing the start
SHOOTING table above for a general view of pos- button, test the switch as follows.
sible problems. Remove the front facia and unplug the multi-function
switch connector.
 WARNING Using a multimeter, measure the resistance be-
To avoid the possibility of a short circuit while tween the following wires.
working on the starter, always disconnect the
battery. POSITION WIRE RESISTANCE
Switch released RED/VIOLET Infinite (0.L)
Fuses and
Switch depressed
Make sure the main fuse (20 amp) is in good con- YELLOW/RED 0.6 Ω max.
and held
dition. If the fuse tests good, continue with the
next tests. Replace multi-function switch if defective.
Battery If switch tests good, check wiring going to electron-
ic module. If the wiring tests good, continue the
To check battery condition, refer to BATTERY next tests.
above. If it tests good, continue with the next
tests. Starting Solenoid
Ignition Switch NOTE: Solenoid is located on the frame, behind
battery rack.
A quick test to check if it is functioning properly.
Ensure the solenoid receives electric current as
Turn the ignition switch to the ON position. If the
follows. Using a multimeter, measure the voltage
headlamps turn on, the ignition switch is good.
between the YELLOW/RED and WHITE/RED
Otherwise, refer to IGNITION SYSTEM for testing
wires when pressing the start button with the ig-
procedure. If it tests good, continue the next tests.
nition key turned ON.
Engine Stop Switch NOTE: Disconnect wires from solenoid.
If engine does not start when placing engine stop If solenoid does not properly receive current, the
switch to RUN and pressing the start button, test electronic module can be suspected. See ELEC-
the engine stop switch as follows. TRONIC MODULE section below.
Remove the console (refer to BODY) and unplug If solenoid receives current, test the solenoid as
the multi-function switch connector. follows.
Disconnect large cables from solenoid.
VMR2004_141_05_04A.FM 05-04-5
Inspect connections and clean as necessary. Sole- ELECTRIC STARTER

noid condition can be checked with an ohmmeter.
Install test probes on large connectors of solenoid.
Measure resistance when current is applied to small
REMOVAL
connectors; if it is more than a few ohms, replace Turn OFF ignition switch.
solenoid. Disconnect BLACK (-) cable from battery.
If solenoid test good, check the electric starter. If
starter test good, the electronic module can be  WARNING
suspected. See ELECTRONIC MODULE below. Always disconnect BLACK (-) cable first and
reconnect last.
Electrical Cables or Connections
Check all connections, cables and wires. Tighten Remove the RH side cover and the engine cover
any loose connections. Replace any chafed (refer to BODY).
wires/cables. Disconnect RED (+) cable from starter.
If wiring and connectors are good, check the elec- Clean starter area.
tric starter. See below.
Remove starter mount screws.
Electric Starter Pull starter out.
Using booster cables, carefully supply current from
the battery directly to the starter. Connect the INSTALLATION
BLACK (-) cable first. Then connect the remaining Installation is the reverse of removal procedure.
jumper cable from the battery then to the starter. However, pay particular attention to the following.
If starter turns ensure the cables/connections Make sure that starter and engine mating surfaces
from battery to solenoid and to starter are in good are free of debris. Serious problem may arise if the
condition. If they test good, the electronic module starter is not properly aligned.
can be suspected. See ELECTRONIC MODULE
below. Torque starter screws to 10 N•m (89 lbf•in).
If starter does not turn, check for mechanical prob- Connect the RED (+) cable to the starter and
lems in the starter. torque nut to 6 N•m (53 lbf•in). Apply dielectric
grease on terminal and nut.
Electronic Module First connect RED (+) cable to battery then con-
When other components have been tested above nect the BLACK (-) cable.
and are good, the electronic module can be sus-
pected. Ensure wiring and connectors are in good  WARNING
condition prior to replacing the electronic module. Always connect RED (+) cable first then
BLACK (-) cable last. Whenever connecting
the RED (+) cable to the starter motor, make
sure the battery cables are disconnected to
prevent electric shock.
Test starter operation.
05-04-6 VMR2004_141_05_04A.FM
Subsection 05 (IGNITION SYSTEM)
IGNITION SYSTEM 0
IGNITION SYSTEM TESTING
PROCEDURE
GENERAL
Ignition Problems
When dealing with ignition problems, the follow-
ing items should be checked in this order. After
one item has been checked and it is found not to
be the problem, continue with the next item:
1. main fuse condition
2. spark occurrence
3. battery condition
4. ignition switch
5. CPS (Crankshaft Position Sensor)
6. ignition coil
7. electronic module.
Intermittent Ignition Problems

In dealing with intermittent problems there is no
easy diagnosis. For example, problems that occur
only at normal engine operating temperature have
to be tested under similar conditions.
In most cases of temperature and/or vibration fail-
ure, only parts replacement might solve the prob-
lem as most of these failures return to normal
when engine is not running.
Multiple Problems
There is always the possibility of more than one
faulty part. If after a component has been re-
placed, the problem still persists, carefully repeat
the complete test procedure to find the other
faulty part.
VMR2004_142_05_05A.FM 05-05-1
TROUBLESHOOTING
NOTE: Check that the transmission is in PARK or NEUTRAL position and the engine stop switch is in
RUN position. Check that main fuse is not burned and if battery is fully-charged before diagnosing.
No spark or poor spark.
Check ignition system connector for poor

connections.
CORRECT LOOSENESS
Measure battery voltage between Poor connections of circuit connectors.

BLACK and RED/VIOLET wires at the
electric module with the ignition switch
in ON position.
CORRECT INCORRECT
Measure ignition coil primary peak voltage. Faulty ignition switch.

NOTE: This method is applicable only with a Faulty engine stop switch.
multimeter and a peak voltage adaptor.
Broken wire harness or poor connections
of circuit connectors.
INCORRECT CORRECT
Inspect ignition coil. Inspect spark plug.
CORRECT INCORRECT CORRECT INCORRECT
Faulty electronic Faulty ignition coil. Poor connection of Faulty spark plug.
module. the spark plug cap.
Poor connection of
ignition connector.
V07G08S
05-05-2 VMR2004_142_05_05A.FM
IGNITION SYSTEM TEST Use a multimeter and measure the resistance be-
Safety Precautions
POSITION WIRE RESISTANCE
 WARNING OFF
RED and
Infinite (0.L)
RED/YELLOW
To prevent powerful electric shocks while
cranking engine, neither touch any electronic OFF
RED and
Infinite (0.L)
ignition components (ignition coil, wire har- RED/VIOLET
ness, etc.) nor tester lead clips. Also make ON RED and
sure that tester leads do not touch any metal- 0.2 ± 0.2 Ω max.
(w/lights) RED/YELLOW
lic object.
ON RED and
0.2 ± 0.2 Ω max.
(w/lights) RED/VIOLET
Main Fuse Condition ON RED and
Infinite (0.L)
Check main fuse (20 A) condition. Replace burnt (w/o lights) RED/YELLOW
fuse as necessary. ON RED and
0.2 ± 0.2 Ω max.
CAUTION: Do not use higher rated fuse as this (w/o lights) RED/VIOLET
can cause severe damage.
Replace switch if defective.
Spark Occurrence If switch is good, continue the other tests.
Remove spark plug and connect to the ignition
coil. While holding the spark plug against a metallic CPS Voltage Testing
part of the engine, crank the engine. Look for a NOTE: The CPS is not adjustable.
spark at the spark plug tip. Replace defective spark
plug. STATIC TEST: CONTINUITY
NOTE: Make sure that the engine stop switch is Check resistance with a high-sensitivity ohmmeter.
in the run position. 1. Remove console and disconnect the CPS con-
Keep in mind that a spark plug might test good this nector.
way while not being able to work properly under 2. Connect multimeter probes to the BLACK/
combustion chamber mixture and pressure. YELLOW wire and to the BLACK wire.
If known good spark plug does not work, continue 3. Measure resistance; it should be between 190 -
the other tests. 300 ohms.
DYNAMIC TEST
Battery Condition
1. Disconnect the CPS connector.
A battery must be present in the vehicle to allow
the ignition system to work. Also, at least 8 V is 2. Connect multimeter probes to the BLACK/
required for proper operation. Check battery volt- YELLOW wire and to the BLACK wire, then
age. bring selector switch to Ṽ and scale to 00.0Vac.
3. Press START button, note result. The obtained
Ignition Switch value should be between 0.4 and 0.7 Vac. Re-
A quick test to verify if it is working properly. Turn peat operation 3 times.
the ignition switch ON. If the headlamps turn on, 4. If the CPS is out of specification, replace it. If it
the ignition switch is good. tests good continue the other tests.
Test
Ignition Coil
Remove console and disconnect ignition switch.
Ignition coil is mounted on frame along steering
Measure voltage between RED supply wire and column, in front of engine.
the battery ground. If voltage is lower than battery
voltage, test the wiring. If voltage is good, test
switch.
VMR2004_142_05_05A.FM 05-05-3
NOTE: An ignition coil with good resistance mea- Secondary Winding

surement can still be faulty. Voltage leak can occur The output voltage should not be less than 12 kV
at high voltage level which is not detectable with (12 000 V).
an ohmmeter. Replacing the ignition coil may be
necessary as a test. The ignition coil outlet caps and the spark plug
caps include a resistance. They should be checked
Primary Winding prior to replacing a suspected ignition coil.
Disconnect the wire connector on the primary side Measure resistance between ignition coil termi-
of the ignition coil. nals and spark plug caps. The obtained value should
Using a multimeter, check the resistance between be between 9 and 14 KΩ. If resistance is good, con-
the terminal and the ignition coil body ground. tinue check. If not, change spark plug wires.
The resistance should be between 0.8 and 1.2 Ω DYNAMIC TEST
at 20°C (68°F). An ignition coil tester available from after-market
If not within specification, replace the ignition coil. tool/equipment suppliers can be used.
If the ignition coil test good, check the power sup- CAUTION: Do NOT use coil tester on metal work
ply on the electronic module. bench. Follow manufacturer instructions.
There should be 12 Vdc between the RED/VIOLET If the ignition coil is out of specification, replace it.
and WHITE/GREEN wires. If it tests good ensure the wiring and connectors
If there is no voltage, either the electronic module are in good condition then continue the next tests.
or the wiring harness is defective.
Electronic Module
A C E
NEGATIVE (-) TESTER LINE
V06G06A B D F A B C D E F
A O.L. 2.97 KΩ 2.356 MΩ 2.447 MΩ UP to ∞
B 2.460 MΩ 2.464 MΩ 5.92 MΩ 6.07 MΩ O.L.
POSITIVE (+) TESTER LINE C 2.976 KΩ O.L. 2.356 MΩ 2.451 KΩ UP to ∞

D O.L. O.L. O.L. O.L. O.L.
E O.L. O.L. O.L. O.L. O.L.
F 2.304 MΩ O.L. 2.304 MΩ 5.65 MΩ 5.79 MΩ
05-05-4 VMR2004_142_05_05A.FM
CDI (Capacitive Discharge Ignition) SPARK PLUG ANALYSIS

When every other components above have been
tested and are good, the electronic module can be
suspected. Ensure wiring and connectors are in
good condition prior to replacing the electronic
module.
TEST
NOTE: On the multimeter, set measuring range
from 1 MΩ − 10 MΩ. Make sure that positive and
negative tester probes are installed on the appro- A00E0AA 1 2 3
priate wires. TYPICAL
If a fault is detected, the electronic module must be 1. Overheated (light grey, white)
2. Normal (light brown, brown)
replaced. 3. Fouled (black, wet or dry, dark deposits, grey, melted coating)
The plug face reveals the condition of the engine,

IGNITION TIMING operating condition, method of driving and fuel
It is impossible to check the ignition timing with a mixture. For this reason it is advisable to inspect
timing lamp because there is no access window or the spark plug at regular intervals, examining the
mark. plug face (i.e. the part of the plug projecting into
the combustion chamber).
SPARK PLUG
SPARK PLUG INSTALLATION
DISASSEMBLY Prior to installation make sure that contact surfaces
of the cylinder head and spark plug are free of grime.
Unplug the spark plug cable.
1. Using a wire feeler gauge, set electrode gap to
Unscrew the spark plug one turn.
0.7 mm (.027 in).
Clean the spark plug and cylinder head with pres-
2. Apply anti-seize lubricant over the spark plug
surized air.
threads to prevent possible seizure.
Unscrew spark plug completely then remove it.
3. Hand screw spark plug into cylinder head and
tighten with a torque wrench and a proper socket.
FOULING
Fouling of the spark plug is indicated by irregular
running of the engine, decreased engine speed
due to misfiring, reduced performance, and in-
creased fuel consumption. This is due to a loss of
compression. Other possible causes are: prolonged
idling or low-speed riding, or running on a too rich 1 2
mixture due to abuse of choke, a clogged air filter,
a faulty carburetor adjustment, incorrect fuel, de-
fective ignition system, incorrect ignition timing,
incorrect spark plug gap, lubricating oil entering
the combustion chamber, or too cold spark plug.
The plug face of a fouled spark plug has either a A00E0BA
wet black deposit or a black carbon fouling. Such

1. Proper socket
coatings form a conductive connection between 2. Improper socket
the center electrode and ground.
4. Torque spark plug to 20 N•m (15 lbf•ft).
VMR2004_142_05_05A.FM 05-05-5
NGK SPARK PLUG SYMBOL EXPLANATION
V04G0DS
05-05-6 VMR2004_142_05_05A.FM
Subsection 06 (INSTRUMENTS AND ACCESSORIES)
INSTRUMENTS AND ACCESSORIES 0

REMOVAL AND INSTALLATION Installation
Reverse the removal procedure.
 WARNING
It is recommended to always disconnect the HEADLAMP
battery when replacing any electric or elec-
tronic parts. Always disconnect battery exact- Test
ly in the specified order, BLACK (-) cable first. Refer to TESTS section.
Do not place tools on battery.

Bulb Replacement
ues and service products as in the exploded views. CAUTION: Never touch glass portion of an halo-
gen bulb with bare fingers, it shortens its operat-
ing life. If glass is touched, clean it with isopropyl
alcohol which will not leave a film on the bulb.
complete procedure. Unplug connector from headlamp.
 WARNING
12-VOLT AUXILIARY POWER

OUTLET
The wires are hidden inside harness near taillight
connector and are protected by heat shrink tubing. V07G09A
The 12-volt auxiliary power outlet allows the instal- Rotate bulb socket counterclockwise then remove
lation of additional accessories like carburetor headlamp bulb.
heater or winch.
Test
Refer to TESTS section.
12-VOLT POWER OUTLET 1 2

Test
Removal
Remove console. Refer to BODY.
Unplug the connectors of the power outlet. V04G03A
Unscrew the retaining nut. 1. Unlock

2. Lock
VMR2004_143_05_06A.FM 05-06-1

der of their removal.
Removal
NOTE: Use the same procedure for RH or LH head-
lamp.
Unplug the headlamp connector.
Remove both knobs.
Remove the last screw retaining headlamp holder.
V04G0GA 1 2
TYPICAL
1. Beam height adjustment
2. Beam side adjustment
HEADLAMP BEAM AIMING

Select high intensity.
Beam aiming is correct when center of high beam
is 131 mm (5 in) below the headlamp horizontal cen-
V04G0FA 2 4 1 3 1 ter line, scribed on a test surface, 5 m (17 ft) away.
TYPICAL
NOTE: Sit down the driver or place the same weight
1. Knobs on the vehicle.
2. Retaining screw
3. Headlamp holder Measure headlamp center distance from ground.
4. Headlamp housing Scribe a line at this height on test surface (wall
or screen). Light beam center should be 131 mm
Installation (5 in) below scribed line.
der of their removal.
Adjustment 90°
Adjust beam aiming as follows:

Turn knobs to adjust beam height and side orien- 2
1
tation as explained below. Adjust both headlamps
evenly.
90°
V01I0VA
TYPICAL
1. Headlamp center lines
2. Light beam center
05-06-2 VMR2004_143_05_06A.FM
90°
A
B
V01I0UA
TYPICAL
1. Light beam center
A. 5 m (17 ft)
B. 131 mm (5 in)
TAILLIGHT V07G1BA 1
1. Switch connector
Bulb Replacement Unscrew the ignition switch nut.
Unscrew lens screws to expose bulb.
V07G1CA
V07G1AA 2 1
1. Lens Installation
2. Screws
For the installation, reverse the removal procedure.
Push bulb in and hold while turning courterclock-
wise to release. ELECTRONIC MODULE
Install the new bulb by first pushing in while turn-
ing clockwise. Test
Refer to IGNITION SYSTEM for testing procedures.
IGNITION SWITCH
Removal
Test The electronic module is located under service
Refer to IGNITION SYSTEM. compartment. Remove the front fender.
To remove, unscrew both bolts retaining electron-
Removal ic module to frame and unplug the connector.
Lift the console and unplug the switch connector.
VMR2004_143_05_06A.FM 05-06-3
Installation 2 1
NOTE: Do not forget the rubber bushings between
electronic module and frame.
SPEEDOMETER
Test
Removal
Remove the steering cover. Refer to BODY.
Unplug the connector.
V07G1EA
1. Tabs
2. Notch
Speedometer Bulbs Replacement

The speedometer is lighted with LEDs. If one LED
burns, replace the speedometer. The LEDs are not
available separately.
Installation
Change from One Unit to the Other

V07G1DA The speedometer is factory pre-set in miles but it
UNPLUG THE CONNECTOR
is possible to change it to kilometer reading.
NOTE: The unit modification is applied to the speed-
Turn the speedometer counterclockwise and align ometer, odometer and trip meter.
the speedometer tabs with the notches then re-
move it. Turn ignition switch OFF and open the access pan-
el. Cut locking ties retaining the change wire to the
rectifier harness.
05-06-4 VMR2004_143_05_06A.FM
3 1 3 1
V07G01A 2 V07A2FA
1. Rectifier harness 1. Power connections

2. Change wire connectors
3. Fuse holders NOTE: Note the position of the power cables for re-
installation.
Plug connectors to change units from miles to kilo-
meters. Unplug to return to miles reading. Remove:
Fix the change wires to the harness with new lock- – locking pin
ing ties.
1
WINCH
XT Models Only
Removal
Disconnect, the battery BLACK (-) cable first, then
the RED (+) cable.
 WARNING
Always respect this order for disassembly; dis-
connect BLACK (-) cable first. Electrolyte or fuel
vapors can be present in engine compartment
and a spark may ignite them and possibly
cause personal injuries. V07A2GA
1. Locking pin
Disconnect the winch power cables.
– hook
– bolts retaining the winch from both LH and RH
sides.
VMR2004_143_05_06A.FM 05-06-5
– No voltage:
1 • Check wiring condition.
– Voltage is good:
• Check accessories.
12-VOLT POWER OUTLET

NOTE: No key required.
Remove the console.
Unplug the power outlet connectors.
Using a multimeter, measure the voltage between
RED/BLACK and BLACK wires.
The obtained value should be between 12 and 14.5
Vdc.
V07A2HA 1 – No voltage:
1. Bolts to be removed • Check accessories fuse (15 A) and wiring con-
Remove winch. dition.
Installation • Change power outlet.
HEADLAMP
WINCH CONTROL SWITCH Apply parking brake, place transmission lever in
XT Models Only NEUTRAL position and start engine.
Test Select low beam position on headlamp switch.
Refer to TESTS section. Using a multimeter, measure the voltage between
GREEN and BLACK wires.
Removal The obtained value should be between 12 and 14.5
Vdc.
Remove screws retaining winch control switch to
handlebar. Place the headlamp switch selector on high beam
position.
Remove steering cover, refer to BODY.
Measure the voltage between BLUE and BLACK
Disconnect the winch control switch connector. wires. The obtained value should be between 12
and 14.5 Vdc.
Installation
– No voltage:
For the installation, reverse the removal procedure. • Check wiring condition and headlamp switch.
TESTS
• Change headlamp bulb(s).
12-VOLT AUXILIARY POWER
OUTLET
NOTE: Turn ignition key ON.
RED/VIOLET and BLACK wires.
The obtained value should be between 12 and 14.5
Vdc.
05-06-6 VMR2004_143_05_06A.FM
MULTI-FUNCTION SWITCH Start Switch

Using a multimeter, measure the resistance be-
Apply parking brake, place transmission lever in
NEUTRAL position and start engine.
SWITCH WIRE RESISTANCE
Start switch
RED/VIOLET Infinite (O.L.)
1 released
and
2 Start switch YELLOW/RED 0.2 ± 0.2 Ω max.
pushed
Replace multifunction switch if defective.

Engine Stop Switch
3
4
SWITCH WIRE RESISTANCE
Engine stop
V07I05A
switch on STOP 0.2 ± 0.2 Ω max.
1. Headlamp switch position BLACK/WHITE
2. Start switch and BLACK
3. Engine stop switch Engine stop
4. Override switch switch on RUN Infinite (O.L.)
position
Headlamp Switch
Select low beam position on headlamp switch. Replace multifunction switch if defective.
Using a multimeter, measure the voltage between Override Switch
GREEN and BLACK wires.
The obtained value should be between 12 and 14.5 tween the following wires.
Vdc.
Place the headlamp switch selector on high beam SWITCH WIRE RESISTANCE
position. Override switch
VIOLET/GREY Infinite (O.L.)
Measure the voltage between BLUE and BLACK pushed
wires. The obtained value should be between 12 and
Override switch VIOLET/GREY
and 14.5 Vdc. 0.2 ± 0.2 Ω max.
released
– No voltage:
• Check wiring condition and headlamp switch. Replace multifunction switch if defective.
• Change headlamp bulb(s).
POSITION WIRE RESISTANCE
RED/YELLOW
Switch to LO 0.2 ± 0.2 Ω max.
and GREEN
RED/YELLOW
Switch to HI 0.2 ± 0.2 Ω max.
and BLUE
Replace multifunction switch if defective.
VMR2004_143_05_06A.FM 05-06-7
SPEEDOMETER
both RED/VIOLET and BLACK wires.
Turn ignition switch to ON. The obtained value
should be between 12 and 14.5 Vdc.
– No voltage on speedometer:
• Check wiring condition and electronic module
connector. If good, change electronic module.
– Voltage on speedometer:
• If VSS (Vehicle Speed Sensor) voltage is good,
change speedometer.
• No voltage on VSS. Check VSS and wiring con-
dition from VSS to electronic module MPEM.
WINCH CONTROL SWITCH

XT Models Only
Remove steering cover, refer to BODY.
Disconnect the winch control switch connector.
tween the connector pin A (RED wire), B (BLACK
wire) and C (GREEN wire).
CONNECTOR
POSITION RESISTANCE
PIN
Switch to “IN” A and C <5Ω
Switch to “OUT” A and B <5Ω
If the resistance is above 5 Ω, replace the winch

control switch.
05-06-8 VMR2004_143_05_06A.FM
Section 06 DRIVE TRAIN
TABLE OF CONTENTS 0
FRONT DRIVE ........................................................................................................................ 06-02-1
GENERAL ........................................................................................................................... 06-02-2
WHEEL HUB....................................................................................................................... 06-02-2
FRONT DRIVE SHAFT ....................................................................................................... 06-02-3
FRONT DIFFERENTIAL ...................................................................................................... 06-02-4
BACKLASH PROCEDURE.................................................................................................. 06-02-6
FRONT PROPELLER SHAFT .............................................................................................. 06-02-14
DISCONNECT UNIT........................................................................................................... 06-02-14
REAR AXLE ............................................................................................................................ 06-03-1

GENERAL ........................................................................................................................... 06-03-2
REAR DIFFERENTIAL OIL LEVEL ...................................................................................... 06-03-2
REAR DIFFERENTIAL OIL REPLACEMENT ................................................................................ 06-03-2
WHEEL HUB....................................................................................................................... 06-03-2
DRIVE SHAFT PROTECTORS............................................................................................ 06-03-4
DRIVE SHAFT..................................................................................................................... 06-03-4
DRIVE SHAFT BOOT ......................................................................................................... 06-03-4
DRIVE SHAFT WEAR RING ............................................................................................... 06-03-5
REAR PROPELLER SHAFT................................................................................................. 06-03-5
REAR PROPELLER SHAFT U-JOINT................................................................................. 06-03-6
REAR DIFFERENTIAL ........................................................................................................ 06-03-7
VMR2004_154_06_01ATOC.FM 06-01-1
Subsection 02 (FRONT DRIVE)
FRONT DRIVE 0
1 2
4
5
3
145 Nm 6
(107 lbfft) Synthetic
grease
7
12
12
18 Nm
(13 lbfft) 14
29 48 Nm
11 10 (35 lbfft)
27
18 Nm 7
31(13 lbfft) 13 42 Nm
32 (31 lbfft)
23 Nm 10 Synthetic
(17 lbfft) 41 30 grease
28 36
34 39
26 37
35
38
33 18 30 Nm
(22 lbfft)
9
40
Synthetic 19 35 Nm
grease (26 lbfft)
15 13 Nm
20 (115 lbfin)
16
150 Nm
(110 lbfft) 22 25
Loctite 243 17
21 24
V07H05S
23
VMR2004_144_06_02A.FM 06-02-1
GENERAL
The procedure explains below is the same for the
RH and LH sides unless otherwise instructed.
For installation, use the torque values and Loctite
products from the exploded views. Clean threads
before using Loctite when reinstalling the screws.
 WARNING
specified. If the efficiency of a locking device V07H07A
Inspection
WHEEL HUB Check wheel hub for cracks or other damages.
Removal Check inner splines for wear or other damages.
Raise the front of vehicle, support it securely on jack If any damage is detected on wheel hub, replace
stands and remove front wheel. it with a new one.
Remove: Check wear ring no. 6. If damage is apparent, re-
place the wear ring.
– wheel cap no. 1
– cotter pin no. 2
– castellated nut no. 3
– flat washer no. 4.
V07H06A
V07H08A 2 1
1. Wheel hub
Extract the wheel hub no. 5. If necessary, use the 2. Wear ring
hub puller (P/N 529 035 612).
Installation
dure.
06-02-2 VMR2004_144_06_02A.FM
FRONT DRIVE SHAFT Installation

Apply grease (P/N 293 550 019) to the splines and
Removal insert the end of drive shaft in differential and pull
Remove: joint a little to make sure that the stop ring is locked
in differential side gear groove.
– wheel hub
– caliper (refer to HYDRAULIC BRAKES). 1
CAUTION: Do not let the caliper hang by the
hose and do not stretch or twist the hose.
Remove the ball joint retaining bolt from lower
suspension arm.
V07H0AA
1. Stop ring
NOTE: The wear ring should be close to the differ-

ential.
V07H09A 2 1
1. Ball joint retaining bolt
2. Lower suspension arm
Separate knuckle from lower suspension arm.

Separate knuckle from the drive shaft no. 7.
Pull drive shaft out of differential no. 8.
NOTE: Pull drive shaft strongly.
Inspection
Inspect the condition of boots. If there is any dam-
age or evidence of leaking lubricant, replace them.
Refer to DRIVE SHAFT BOOT section. V07H0BA
Check splines for excessive wear. Replace if nec-

Insert the other end of drive shaft in the knuckle
essary.
and install the knuckle to the lower suspension
NOTE: If the splines on differential side are worn, arm. Install and torque the ball joint retaining bolt
a check of differential inner splines should be to 48 N•m (35 lbf•ft).
done.
Install the flat washer and torque the castellated
Check the stop ring no. 9 at the end of drive shaft. nut on the drive shaft end to 145 N•m (107 lbf•ft)
If wear is apparent, replace the wear ring. minimum. Install a new cotter pin and the wheel
Check if the bearings in knuckle move freely and cap. Fold one pin of cotter pin over drive shaft end.
smoothly. If not, replace them. Refer to STEER-
ING SYSTEM.
VMR2004_144_06_02A.FM 06-02-3
Inspection
Check bearing in plunging joint or CV joint. If bear-
ing is hard to move, change plunging joint or CV
joint.
Check circlip for damage, change as necessary.
Installation
Insert boot, do not forget the small clamp.
Insert shaft and push firmly.
Pack bearing area with grease (included with the
new boot kit).
NOTE: Do not use or add other grease.
V07H0CA
FRONT DIFFERENTIAL
Reinstall the front wheel and torque nuts to 70 N•m
(52 lbf•ft). Front Differential Oil Level
Clean filler plug prior to checking oil level.
Drive Shaft Boot
Removal 1
Remove:
– clamps from rubber boot using boot clamp pli-
ers (P/N 295 000 069 and 295 000 054)
– large end of the boot from plunging joint or CV joint.
Move apart circlip and pull out the shaft from bear-
ing. Do not remove circlip.
V07H0DA
1. Filler plug
With vehicle on a level surface, check oil level by

removing filler plug. Oil level must reach the lower
edge.
Add oil if necessary. Refer to TECHNICAL DATA for
capacity and recommended oil.
V01H0XA 2 1
1. Circlip
2. Shaft
Remove boot from drive shaft.
06-02-4 VMR2004_144_06_02A.FM
Front Differential Oil Change

Place vehicle on a level surface. Set transmission
in park position.
Lift LH side of vehicle.
Clean drain plug area.
Place a drain pan under differential drain plug area.
Remove drain plug no. 17.
Unscrew filler plug.
2
V07H0FA
– brake hose from its support
V07H0DB 1
1. Drain plug
2. Filler plug
Clean drain plug area then reinstall plug.

Lower vehicle.
Use a funnel and refill front differential at the prop-
er level with the recommended oil. Refer to TECH-
V07H0GA
NICAL DATA.
Reinstall filler plug. – both differential mounting bolts no. 12.
Removal
Raise front of vehicle, support it securely on jack
stands and remove front wheels.
On both sides, remove the drive shafts (refer to
FRONT DRIVE SHAFT above).
Drain the differential.
NOTE: It is possible to remove differential without
draining it, in this case, do not tilt it.
Remove:
– Oetiker clamp no. 10 (discard it) on propeller
shaft no. 11 (differential side)
V07H0HA 1
1. Differential mounting bolts
VMR2004_144_06_02A.FM 06-02-5
Move the differential forward to disconnect the Install the backlash measurement tool (P/N 529
propeller shaft. 035 665) at the end of the pinion gear.
Remove the differential from the RH side.
Unscrew bolt no. 13 retaining the propeller shaft
adaptor no. 14.
Inspection
Turn front differential gear with a finger; it should
turn smoothly. Replace if necessary.
Check backlash, see BACKLASH PROCEDURE
further in this section.
Check if oil seals are brittle, hard or damaged. Re-
place if necessary.
Installation
cedure.
V04H0KA 1
BACKLASH PROCEDURE TYPICAL
1. Backlash measurement tool
Backlash adjustment is the last procedure to do
before the final re-assembly of a differential. From center of bolt, measure 25.4 mm (1 in) and
Temporarily, re-assemble the differential. place a mark on the tab.
Install a drive shaft in vise then place the differen-
tial on the drive shaft end.
V04H0LA
TYPICAL
1. Tab of backlash measurement tool
V04H0JA
2. Mark on tab
A. 25.4 mm (1 in)
TYPICAL
NOTE: The drive shaft prevents the gears from NOTE: This measure is equaled to the radius of
moving. pinion gear.
06-02-6 VMR2004_144_06_02A.FM
Position the dial indicator against the tab at a 90 Scenario 2

degree angle and gently move the pinion shaft If the backlash is correct but the preload is too
back and forth. high, then decrease the preload shim pack to the
next lower option.
Scenario 3
If the preload is correct but more than one back-
lash measurement is less than 0.025 mm (.001 in)
(low backlash) then increase the backlash shim
pack.
90° NOTE: The preload shim will need to be de-
creased by the same amount to keep the preload
within specification.
Reassemble the differential and recheck backlash
and preload torque. Repeat adjustment procedure
until both backlash and preload are within specifi-
cation.
V04H0MA Scenario 4
TYPICAL If the preload is correct but one or more of the
The reading on the dial indicator gives the backlash backlash measurements are over 0.152 mm
measurement. (.006 in) (high backlash) then decrease the back-
lash shim pack.
To be acceptable, the backlash must be in the
0.025 to 0.152 mm (.001 to .006 in). NOTE: The preload shim pack must increase by
the same amount to keep the preload within spec-
NOTE: Measure backlash at 5 points, every 2 ification.
teeth of the pinion gear.
Reassemble the differential and recheck backlash
If the backlash is not within specification, disas- and preload torque. Repeat adjustment procedure
semble the differential and adjust the shims of the until both backlash and preload are within specifi-
ring gear carrier accordingly in order to move it ei- cation.
ther closer to or further away from the pinion.
Scenario 5
The backlash is adjusted by moving shims from
one end of the bearing carrier to the other as re- If both preload and backlash are out of specifica-
quired. tion then adjust both shim packs in the appropriate
direction.
CAUTION: Never eliminate any shims, simply
move them from one end to the other to be able Reassemble the differential and recheck backlash
to move the carrier assembly either closer to or and preload torque. Repeat adjustment procedure
further away from the pinion in order to get the until both backlash and preload are within specifi-
correct backlash. cation.
NOTE: If either backlash or preload is out of spec- After obtaining the proper backlash, do the final
ification then the shims must be adjusted. Refer reassembly.
to the tables provided further in this section.
Scenario 1
If the backlash is correct but the preload is too low,
then increase the preload shim pack to the next
thicker option.
VMR2004_144_06_02A.FM 06-02-7
Disassembly Pinion Gear and Ring Gear Carrier

Ring Gear Carrier/Ring Gear Removal Recentering
To change ring gear carrier no. 15 or ring gear NOTE: All measurements require great care and
no. 16: absolute cleanliness if accurate results are to be
obtained.
– Unscrew the drain plug no. 17 and empty dif-
ferential. Use following course of calculation to calculate
the proper shim thickness.
– Unscrew the TORX screws no. 18, then sepa-
rate half housings. Measure following items and enter measurement
in the following list:
– Extract ring gear carrier with ring gear out of half
housing. LETTER MEASUREMENT
– Unscrew Allen socket screws no. 19 then sep- PINION GEAR ADJUSTMENT
arate ring gear from ring gear carrier.
A
To assembly, reverse the removal procedure. Pay
attention to the following details. B 64.450 mm
(given value) (2.5374 in)
NOTE: If ring gear carrier, pinion gear, ring gear,
housing or bearing is (are) changed, recenter the C=A-B
ring gear carrier in the housing before final assem-
bly. See PINION GEAR AND RING GEAR CARRIER RING GEAR CARRIER ADJUSTMENT
RECENTERING below. D 1.15 mm (.045 in)
Verify condition of half housing seal no. 20. E
Change seal if necessary.
F
Check all bearings and all oil seals. Change them
if necessary. G=E-F
Pinion Gear Removal H
Remove oil seal no. 21. I = G - (H + 0.70 mm (.028 in))
Unscrew the pinion nut no. 22. Use the differen-
tial spanner socket (P/N 529 035 649). First; center pinion gear.
Remove the bearing no. 23 at the same time as
the pinion gear no. 24.
NOTE: The pinion gear and bearing can be easily
removed using the following suggested tool:
– pipe 3-1/2 in dia. x 5 in (1)
– screwed rod M10 x 1.25, 7 in length (1)
– nut M10 x 1.25 (3)
– flat bar (1).
To install, reverse the removal procedure. Pay at-
tention to the following details.
Check O-ring no. 25 for damage. If so, change it.
Install the shim then the ball bearing.
NOTE: If ring gear carrier, pinion gear, ring gear,
housing or bearing is (are) changed, recenter the
ring gear carrier in the housing before final assem-
bly. See below.
Install the nut and a new oil seal.
06-02-8 VMR2004_144_06_02A.FM
V01H1KA
TYPICAL
Measure distance between pinion gear surface to

low point of carrier bearing. This is measure “A”.
The measure “B” is a given value of 64.450 mm
(2.5374 in).
Subtract the largest value of “A” or “B” by the
smallest value. This result is the value “C”.
VMR2004_144_06_02A.FM 06-02-9
Locate value “C” in the following chart and select the proper shims.
SHIM CHART
VALUE “C” SHIM QUANTITY x SHIM THICKNESS SHIM PACK THICKNESS
0.000 to 0.073 mm (.0000 to .0029 in) 3 x 0.51 mm (.020 in) 1.53 mm (.0602 in)
2 x 0.51 mm (.020 in)
0.076 to 0.124 mm (.0030 to .0049 in) 1.58 mm (.0622 in)
1 x 0.56 mm (.022 in)
2 x 0.51 mm (.020 in)
0.127 to 0.175 mm (.0050 to .0069 in) 1.58 mm (.0622 in)
1 x 0.56 mm (.022 in)
1 x 0.51 mm (.020 in)
0.177 to 0.226 mm (.0070 to .0089 in) 1.63 mm (.0642 in)
2 x 0.56 mm (.022 in)
1 x 0.25 mm (.010 in)
2 x 0.51 mm (.020 in)
1 x 0.25 mm (.010 in)
1 x 0.38 mm (.015 in)
0.330 to 0.378 mm (.0130 to .0149 in) 1.7 mm (.0669 in)
1 x 0.51 mm (.020 in)
1 x 0.56 mm (.022 in)
1 x 0.25 mm (.010 in)
2 x 0.56 mm (.022 in)
1 x 0.25 mm (.010 in)
1 x 0.56 mm (.022 in)
SHIM THICKNESS/SHIM NOTCH(ES) Install pinion, shims, bearing and pinion nut. Apply
Loctite 243 to nut and torque to 150 N•m (110
THICKNESS NOTCHES lbf•ft).
0.25 mm (.010 in) 0 After pinion installation, center ring gear carrier.
0.38 mm (.015 in) 1 Install a 1.15 mm (.045 in) shim pack to location
“D”.
0.51 mm (.020 in) 2
0.56 mm (.022 in) 4
D
V07H20C
06-02-10 VMR2004_144_06_02A.FM
Measure “E” (cap side measurement from bear- Measure “H” (carrier side measurement from
ing to outer edge). Visco-Lock to carrier flange).
V01H1EA
TYPICAL
Measure the edge of half housing. This is measure V07H20D

“F”.
Add 0.70 mm (.028 in) to measure “H”. Subtract
this result from measure “G”. Note this result “I”.
G - (H + 0.70 (.028)) = I
– Example of shimming procedure:
– E = 86.96 mm (3.42 in)
– F = 5.80 mm (.228 in)
– G = 81.16mm (3.20 in)
– H = 80.26 mm (3.16 in)
– I= 1.60 mm (.063 in)
– NOTE: Actual I is 1.61 mm (.063 in) (see SHIM
CHART farther in this section. Use nearest com-
bination).
CAUTION: Do not use the previous table to se-
lect shims. The previous table must be used to
V01H1FA choose the pinion gear shims only.
TYPICAL Assemble differential using shim packs D and I.
Subtract the measure “F” from measure “E”. Confirm preload torque is within range 0.8 to 1.7
Note this result “G”. N•m (7 to 15 lbf•in).
E - F = G (housing inside length) Perform a backlash procedure.
Assembly
The differential assembly is essentially the reverse
of the disassembly procedure.
VMR2004_144_06_02A.FM 06-02-11
BACKLASH SHIM CHART

SHIM - mm (in) ACTUAL TARGET SHIM - mm (in) ACTUAL TARGET
#1 #2 #3 TOTAL TOTAL #1 #2 #3 TOTAL TOTAL
0.25 (.010) 0.25 (.010) 0.50 (.020) 0.50 (.020) 0.33 (.013) 0.64 (.025) 0.97 (.038) 0.97 (.038)
0.51 (.020) 0.51 (.020) 0.51 (.020)
0.51 (.020) 0.51 (.020) 0.52 (.020) 0.45 (.018) 0.53 (.021) 0.98 (.039) 0.98 (.039)
0.53 (.021) 0.53 (.021) 0.53 (.021)

0.53 (.021) 0.53 (.021) 0.54 (.021) 0.35 (.014) 0.64 (.025) 0.99 (.039) 0.99 (.039)
0.25 (.010) 0.30 (.012) 0.55 (.022) 0.55 (.022) 0.30 (.012) 0.30 (.012) 0.40 (.016) 1.00 (.040) 1.00 (.040)
0.56 (.022) 0.56 (.022) 0.56 (.022) 0.40 (.016) 0.61 (.024) 1.01 (.040) 1.01 (.040)
0.56 (.022) 0.56 (.022) 0.57 (.022)
0.25 (.010) 0.33 (.013) 0.58 (.023) 0.59 (.023) 0.38 (.015) 0.64 (.025) 1.02 (.040) 1.02 (.040)
0.25 (.010) 0.33 (.013) 0.58 (.023) 0.59 (.023)
0.61 (.024) 0.61 (.024) 0.60 (.024)
0.61 (.024) 0.61 (.024) 0.61 (.024) 0.33 (.013) 0.35 (.014) 0.35 (.014) 1.03 (.041) 1.03 (.041)
0.61 (.024) 0.61 (.024) 0.62 (.024)
0.30 (.012) 0.33 (.013) 0.63 (.025) 0.63 (.025) 0.40 (.016) 0.64 (.025) 1.04 (.041) 1.04 (.041)
0.64 (.025) 0.64 (.025) 0.64 (.025) 0.40 (.016) 0.40 (.016) 0.25 (.010) 1.05 (.042) 1.05 (.042)
0.30 (.012) 0.35 (.014) 0.65 (.026) 0.65 (.026) 0.45 (.018) 0.61 (.024) 1.06 (.042) 1.06 (.042)
0.33 (.013) 0.33 (.013) 0.66 (.026) 0.66 (.026) 0.43 (.017) 0.64 (.025) 1.07 (.042) 1.07 (.042)
0.33 (.013) 0.33 (.013) 0.66 (.026) 0.67 (.026)
0.30 (.012) 0.38 (.015) 0.68 (.027) 0.68 (.027) 0.35 (.014) 0.35 (.014) 0.38 (.015) 1.08 (.043) 1.08 (.043)
0.30 (.012) 0.38 (.015) 0.68 (.027) 0.69 (.027)
0.35 (.014) 0.35 (.014) 0.70 (.028) 0.70 (.028) 0.45 (.018) 0.64 (.025) 1.09 (.043) 1.09 (.043)
0.33 (.013) 0.38 (.015) 0.71 (.028) 0.71 (.028) 0.35 (.014) 0.35 (.014) 0.40 (.016) 1.10 (.044) 1.10 (.044)
0.33 (.013) 0.38 (.015) 0.71 (.028) 0.72 (.028)
0.35 (.014) 0.38 (.015) 0.73 (.029) 0.73 (.029)
0.35 (.014) 0.38 (.015) 0.73 (.029) 0.74 (.029) 0.35 (.014) 0.38 (.015) 0.38 (.015) 1.11 (.044) 1.11 (.044)
0.30 (.012) 0.45 (.018) 0.75 (.030) 0.75 (.030) 0.56 (.022) 0.56 (.022) 1.12 (.044) 1.12 (.044)
0.25 (.010) 0.51 (.020) 0.76 (.030) 0.76 (.030)
0.25 (.010) 0.51 (.020) 0.76 (.030) 0.77 (.030) 0.35 (.014) 0.35 (.014) 0.43 (.017) 1.13 (.045) 1.13 (.045)
0.38 (.015) 0.40 (.016) 0.78 (.031) 0.78 (.031) 0.53 (.021) 0.61 (.024) 1.14 (.045) 1.14 (.045)
0.38 (.015) 0.40 (.016) 0.78 (.031) 0.79 (.031)
0.40 (.016) 0.40 (.016) 0.80 (.032) 0.80 (.032) 0.51 (.020) 0.64 (.025) 1.15 (.045) 1.15 (.045)
0.38 (.015) 0.43 (.017) 0.81 (.032) 0.81 (.032) 0.30 (.012) 0.30 (.012) 0.56 (.022) 1.16 (.046) 1.16 (.046)
0.38 (.015) 0.43 (.017) 0.81 (.032) 0.82 (.032)
0.38 (.015) 0.45 (.018) 0.83 (.033) 0.83 (.033) 0.53 (.021) 0.64 (.025) 1.17 (.046) 1.17 (.046)
0.33 (.013) 0.51 (.020) 0.84 (.033) 0.84 (.033) 0.38 (.015) 0.40 (.016) 0.40 (.016) 1.18 (.047) 1.18 (.047)
0.40 (.016) 0.45 (.018) 0.85 (.034) 0.85 (.034) 0.38 (.015) 0.38 (.015) 0.43 (.017) 1.19 (.047) 1.19 (.047)
0.30 (.012) 0.56 (.022) 0.86 (.034) 0.86 (.034) 0.56 (.022) 0.64 (.025) 1.20 (.047) 1.20 (.047)
0.30 (.012) 0.56 (.022) 0.86 (.034) 0.87 (.034)
0.43 (.017) 0.45 (.018) 0.88 (.035) 0.88 (.035) 0.30 (.012) 0.40 (.016) 0.51 (.020) 1.21 (.048) 1.21 (.048)
0.33 (.013) 0.56 (.022) 0.89 (.035) 0.89 (.035) 0.64 (.025) 0.25 (.010) 0.33 (.013) 1.22 (.048) 1.22 (.048)
0.45 (.018) 0.45 (.018) 0.90 (.036) 0.90 (.036) 0.40 (.016) 0.40 (.016) 0.43 (.017) 1.23 (.049) 1.23 (.049)
0.40 (.016) 0.51 (.020) 0.91 (.036) 0.91 (.036)
0.40 (.016) 0.51 (.020) 0.91 (.036) 0.92 (.036) 0.30 (.012) 0.30 (.012) 0.64 (.025) 1.24 (.049) 1.24 (.049)
0.40 (.016) 0.53 (.021) 0.93 (.037) 0.93 (.037) 0.35 (.014) 0.45 (.018) 0.45 (.018) 1.25 (.050) 1.25 (.050)
0.30 (.012) 0.64 (.025) 0.94 (.037) 0.94 (.037) 0.35 (.014) 0.35 (.014) 0.56 (.022) 1.26 (.050) 1.26 (.050)
0.45 (.018) 0.51 (.020) 0.96 (.038) 0.95 (.038) 0.25 (.010) 0.51 (.020) 0.51 (.020) 1.27 (.050) 1.27 (.050)
0.45 (.018) 0.51 (.020) 0.96 (.038) 0.96 (.038)
06-02-12 VMR2004_144_06_02A.FM
PRELOAD SHIM CHART

SHIM - mm (in) ACTUAL TARGET SHIM - mm (in) ACTUAL TARGET
#1 #2 #3 TOTAL TOTAL #1 #2 #3 TOTAL TOTAL
0.38 (.015) 0.45 (.018) 0.83 (.033) 0.83 (.033) 0.40 (.016) 0.40 (.016) 0.43 (.017) 1.23 (.049) 1.23 (.049)
0.33 (.013) 0.51 (.020) 0.84 (.033) 0.84 (.033) 0.30 (.012) 0.30 (.012) 0.64 (.025) 1.24 (.049) 1.24 (.049)
0.40 (.016) 0.45 (.018) 0.85 (.034) 0.85 (.034) 0.35 (.014) 0.45 (.018) 0.45 (.018) 1.25 (.050) 1.25 (.050)
0.30 (.012) 0.56 (.022) 0.86 (.034) 0.86 (.034) 0.35 (.014) 0.35 (.014) 0.56 (.022) 1.26 (.050) 1.26 (.050)
0.30 (.012) 0.56 (.022) 0.86 (.034) 0.87 (.034)
0.43 (.017) 0.45 (.018) 0.88 (.035) 0.88 (.035) 0.25 (.010) 0.51 (.020) 0.51 (.020) 1.27 (.050) 1.27 (.050)
0.33 (.013) 0.56 (.022) 0.89 (.035) 0.89 (.035) 0.38 (.015) 0.45 (.018) 0.45 (.018) 1.28 (.051) 1.28 (.051)
0.45 (.018) 0.45 (.018) 0.90 (.036) 0.90 (.036) 0.38 (.015) 0.38 (.015) 0.53 (.021) 1.29 (.051) 1.29 (.051)
0.40 (.016) 0.51 (.020) 0.91 (.036) 0.91 (.036)
0.40 (.016) 0.51 (.020) 0.91 (.036) 0.92 (.036) 0.64 (.025) 0.25 (.010) 0.41 (.016) 1.30 (.051) 1.30 (.051)
0.40 (.016) 0.53 (.021) 0.93 (.037) 0.93 (.037) 0.25 (.010) 0.53 (.021) 0.53 (.021) 1.31 (.052) 1.31 (.052)
0.30 (.012) 0.64 (.025) 0.94 (.037) 0.94 (.037) 0.64 (.025) 0.25 (.010) 0.43 (.017) 1.32 (.052) 1.32 (.052)
0.45 (.018) 0.51 (.020) 0.96 (.038) 0.95 (.038) 0.43 (.017) 0.45 (.018) 0.45 (.018) 1.33 (.053) 1.33 (.053)
0.45 (.018) 0.51 (.020) 0.96 (.038) 0.96 (.038)
0.33 (.013) 0.64 (.025) 0.97 (.038) 0.97 (.038) 0.35 (.014) 0.35 (.014) 0.64 (.025) 1.34 (.053) 1.34 (.053)
0.45 (.018) 0.53 (.021) 0.98 (.039) 0.98 (.039) 0.45 (.018) 0.45 (.018) 0.45 (.018) 1.35 (.054) 1.35 (.054)
0.35 (.014) 0.64 (.025) 0.99 (.039) 0.99 (.039) 0.40 (.016) 0.40 (.016) 0.56 (.022) 1.36 (.054) 1.36 (.054)
0.30 (.012) 0.30 (.012) 0.40 (.016) 1.00 (.040) 1.00 (.040) 0.38 (.015) 0.38 (.015) 0.61 (.024) 1.37 (.054) 1.37 (.054)
0.40 (.016) 0.61 (.024) 1.01 (.040) 1.01 (.040) 0.40 (.016) 0.45 (.018) 0.53 (.021) 1.38 (.055) 1.38 (.055)
0.38 (.015) 0.64 (.025) 1.02 (.040) 1.02 (.040) 0.33 (.013) 0.53 (.021) 0.53 (.021) 1.39 (.055) 1.39 (.055)
0.33 (.013) 0.35 (.014) 0.35 (.014) 1.03 (.041) 1.03 (.041) 0.64 (.025) 0.25 (.010) 0.51 (.020) 1.40 (.055) 1.40 (.055)
0.40 (.016) 0.64 (.025) 1.04 (.041) 1.04 (.041) 0.35 (.014) 0.53 (.021) 0.53 (.021) 1.41 (.056) 1.41 (.056)
0.40 (.016) 0.40 (.016) 0.25 (.010) 1.05 (.042) 1.05 (.042) 0.64 (.025) 0.25 (.010) 0.53 (.021) 1.42 (.056) 1.42 (.056)
0.45 (.018) 0.61 (.024) 1.06 (.042) 1.06 (.042) 0.45 (.018) 0.45 (.018) 0.53 (.021) 1.43 (.057) 1.43 (.057)
0.43 (.017) 0.64 (.025) 1.07 (.042) 1.07 (.042) 0.38 (.015) 0.53 (.021) 0.53 (.021) 1.44 (.057) 1.44 (.057)
0.35 (.014) 0.35 (.014) 0.38 (.015) 1.08 (.043) 1.08 (.043) 0.64 (.025) 0.25 (.010) 0.56 (.022) 1.45 (.057) 1.45 (.057)
0.45 (.018) 0.64 (.025) 1.09 (.043) 1.09 (.043) 0.40 (.016) 0.53 (.021) 0.53 (.021) 1.46 (.058) 1.46 (.058)
0.35 (.014) 0.35 (.014) 0.40 (.016) 1.10 (.044) 1.10 (.044) 0.25 (.010) 0.61 (.024) 0.61 (.024) 1.47 (.058) 1.47 (.058)
0.35 (.014) 0.38 (.015) 0.38 (.015) 1.11 (.044) 1.11 (.044) 0.64 (.025) 0.38 (.015) 0.46 (.018) 1.48 (.058) 1.48 (.058)
0.56 (.022) 0.56 (.022) 1.12 (.044) 1.12 (.044) 0.43 (.017) 0.53 (.021) 0.53 (.021) 1.49 (.059) 1.49 (.059)
0.35 (.014) 0.35 (.014) 0.43 (.017) 1.13 (.045) 1.13 (.045) 0.38 (.015) 0.56 (.022) 0.56 (.022) 1.50 (.059) 1.50 (.059)
0.53 (.021) 0.61 (.024) 1.14 (.045) 1.14 (.045) 0.45 (.018) 0.53 (.021) 0.53 (.021) 1.51 (.060) 1.51 (.060)
0.51 (.020) 0.64 (.025) 1.15 (.045) 1.15 (.045) 0.30 (.012) 0.61 (.024) 0.61 (.024) 1.52 (.060) 1.52 (.060)
0.30 (.012) 0.30 (.012) 0.56 (.022) 1.16 (.046) 1.16 (.046) 0.64 (.025) 0.38 (.015) 0.51 (.020) 1.53 (.060) 1.53 (.060)
0.53 (.021) 0.64 (.025) 1.17 (.046) 1.17 (.046) 0.45 (.018) 0.45 (.018) 0.64 (.025) 1.54 (.061) 1.54 (.061)
0.64 (.025) 0.38 (.015) 0.53 (.021) 1.55 (.061) 1.55 (.061)
0.38 (.015) 0.40 (.016) 0.40 (.016) 1.18 (.047) 1.18 (.047) 0.64 (.025) 0.38 (.015) 0.53 (.021) 1.55 (.061) 1.56 (.061)
0.38 (.015) 0.38 (.015) 0.43 (.017) 1.19 (.047) 1.19 (.047) 0.61 (.024) 0.40 (.016) 0.56 (.022) 1.57 (.062) 1.57 (.062)
0.56 (.022) 0.64 (.025) 1.20 (.047) 1.20 (.047) 0.64 (.025) 0.38 (.015) 0.56 (.022) 1.58 (.062) 1.58 (.062)
0.64 (.025) 0.38 (.015) 0.56 (.022) 1.58 (.062) 1.59 (.062)
0.30 (.012) 0.40 (.016) 0.51 (.020) 1.21 (.048) 1.21 (.048) 0.64 (.025) 0.40 (.016) 0.56 (.022) 1.60 (.063) 1.60 (.063)
0.64 (.025) 0.25 (.010) 0.33 (.013) 1.22 (.048) 1.22 (.048)
VMR2004_144_06_02A.FM 06-02-13
FRONT PROPELLER SHAFT DISCONNECT UNIT

Removal Test
Remove: Remove RH inner fender.
– RH footwell Unplug disconnect unit connector.
– RH inner fender Using an voltmeter, check if the selector works
– RH drive shaft no. 7 properly.
– both external Oetiker clamps no. 10 (discard Turn ignition key ON.
them) Select 2WD position, install the RED probe to the
WHITE wire connector and the BLACK probe to
the WHITE/BLACK wire connector. The obtained
value should be 12 Vdc.
Select 4WD position, install the RED probe to the
WHITE/BLUE wire connector and the BLACK
probe to the WHITE wire connector. The obtained
value should be 12 Vdc.
If the selector is out of specifications, check wires,
connectors and replace the selector if necessary.
If the selector is good, replace the actuator no. 27.
Removal
V07H0IA 1 Remove front propeller shaft no. 11.
1. Remove these clamps
Unplug disconnect unit connector and 2WD/4WD
– differential mounting bolts no. 12. switch connector.
Pull differential no. 8 back then separate propeller
shaft no. 11 from differential and disconnect unit
no. 26.
Inspection
Check:
– splines for wear or damage
– bellows for holes or brittleness.
Installation
Installation is the reverse of removal procedure.
V07H0JA
Unscrew bolts no. 28 retaining the disconnect

unit no. 26 to the engine.
Pull out the disconnect unit.
06-02-14 VMR2004_144_06_02A.FM
Disassembly – pin no. 32

2WD/4WD Switch
Unscrew switch then remove it along with the
sealing washer.
V07H0KA 1
1. Sealing ring
Actuator
Remove the three (3) bolts no. 29 retaining the ac-
tuator no. 27 to the disconnect unit housing no. 26. V07H0NA
Separate actuator from housing.

– sliding sleeve no. 33
Disconnect Unit Housing
Remove:
– oil seal no. 30
– Allen screw no. 31
V07H0OA
V07H0MA 1
1. Allen screw
VMR2004_144_06_02A.FM 06-02-15
– shifter plate no. 34 – outer circlip no. 36
V07H0PA V07H0RA 1
1. Outer circlip
– coupling sleeve no. 35
– inner circlip no. 37
V07H0SA 1
1. Inner circlip
– shaft no. 38.

Using a suitable puller, remove the ball bearing
no. 39.
V07H0QA
NOTE: Remove the ball bearing only if it does not
turn freely and smoothly.
06-02-16 VMR2004_144_06_02A.FM
Inspection Check sliding sleeve dog for bend and measure it.
Check disconnect unit housing and actuator for SLIDING SLEEVE DOG THICKNESS
cracks or other damages. Replace defective
part(s) if necessary. SERVICE LIMIT 4.80 mm (.189 in)
Check if the O-rings no. 40 and no. 41 are brittle,
hard or damaged. Measure the sliding sleeve groove.
Check splines of coupling sleeve no. 35 for wear SLIDING SLEEVE GROOVE WIDTH
or other damages.
V07H0TA
Measure the coupling sleeve groove. If the width

of groove is out of specification replace the cou- V07H0WA B
pling sleeve. A. Sliding sleeve dog thickness
B. Sliding sleeve groove width
COUPLING SLEEVE GROOVE WIDTH Check shifter plate for visible damages, wear or
SERVICE LIMIT 5.00 mm (.197 in) bent claws.
Measure the shifter plate claws thickness.
A SHIFTER PLATE CLAWS THICKNESS
V07H0XA
V07H0UA
A. Shifter plate thickness
A. Groove width
VMR2004_144_06_02A.FM 06-02-17
Check inner and outer shaft splines for wear or Insert pin and install Allen screw.
other damages. Replace shaft if necessary. Check if the shifter plate and the coupling sleeve
Measure shaft for wear limit. are installed properly.
When the sliding sleeve is positioned on left side,
SHAFT
the coupling sleeve is equal with the end of the
SERVICE LIMIT 29.995 mm (1.181 in) shaft splines.
A
V07H0YA
A. Shaft diameter in the area of bearing
Assembly
The assembly is the reverse of the disassembly
procedure. Pay attention to the following details.
Apply engine oil on moving parts.
Install the shifter plate and coupling sleeve as per
the following illustrations.
V07H12A
V07H0ZA
06-02-18 VMR2004_144_06_02A.FM
Move the sliding sleeve on right side and check if CAUTION: Do not cut or break the O-ring. Ap-
the coupling sleeve is flush with the end of shaft. ply a small amount of engine oil on O-ring.
Turn the actuator counterclockwise to position ac-
tuator holes with threaded holes. Screw actuator
on housing.
V07H19A
Installation
V07H15A The installation is the reverse of removal proce-
dure.
To install the actuator on housing, align the fork
with the sliding sleeve dog. Push the actuator in
the housing. At this moment the actuator is posi-
tioned as per following illustration.
V07H18A
VMR2004_144_06_02A.FM 06-02-19
Subsection 03 (REAR AXLE)
REAR AXLE 0
Outlander MAX and
1 Outlander MAX XT
2
250 Nm 3 5
(184 lbfft) 4
Loctite
271
185 Nm 6
(136 lbfft) 1
2
3 5 9
4
Outlander and 6
Outlander XT
10 80 Nm
(59 lbfft)
Synthetic 9 13
grease 14 15 23 Nm
34 Nm 18 (17 lbfft)
(25 lbfft) 16
17 Synthetic grease 12
18 112 Nm 80 Nm
Synthetic grease 7
19 2.5 Nm
(22 lbfin) 8 9
11
20
34 Nm 22 23
(25 lbfft)
150 Nm 29
10 (111 lbfft)
28
25 21
24 27 7 Nm
26 (62 lbfin)
Loctite 243
V07H24S
VMR2004_145_06_03A.FM 06-03-1
GENERAL REAR DIFFERENTIAL OIL

At installation, use torque values and Loctite prod- REPLACEMENT
ucts from the exploded view. Clean threads before Ensure vehicle is on a level surface.
using Loctite products when reinstalling screws.
Clean drain plug area.
 WARNING Place a drain pan under rear differential drain plug
Torque wrench tightening specifications area.
must strictly be adhered to. Unscrew filler plug.
Locking devices (ex.: locking tabs, elastic Remove drain plug.
be installed or replaced with new ones 2
REAR DIFFERENTIAL OIL LEVEL

Place bottom of frame horizontally.
Clean filler plug prior to check oil level. Check oil
level by removing filler plug. Oil level must reach
lower edge.
1 1
V07H26B
1. Drain plug
2. Filler plug
Clean drain plug area then reinstall drain plug.

Use a funnel and refill rear differential at the proper
level with recommended oil.
Reinstall filler plug.
WHEEL HUB
Removal
V07H26A
Outlander and Outlander XT Models

1. Filler plug
Remove:
Add oil if necessary.
– appropriate wheel
MODEL CAPACITY RECOMMENDED OIL – wheel cap no. 1
Bombardier differential – cotter pin no. 2
All 300 mL oil (P/N 293 600 043) or – castellated nut no. 3
models (10 U.S. oz) REDLINE pump oil
75W90 (API GL5) – washer no. 4
– wheel hub no. 5.
NOTE: If necessary, use the wheel hub puller (P/N
529 035 612).
06-03-2 VMR2004_145_06_03A.FM
Outlander MAX and Outlander MAX XT

Models
Remove:
– wheel cap no. 1
– cotter pin no. 2 (discard)
– castellated nut no. 3 (discard)
– washer no. 4.
Using a propane torch, heat the wheel hub no. 5
around its center. Do not overheat.
1 V07H1SA 2 1
1. Wheel hub
2. Wear ring
Installation
Outlander and Outlander XT Models
dure.
Outlander MAX and Outlander MAX XT
Models
Remove all Loctite deposits on splines (shaft and
hub) with a copper brush.
After Loctite removal, clean splines with
V07H25A
Bombardier pulley flange cleaner (P/N 413 711
809).
1. Heat this section
Apply Loctite primer N (P/N 293 800 041) on shaft
Install the wheel hub puller (P/N 529 035 612) then splines and allow to dry for 30 seconds.
remove the wheel hub no. 5. Apply a thick coat of Loctite 271 (P/N 293 800 005)
on splines.
Inspection
Install the wheel hub, the washer and a new cas-
Check wheel hub for cracks or other damages. tellated nut. Tighten castellated nut to the specific
Check inner splines for wear or other damages. torque, 250 N•m (184 lbf•ft), and further tighten
If any damage is detected on wheel hub, replace until its grooves align with cotter pin hole.
it with a new one. CAUTION: Always use the recommended washer
Check wear ring no. 6. If wear is evident, replace and castellated nut. Using other nuts can cause
the wear ring. hub damage.
NOTE: The castellated nut must be changed to
avoid using a warped one.
Install a new cotter pin then the wheel cap.
VMR2004_145_06_03A.FM 06-03-3
DRIVE SHAFT PROTECTORS Installation

Removal Insert the end of drive shaft in differential and pull
joint a little to make sure that the stop ring no. 11
Wheel Side is locked in differential gear groove.
Using a 3/16 in drill, remove the pop rivets retain-
ing the protector to the trailing arm.
Central
Remove bolts no. 7 retaining the protector no. 8
to the hitch.
Installation
dure.
DRIVE SHAFT
V01H0FA 1
Removal 1. Stop ring
Remove the appropriate wheel hub and the foot-
NOTE: Make sure that you do not interchange LH
well on this side.
and RH drive shafts. The wear rings are not posi-
Near trailing arm and frame junction, remove: tioned at the same distance.
– protective cap Install the other parts in the reverse order of re-
– elastic nut moval procedure. Refer to the appropriate sec-
tions to apply the proper torque.
– washer
Reinstall wheel and torque nuts to 70 N•m
– torsion bar lever
(52 lbf•ft).
– lower shock absorber bolt.
CAUTION: Always use the recommended wheel
Remove trailing arm. nuts (P/N 250 100 039). Using other nuts can cause
Pull drive shaft no. 9 out of differential no. 10. rim damage.
NOTE: Pull drive shaft strongly.
DRIVE SHAFT BOOT
Inspection
Removal
Inspect the condition of boots. If there is any dam-
age or evidence of leaking lubricant, replace them. Remove:
Refer to DRIVE SHAFT BOOT section. – clamps from rubber boot using boot clamp pliers
Check shaft splines. Replace drive shaft if necessary. (P/N 295 000 069 and 295 000 054)
Check wear ring on drive shaft end. Replace if nec- – large end of the boot from plunging joint or CV
essary. See special procedure further. joint.
06-03-4 VMR2004_145_06_03A.FM
Move apart circlip and pull out the shaft from bear-
ing. Do not remove circlip.
V07H1TA
V01H0XA 2 1 Installation
1. Circlip The LH and RH wear rings are not installed at the
2. Shaft same distance. To install the wear rings properly,
Remove boot from drive shaft. use the wear ring installer (P/N 529 035 915).
Use the proper side of installer depending which
Inspection drive shaft is used.
Check bearing in plunging joint or CV joint. If bear-
ing is hard to move, change plunging joint or CV
joint.
Check circlip for damage, change as necessary. 1 2
Installation
Pay attention to the following details. V07H1UA
Insert boot, do not forget the small clamp. 1. For the LH drive shaft
2. For the RH drive shaft
Insert shaft and push firmly.
Pack bearing area with grease (including with the REAR PROPELLER SHAFT
new boot kit).
NOTE: Do not use any other grease. Removal
Install a jack stand under rear differential to sup-
DRIVE SHAFT WEAR RING port the vehicle during the procedure.
Remove:
Removal – LH rear wheel
Place a long 30 mm socket in vise then insert the – LH lower shock absorber bolt
end of drive shaft into the socket.
– caliper bolts
Using a punch, extract the wear ring.
CAUTION: Do not let caliper hang by the hose
and do not stretch or twist hose.
– central protector no. 8
VMR2004_145_06_03A.FM 06-03-5
– lower differential bolts no. 12 Removal

– hitch. Remove internal snap ring from bearing caps.
Reinstall the lower differential bolts. Do not torque.
Remove:
– upper differential bolts no. 13
– rear propeller shaft bolt no. 14 and washer no. 15
NOTE: During this procedure, remove the lower
differential bolts to move the differential back-
wards to allow a complete removal of propeller
shaft bolt.
– RH footwell
– front propeller shaft screw no. 16 and washer
no. 17.
Unplug the propeller shaft no. 18 from the differ-
V01H0YA 1
ential then remove it from vehicle.
1. Snap ring
Inspection Support inner yoke in vice and drive other yoke down
Check yoke U-joint no. 19 for wear, backlash or with a soft hammer.
axial play, replace if necessary.
Inspect engine seal for damage or leak. Replace if
necessary.
Inspect disc brake (refer to HYDRAULIC BRAKES).
Installation
Installation is essentially the reverse of removal
procedure. Pay attention to the following details.
Apply grease to splines from engine.
Install the front propeller shaft bolt and torque it to
34 N•m (25 lbf•ft).
Apply grease (P/N 293 550 019) to splines before
insert the end of the propeller shaft into differential. V01H0ZA
Torque bolt to 34 N•m (25 lbf•ft).

Support U-joint in vice and drive inner yoke down
Reinstall all other removed parts. to remove remaining bearing caps.
Grease U-joint from rear propeller shaft. Use a Remove U-joint cross.
grease gun with SHELL, Alvania EP-2 grease only.
Installation
REAR PROPELLER SHAFT Install new U-joint cross in inner yoke.
U-JOINT Install new bearing cap by hand.
Remove the disc brake before working on differ- NOTE: Carefully install U-joint cross with grease
ential side of propeller shaft. fitting properly positioned.
06-03-6 VMR2004_145_06_03A.FM
REAR DIFFERENTIAL
Removal
Install a jack stand under differential to support the
vehicle during the following procedure.
Remove:
– rear wheels
– trailing arms
– drive shafts
V01H10A – central protector no. 8
– lower differential bolts no. 12
Tighten vise to force bearing caps in.
– hitch
– upper differential bolts no. 13
– rear propeller shaft bolt no. 14 and washer
no. 15
– differential no. 10.
Disassembly
Ring Gear Removal
To change ring gear no. 20:
– Unscrew the drain plug no. 21 and empty dif-
ferential.
V01H11A – Unscrew the TORX screws no. 22, then sepa-
rate half housings.
Using a suitable tappet, fully seat bearing cap in
– Extract ring gear out of half housing.
one side. Continually, check for free movement of
bearing cross as bearing caps are assembled. NOTE: Keep track of shims on each end of gear.
To assembly, reverse the removal procedure. Paying
attention to the following details.
NOTE: If pinion gear, ring gear, housing or bearing
is (are) changed, recenter the ring gear in the hous-
ing before final assembly. See PINION GEAR AND
RING GEAR RECENTERING below.
Verify condition of half housing seal no. 23. Change
seal if necessary.
Check all bearings and all oil seals. Change them
if necessary.
V01H12A
Install snap ring.

Repeat procedure for other sides.
Grease U-joint, using a grease gun with SHELL,
Alvania EP-2 grease only.
VMR2004_145_06_03A.FM 06-03-7
Pinion Gear Removal Pinion Gear and Ring Gear Recentering

Unscrew bolt retaining the inserting tube to differ- NOTE: All measurements require great care and
ential. absolute cleanliness if accurate results are to be
Remove oil seal no. 24. obtained.
Unscrew the pinion nut no. 25. Use the differen- First; center pinion gear.
tial spanner socket (P/N 529 035 649). Measure distance between pinion gear surface to
Remove the bearing no. 26 at the same time as low point of carrier bearing. This is measure “A”.
the pinion gear no. 27.
NOTE: The pinion gear and bearing can be easily
removed using the following suggested tool:
– pipe 3-1/2 in diameter x 5 in (1)
– screwed rod M10 x 1.25, 7 in length (1)
– nut M10 x 1.25 (3)
– flat bar (1).
To install, reverse the removal procedure. Pay at-
tention to the following details.
Check O-ring no. 28 for damage. If so, change it.
Install the shim no. 29 then the ball bearing.
NOTE: If pinion gear, ring gear, housing or bearing A
is (are) changed, recenter the ring gear in the hous-
ing before final assembly. See below.
Install the nut and a new oil seal.
V01H1KA
The measure “B” is a given value of 64.450 mm

(2.5374 in).
Subtract the largest value of “A” or “B” by the
smallest value. This result is the value “C”.
06-03-8 VMR2004_145_06_03A.FM
Locate value “C” in the following chart and select the proper shims.
SHIM PACK
VALUE “C” SHIM QUANTITY x SHIM THICKNESS
THICKNESS
2 x 0.51 mm (.020 in)
0.076 to 0.124 mm (.0030 to .0049 in) 1.58 mm (.0622 in)
1 x 0.56 mm (.022 in)
2 x 0.51 mm (.020 in)
0.127 to 0.175 mm (.0050 to .0069 in) 1.58 mm (.0622 in)
1 x 0.56 mm (.022 in)
1 x 0.51 mm (.020 in)
0.177 to 0.226 mm (.0070 to .0089 in) 1.63 mm (.0642 in)
2 x 0.56 mm (.022 in)
1 x 0.25 mm (.010 in)
2 x 0.51 mm (.020 in)
1 x 0.25 mm (.010 in)
1 x 0.38 mm (.015 in)
0.330 to 0.378 mm (.0130 to .0149 in) 1.7 mm (.0669 in)
1 x 0.51 mm (.020 in)
1 x 0.56 mm (.022 in)
1 x 0.25 mm (.010 in)
2 x 0.56 mm (.022 in)
1 x 0.25 mm (.010 in)
1 x 0.56 mm (.022 in)
The total thickness of shim pack is 1.65 mm (.0649 in).

SHIM THICKNESS/SHIM NOTCH(ES)
Install pinion, shims, bearing and pinion nut. Apply
THICKNESS NOTCHES Loctite 243 to nut and torque to 98 N•m (72 lbf•ft).
0.25 mm (.010 in) 0 After pinion installation, center ring gear.
Take the half housing with pinion gear. Measure
0.38 mm (.015 in) 1
distance between housing edge and the inner ring
0.51 mm (.020 in) 2 of bearing. This is measure “D”.
0.56 mm (.022 in) 4
Example:
The measure “A” = 64.700 mm (2.5472 in).
The measure “B” (given) = 64.450 mm (2.5374 in).
A-B=C
The result “C” is 0.250 mm (.0098 in).
In accordance with the previous table, find the re-
sult “C” and choose the proper shims:
• 1 x 0.25 mm (.010 in)
• 1 x 0.38 mm (.015 in)
V04H09A
• 2 x 0.51 mm (.020 in).
TYPICAL
VMR2004_145_06_03A.FM 06-03-9
Measure the other half housing between housing Measure ring gear carrier length. This is measure
edge and the inner ring of bearing. This is measure “H”.
“E”.
V04H0AA
TYPICAL
V04H0CA
Measure the edge of half housing. This is measure
TYPICAL
“F”.
Measure the distance between the end of ring
gear and the bearing shoulder. Note this measure
“J”.
V04H0BA
TYPICAL
Subtract the measure “F” from measure “E” then

add this result to “D”. Note this result “G”.
D + (E - F) = G (housing inside length) V04H0DA
TYPICAL
06-03-10 VMR2004_145_06_03A.FM
Take the same distance to the other end. This is

measure “K”.
V04H05A
TYPICAL
Add measure “J” from measure “K”. Subtract

this result from measure “H”. Note this result
“L”.
The result “L” is the length of ring gear carrier be-
tween bearings.
H - (J + K) = L
Subtract result “L” from “G”. At this measure
subtract the clearance 0.127 mm (.005 in). The re-
sult is the shim thickness.
G - L = M - 0.127 mm (.005 in) = shim thickness
CAUTION: Do not use the previous table to se-
lect shims. The previous table must be used to
choose the pinion gear shims only.
Determine the appropriate shim.
SHIM THICKNESS/SHIM NOTCH(ES)

THICKNESS NOTCHES
0.25 mm (.010 in) 0
0.38 mm (.015 in) 1
0.51 mm (.020 in) 2
0.64 mm (.025 in) 3
0.56 mm (.022 in) 4
Distribute total shim thickness between both end

of ring gear carrier to obtain specified backlash be-
tween ring gear and pinion gear.
VMR2004_145_06_03A.FM 06-03-11
F
E
K
J
D
V01H1LS
Assembly and Installation

The rear differential assembly is essentially the reverse of the disassembly procedure. Paying attention
to the following detail.
Install the rear differential on the vehicle before filling oil. Use specified oil, refer to TECHNICAL DATA.
06-03-12 VMR2004_145_06_03A.FM
Section 07 STEERING/CONTROL SYSTEMS
TABLE OF CONTENTS 0
STEERING SYSTEM .............................................................................................................. 07-02-1
GENERAL ........................................................................................................................... 07-02-2
HANDLEBAR GRIP ............................................................................................................ 07-02-2
HANDLEBAR COVERS ...................................................................................................... 07-02-2
HANDLEBAR ...................................................................................................................... 07-02-3
STEERING COLUMN ......................................................................................................... 07-02-3
TIE-ROD.............................................................................................................................. 07-02-4
TOE ADJUSTMENT ........................................................................................................... 07-02-4
STEERING COLUMN BEARING........................................................................................ 07-02-6
KNUCKLE ........................................................................................................................... 07-02-6
WHEEL BEARING .............................................................................................................. 07-02-7
MULTI-FUNCTION SWITCH ............................................................................................. 07-02-8
THROTTLE HANDLE.......................................................................................................... 07-02-9
HANDLE BRAKE ................................................................................................................ 07-02-10
VMR2004_154_07_01ATOC.FM 07-01-1
Section 07 STEERING
Subsection 02 (STEERING SYSTEM)
STEERING SYSTEM 0
XT 2.5 Nm
(29 lbfin)
2 Nm
5 (18 lbfin)
STD 8 7
2 Nm
5 2 Nm (18 lbfin)
(18 lbfin) 9
4
10
1
3 2
0.5 Nm
9 (4 lbfin)
22 Nm (16 lbfft) Loctite 406
18 14
17 18
24 Nm
16 (18 lbfft)
20 19 Synthetic
15 21 grease
22
20
21
22 34 Nm
26 75 Nm 22 (25 lbfft)
22 (55 lbfft) 27
21 15
20
23
24
2X4
75 Nm 25 22
(55 lbfft) 10 Nm
12 (89 lbfin)
26 21
13 20 2X4
11 26
26
V07I17S
VMR2004_146_07_02A.FM 07-02-1
Section 07 STEERING
GENERAL HANDLEBAR COVERS

During assembly/installation, use the torque val- Removal
Front Handlebar Cover
fer to SELF-LOCKING FASTENERS and LOCTITE AP- Remove screws no. 4.
plete procedure
 WARNING
be installed or replaced with new ones
V07L07A 1 1
TYPICAL
HANDLEBAR GRIP 1. Handlebar cover screws
Removal Separate the front handlebar cover no. 5 from the

rear handlebar cover no. 6.
Loosen the screw no. 2 at the end of handlebar
grip no. 1.
Remove the handlebar grip cap no. 3.
Cut and remove the handlebar grip.
Installation
Remove all rubber residues of the old grip before
installing the new.
Clean the handlebar with pulley flange cleaner
(P/N 413 711 809) or alcohol to remove any greasy
matter on it.
Install handlebar grip by blowing compressed air
between handle grip and handlebar.
Install Smoothflow™ tapered tip on Loctite 406
V07L08A
glue bottle (P/N 293 800 095).
Lift a part of the grip using a metal tool and inject
Loctite 406 (about 4 spots per side).
NOTE: The Loctite 406 dries quickly. Do not apply
Loctite before installing grip.
Apply pressure on the grip for approximately
30 seconds to set the glue.
Install the handlebar grip cap and torque screw
0.5 N•m to 1.0 N•m (4 lbf•in to 9 lbf•in).
07-02-2 VMR2004_146_07_02A.FM
Section 07 STEERING
Rear Handlebar Cover HANDLEBAR

Remove:
– front handlebar cover Removal
– screws no. 7. Remove:
– handlebar covers no. 5 and no. 6
– handlebar grips no. 1
– brake handle
(see below in this section)
– throttle handle and multi-function switch
(see below in this section)
NOTE: Remove handlebar grips, throttle handle
and multi-function switch only if the handlebar is
defective and replace with a new.
– steering clamp mounting bolts no. 8 and steer-
ing clamp no. 9
– handlebar no. 10.
Inspection
V07L09A 1
Inspect the handlebar for damage, cracks or bend-
TYPICAL ing, replace if any of these problems is detected.
1. Rear cover screws
Unplug the speedometer. Installation

STEERING COLUMN
Removal
Remove:
– front fender (refer to BODY)
– front handlebar cover
– handlebar (if necessary)
– cotter pin no. 11 (discard), elastic nut no. 12
and flat washer no. 13 to bottom end of steer-
ing column no. 14.
Separate steering column and tie-rods no. 15. Re-
V07I0LA
fer to TIE-ROD, further in this section.
Remove half bushing bolts no. 16, stopper plate
Inspection no. 17, half bushing no. 18 and bushings no. 19.
Check covers for cracks or other damages. Replace Pull out steering column.
if necessary.
Inspection
Installation Inspect steering column for damage, cracks or bend-
The installation is the reverse of removal proce- ing, replace if any of these problems is detected.
dure.
Installation
VMR2004_146_07_02A.FM 07-02-3
Section 07 STEERING
NOTE: Install a new cotter pin. Both ends of cotter TOE ADJUSTMENT
pin must be folded.
Place vehicle on level surface.
TIE-ROD Check that handlebar is straight.
NOTE: Use the same procedure for RH and LH Check pressure in each tires. Always follow rec-
side. ommended pressure.
Place a rope around the vehicle and using an elas-
Removal tic, link both ends together.
Place the vehicle on jack stands and remove the Install spacers on rear rims. These spacers will
appropriate wheel. prevent the rope from touching the tires.
Remove cotter pin no. 20 (discard), elastic nut
no. 21 and hardened washers no. 22.
Inspection
Inspect ball joint ends for wear or looseness, if ex-
cessive, replace.
Installation
For the installation, reverse the removal proce- 1
dure. Pay attention to the following details.
When installing a tie-rod, screw threaded end of
tie-rod into ball joint. The maximum length for tie-
rod groove to ball joint end must match value A in
the following chart:
A A V01I1EA 2
TYPICAL
B 1. Rear wheel
V07I0MA 2. Spacers
NOTE: Many items can be used as spacers. Mag-

MODEL A B nets are recommended.
mm 17 ± 5 354 ± 1
ALL 13-15/16
in .67 ± .20
± .039
NOTE: Torque the ball joint lock nut no. 27 to

34 N•m (25 lbf•ft).
Install a new cotter pin. Both ends of cotter pin
must be folded.
07-02-4 VMR2004_146_07_02A.FM
Section 07 STEERING
The rope must be place at the center of the wheels.

Do not place rope on tire threads.
V01I1FA
TYPICAL
V01I1HA
From the front of vehicle, near the front of rim,
move rope so that it does not touch the first spacer. TYPICAL
Keep this position and measure the distance be-

tween the rope and the rim, to the front and to the
rear of wheel.
V01I1GA
TYPICAL
Then, bring the rope back until it touches the spacer.
V01I1KA
TYPICAL
VMR2004_146_07_02A.FM 07-02-5
Section 07 STEERING
The perfect total toe-out adjustment is 0 mm ±

4 mm (0 in ± .157 in) each side.
Set alignment of wheel by adjusting tie-rod.
STEERING COLUMN BEARING

Removal
Place vehicle on jack stands and remove one wheel.
Remove front fender and console. Refer to BODY.
Separate tie-rods no. 15 from steering column
no. 14. Refer to TIE-ROD section.
V07I0OA 1 2
1. Flanged collar
2. Bearing
Install bolts no. 23.

Install the steering column, flat washer, elastic nut
and a new cotter pin. Both ends of cotter pin must
be folded.
KNUCKLE
Removal
Place vehicle on jack stands and remove the ap-
propriate wheel.
V07I0NA
Separate tie-rod no. 15 from knuckle no. 26.
TYPICAL
Remove cotter pin no. 11, elastic nut no. 12 and

flat washer no. 13 to bottom end of steering col-
umn no. 14.
Pull up steering column.
Remove bolts no. 23 and bearing flanges no. 24.
Remove bearing no. 25.
Installation
Place flanged collar outward.
NOTE: Install both bearing flanges on top of frame
support. V07I0PA
TYPICAL
07-02-6 VMR2004_146_07_02A.FM
Section 07 STEERING
Remove: Installation
– wheel hub (refer to FRONT DRIVE) The installation is the reverse of removal proce-
– bolt retaining the ball joint to the knuckle dure.
WHEEL BEARING
Inspection
Raise the front of vehicle.
Hold the wheel by the top and the bottom and
move it. Check for lateral play.
If there is any loose, replace the wheel bearing.
NOTE: First, check if ball joint is loose. If neces-
sary repair all defective parts before checking the
wheel bearing condition. Be careful not to mis-
judge loose in the ball joint and loose in the wheel
bearing.
V07I0QA
Removal
– strut bolts Remove:
– knuckle, (see above)
– seal (discard)
V07J0BA
TYPICAL
– knuckle.
Inspection
V07I0RA
Check knuckle for cracks or other damages. Re-
place if necessary.
Check if wheel bearings turn freely and smoothly.
See WHEEL BEARING below if the replacement
is necessary.
VMR2004_146_07_02A.FM 07-02-7
Section 07 STEERING
– circlip. Removal
1 Remove choke cable from multi-function switch.
Refer to CARBURETOR for procedure.
Remove bolts.
V07I0SA
1. Circlip
Using a press machine, push the bearing out of

knuckle.
NOTE: It may be necessary to heat the knuckle to
remove the bearing. Clean all grease before heat-
ing. V07I0TA 1
1. Remove the bolts
 WARNING Separate multi-function switch from handlebar
Clean all grease, outside and inside, from no. 10.
knuckle before heating it.
Remove console. Refer to BODY.
Unplug multi-function switch connector. The con-
Installation nector is located under console.
Place the bearing in a freezer for 10 minutes be-
fore installing.
Place the knuckle in oven to 100°C (212°F) for
30 minutes maximum to ease bearing installation.
When knuckle is cold, install the circlip and the
new seal.
Install the other parts in the reverse order of re-
moval procedure.
MULTI-FUNCTION SWITCH
Test
Refer to INSTRUMENTS AND ACCESSORIES for
V07I0UA 1
Hi-Lo Beam button.
UNDER CONSOLE
Refer to STARTING SYSTEM for engine stop 1. Unplug these connectors
switch and start button.
07-02-8 VMR2004_146_07_02A.FM
Section 07 STEERING
Installation Screw in the throttle cable adjuster.

For installation, reverse the removal procedure. Remove inner housing protector.
NOTE: Install choke cable and adjust it. Refer to
CARBURETOR.
THROTTLE HANDLE
Removal
Remove screws.
1
V07I0HA 1
1. Inner housing protector
Remove throttle cable from housing.
V07I0FA
1. Remove screws
Separate throttle handle from handlebar no. 10.

Slide rubber protector back to expose throttle cable
adjuster.
V07I0IA
Slide cable in clip slot and remove the end of the

cable from clip.
Installation
V07I0GA 1 2 3 4 Refer to CARBURETOR for adjustment procedure.
1. Cable protector
2. Throttle cable adjuster
3. Lock nut
4. Throttle lever housing
VMR2004_146_07_02A.FM 07-02-9
Section 07 STEERING
HANDLE BRAKE
Removal
Remove screws.
V07I0VA 1
1. Remove the screws
Separate handle brake from handlebar no. 10.
Hose Removal
Refer to HYDRAULIC BRAKES for specifics in-
structions.
Installation
07-02-10 VMR2004_146_07_02A.FM
Section 08 SUSPENSION
TABLE OF CONTENTS 0
FRONT SUSPENSION ........................................................................................................... 08-02-1
GENERAL ........................................................................................................................... 08-02-2
STRUT-TYPE FRONT SUSPENSION ................................................................................ 08-02-2
LOWER SUSPENSION ARM PROTECTOR ...................................................................... 08-02-3
LOWER SUSPENSION ARM ............................................................................................. 08-02-4
BALL JOINT ....................................................................................................................... 08-02-5
REAR SUSPENSION............................................................................................................. 08-03-1

GENERAL ........................................................................................................................... 08-03-2
REAR SHOCK ..................................................................................................................... 08-03-2
TORSION BAR.................................................................................................................... 08-03-3
TRAILING ARM .................................................................................................................. 08-03-4
TRAILING ARM BEARINGS .............................................................................................. 08-03-5
VMR2004_154_08_01ATOC.FM 08-01-1
Subsection 02 (FRONT SUSPENSION)
FRONT SUSPENSION 0
5
3
6 4
55 Nm Loctite 243
(41 lbfft)
3
7 Loctite 243
4 55 Nm
(41 lbfft)
2
12
48 Nm
(35 lbfft)
80 Nm 1
4 X 4 Models only (59 lbfin)
80 Nm
4 Nm (59 lbfft)
(35 lbfin) Synthetic 2
grease
15
14 48 Nm
12 (35 lbfft)
48 Nm
(35 lbfft)
23 Nm 4 X 4 Models only
(17 lbfft)
13 11 4 Nm
(35 lbfin)
11
15
48 Nm 10
(35 lbfft)
9 48 Nm 14
(35 lbfft) 8
4 X 4 Models only
48 Nm
(35 lbfft) 9
23 Nm
V07J0GS
4 X 4 Models only (17 lbfft)
VMR2004_147_08_02A.FM 08-02-1
GENERAL – circlip no. 3

– strut nut no. 4.
The procedure explained below is the same for the
RH and LH sides unless otherwise noted.
ues and service products as in the exploded view.
complete procedure
 WARNING
be installed or replaced with new ones
V07J03A 2 1
STRUT-TYPE FRONT 1. Circlip

2. Strut nut
SUSPENSION NOTE: To unscrew the strut nut, use the 41 mm
socket for Traxter swing arm nut.
Removal
Separate strut from knuckle.
Loosen wheel nuts.
Lift front of vehicle until front struts no. 1 are fully Disassembly
extended then install a jack stand under the frame
For shock spring disassembly use shock spring re-
to support the vehicle off the ground.
mover (P/N 529 035 504) and adaptor kit (P/N 529
Remove: 035 928) in a vise.
– wheel Install the adaptor kit on shock spring remover or
– front rack if the kit is already installed, place the right spring
support outside of support arm.
– bolts no. 2 retaining strut to the knuckle
V07J02A
TYPICAL
08-02-2 VMR2004_147_08_02A.FM
– A skip or hang up when reversing stroke at mid

travel.
– Seizing or binding conditions except at extreme
end of either stroke.
– A gurgling noise after completing one full com-
pression and extension stroke.
Replace strut if any of these conditions are found.
1
Installation
For assembly, reverse the disassembly and removal
2 procedures.
NOTE: Do not interchange left and right tires. The
tires are directional and their rotation must be kept
in a specific direction for proper operation.
V07J04A
1. Right spring support

2. Support arm
Place the vertical lever in the second handle hole.
V07J06A
DIRECTION OF ROTATION
V07J05A 2 1 Torque wheel nuts to 70 N•m (52 lbf•ft) in a criss-
1. Vertical lever cross sequence.
2. Handle
Mount shock in it and turn shock so that spring LOWER SUSPENSION ARM
coils matches spring compressor. PROTECTOR
Close and lock the bar. Adjust the handle horizontal
4 X 4 Models Only
position by changing the position of the clevis pin.
Push down on the handle until it locks. Remove Inspection
spring stopper no. 5 and no. 6 then release han-
dle. Check protector no. 8 for cracks or other damag-
es. Replace if necessary.
Inspection
Removal
Inspect the spring no. 7 for damage. Replace if
necessary. Remove screw no. 9 then the protector.
Inspect strut for oil leakage. Extend and compress Installation
the piston several times over its entire stroke.
Check that it moves smoothly and with uniform The installation is the reverse of removal proce-
resistance with rod up. Any of the following con- dure.
ditions will denote a defective strut:
VMR2004_147_08_02A.FM 08-02-3
LOWER SUSPENSION ARM

Inspection
Check lower suspension arms no. 10 for distor-
tion or damage. Replace suspension arms if nec-
essary.
Move suspension arm from side to side. There
should be no noticeable loose. Replace bushings
if necessary.
Move suspension arm up and down. There should
be no noticeable loose. Replace bushings if nec-
essary.
The following items are performed when the sus-
V07J08A 1 2 3 4
pension arm is removed.
TYPICAL
Inspect pivot bushings no. 11 for wear or damag-
1. Lower suspension arm
es. Replace bushings if necessary. 2. Ball joint bolt
3. Ball joint
4. Knuckle
Separate lower suspension arm from knuckle.

Remove bolts no. 13 retaining lower suspension
arm to frame.
V07J07A 1
TYPICAL
1. Pivot bushing
Check ball joint rubber on lower suspension arm

for cracks or any other damage. Inspect ball joint
end for damage. Ensure it’s moving freely. Replace
ball joints as required, see below for procedure. V07J09A 2 1 2
TYPICAL
Removal 1. Lower suspension arm
2. Remove bolts
Remove wheel.
Remove lower suspension arm from vehicle.
Remove bolt no. 12 retaining lower suspension
arm no. 10 to the knuckle. Installation
For assembly, reverse the disassembly proce-
dure. However, pay attention to the following.
Install lower suspension arm to frame.
Attach lower suspension arm no. 10 to knuckle.
Install wheel.
08-02-4 VMR2004_147_08_02A.FM
NOTE: Do not interchange left and right tires. The Removal

tires are directional and their rotation must be kept
Remove:
in a specific direction for proper operation.
– wheel
– lower suspension arm from knuckle
– bolts no. 15 retaining ball joint to lower suspen-
sion arm.
V07J06A
DIRECTION OF ROTATION
V07J0AA
Torque wheel nuts to 70 N•m (52 lbf•ft) in a criss-

cross sequence. Extract the ball joint by pulling it out of lower sus-
pension arm.
BALL JOINT
Installation
Inspection The installation is the reverse of removal procedure.
Check ball joint no. 14 for damage, pitting, loose-
ness and roughness. If so, replace ball joint.
Check ball joint rubber boot for cracks. Change if
necessary.
VMR2004_147_08_02A.FM 08-02-5
Subsection 03 (REAR SUSPENSION)
REAR SUSPENSION 0
9
8 10 Loctite
11
14 16 243
17
13
18
4 1 2
3
4
48 Nm Loctite 271
(35 lbfft)
12 Loctite 271
Loctite
243
3 4
1 1 48 Nm
(35 lbfft)
190 Nm
5 (140 lbfft) Loctite
16 243
6
11
19 10
14
7 8
V07H1YS
VMR2004_148_08_03A.FM 08-03-1
GENERAL Disassembly
The procedure described below is the same for Use shock spring remover (P/N 529 035 504) and
the RH and LH sides, unless otherwise instructed. put it in a vise.
During assembly/installation, use the torque val- Mount shock in it and turn shock so that spring coils
ues and service products as in the exploded views. no. 19 match spring compressor.
Clean threads before applying a threadlocker. Re- Close and lock bar. Adjust handle horizontal by
fer to SELF-LOCKING FASTENERS and LOCTITE changing position of clevis pin.
APPLICATION at the beginning of this manual for Push down on handle until it locks. Remove spring
complete procedure. stopper and cap then release handle.
 WARNING
Locking devices (ex.: locking tabs, elastic stop 1
stalled or replaced with new ones where spec- 2
ified. If the efficiency of a locking device is im-
paired, it must be renewed.
REAR SHOCK
Removal
Lift rear of vehicle until rear shock absorbers no. 1 3
are fully extended.
Install jack stands or blocks under the frame to
support the vehicle.
Remove upper no. 2 and lower no. 3 bolts and
nuts no. 4 retaining shock absorbers each side. A01B4LA
1. Clevis pin
2. Bar
3. Handle
At installation, cap opening no. 5 must be 180°

from spring stopper opening no. 6.
Inspection
Secure the shock body end no. 7 in a vise with its
rod upward.
A14F0BA
TYPICAL
1. Clamp here
V07H1CA
08-03-2 VMR2004_148_08_03A.FM
CAUTION: Do not clamp directly on shock body.

Examine each shock for leaks. Extend and com-
press the piston several times over its entire
stroke. Check that it moves smoothly and with uni-
form resistance with its rod upward.
Pay attention to the following conditions that will
denote a defective shock:
– A skip or a hang back when reversing stroke at
mid travel.
– Seizing or binding condition except at extreme
end of either stroke.
– Oil leakage.
– A gurgling noise, after completing one full com-
pression and extension stroke.
Renew if any faults are present.
V07H1GA 1 3 2
Installation
1. Elastic nut
Assembly and installation are essentially the re- 2. Washer
verse of disassembly and removal procedures. 3. Torsion bar lever
– torsion bar no. 12.

TORSION BAR
Inspection
Removal Check:
Apply parking brake and lift rear of vehicle until – torsion bar for cracks, bending or other damages
rear shock absorbers no. 1 are fully extended.
– splines for damages (torsion bar and torsion bar
Install a jack stand or blocks under the frame to lever)
safely support the vehicle.
– torsion bar lever tabs for racking, cracks or other
Remove: damages.
– rear wheels NOTE: If a tab is damaged, check the trailing arm
– both footwells no. 13 for damages.
– protective covers no. 8 Replace all damaged parts.
– clamp no. 14 (discard)
Installation
NOTE: Heat the elastic nut using a heat gun to
facilitate the removal. Clean the torsion bar splines using a heat gun.
– elastic nuts no. 9 (discard) Apply Loctite 271 (P/N 293 800 005) on both sides
of torsion bar splines.
– flat washers no. 10
Insert the torsion bar into the frame and install the
– torsion bar levers no. 11 torsion bar lever (one on each side).
VMR2004_148_08_03A.FM 08-03-3
NOTE: Ensure lever is aligned with the cut-outs Frame Side

on the swing arm and arrow is pointing up. Remove:
– protective covers no. 8
– clamp no. 14
– elastic nut no. 9 (discard)
– washer no. 10
– torsion bar lever no. 11
V07H1GB
Install the washer and a new elastic nut.

First torque the right hand side elastic nut to 55 N•m
(41 lbf•ft), then the left hand side to 120 N•m
(89 lbf•ft). V07H1IA
Reinstall both torsion bar covers with new clamps.

– trailing arm nut no. 16
TRAILING ARM NOTE: To remove the trailing arm nut, use the span-
ner wrench (P/N 529 035 925).
Removal
Apply parking brake and lift rear of vehicle until
rear shock absorbers no. 1 are fully extended.
Install a jack stands or a blocks under the frame to
safely support the vehicle.
Wheel Side
Remove:
– wheel cap
– cotter pin (discard)
– castellated nut V07H1JA
– washer
– lower bolt no. 3 of shock absorber
– wheel hub.
– trailing arm no. 13.
NOTE: Use the hub puller (P/N 529 035 612) if nec-
essary.
08-03-4 VMR2004_148_08_03A.FM
Inspection Torque the shock absorber bolt to 48 N•m (35 lbf•ft).

Check: Install wheel.
– trailing arms for cracks, bending or other damages CAUTION: Always use the recommended wheel
nuts (P/N 250 100 039). Using a different nut
– bearings for smooth and free operation.
could cause damages to the rim.
Replace all damaged parts.
TRAILING ARM BEARINGS
Installation
Insert drive shaft end into trailing arm. Inspection
Install the trailing arm on frame. Check inner race of each bearing no. 17 with your
Install the lower shock absorber bolt to support the finger. The bearings should turn smoothly and qui-
trailing arm. Do not torque yet. etly. Remove and discard bearings if race does not
turn smoothly or quietly.
Frame Side
Apply Loctite 243 on trailing arm nut threads. Removal
Install the trailing arm nut and torque it to 190 N•m The same procedure can be used for both bearings.
(140 lbf•ft). Apply a thin coat of Loctite MAXI- To perform the following, these tools are necessary.
COAT (P/N 293 800 105) on the remaining threads.
TOOLS
Install circlip, torsion bar lever, washer and a
new elastic nut. Torque the elastic nut to 120 N•m WHEEL SIDE
(89 lbf•ft). Trailing arm support 529 035 922
Install protective cap. Extractor/Installer 529 035 918
Wheel Side FRAME SIDE
Install: Trailing arm support 529 035 922
– wheel hub Extractor/Installer 529 035 920
– washer
– castellated nut. NOTE: Before extracting the bearing on wheel
side, remove the protector by drilling the pop riv-
Torque castellated nut to 185 N•m (136 lbf•ft) and ets with a 3/16” drill.
further tighten until its grooves align with the next
cotter pin hole. Remove the circlip no. 18.
Install a new cotter pin then the wheel cap.
NOTE: The longer end of cotter pin must be folded
over shaft end.
V07H1LA
V07H1KA
WHEEL SIDE
VMR2004_148_08_03A.FM 08-03-5
V07H1MA
V07H1OA
FRAME SIDE FRAME SIDE

Place the trailing arm support on the end of trailing Using a press and the bearing extractor/installer,
arm. remove the bearing.
V07H1NA
WHEEL SIDE
V07H1PA
WHEEL SIDE
08-03-6 VMR2004_148_08_03A.FM
V07H1QA
V07H1HA
FRAME SIDE
FRAME SIDE
Installation
Install the circlip. If the circlip is slacked, replace it
Clean the bearing housing. with a new.
Using the proper extractor/installer, push the bear-
ing in its location.
V07H1RA
WHEEL SIDE
VMR2004_148_08_03A.FM 08-03-7
Section 09 BRAKES
TABLE OF CONTENTS 0
HYDRAULIC BRAKES............................................................................................................ 09-02-1
GENERAL ........................................................................................................................... 09-02-3
PARKING BRAKE MECHANISM ....................................................................................... 09-02-3
BRAKE LEVER .................................................................................................................... 09-02-4
BRAKE FLUID..................................................................................................................... 09-02-4
MASTER CYLINDER .......................................................................................................... 09-02-6
CALIPER ............................................................................................................................. 09-02-9
BRAKE PADS ..................................................................................................................... 09-02-10
BRAKE DISC....................................................................................................................... 09-02-11
BRAKE PEDAL ................................................................................................................... 09-02-12
BRAKE HOSES................................................................................................................... 09-02-13
BRAKE LIGHT SWITCH ..................................................................................................... 09-02-14
VMR2004_154_09_01ATOC.FM 09-01-1
Section 09 BRAKES
Subsection 02 (HYDRAULIC BRAKES)
HYDRAULIC BRAKES 0
Two-Wheel Drive Models
23 Nm 15
(17 lbfft)
16
19
17
14
5 Nm
17 Nm 34 (44 lbfin) 16
(13 lbfft) 27
9
Synthetic
grease
32
35
30
36 34 Nm 19
31 (25 lbfft)
25 Nm
37 (18 lbfft)
7 Nm
2 (62 lbfin) 25 Nm
4 (18 lbfft)
8 40 30
3
9
7 6 23
Pipe
9 sealant
5 Nm 11
24 1 (44 lbfin) 25 Nm 34
25 5 (18 lbfft) 17 Nm
37 (13 lbfft)
8 Nm 18
(11 lbfin)
17 Nm 48 Nm
34 (13 lbfft) (35 lbfft)
32 22 39
15 5 Nm 5 38
23 Nm (44 lbfin)
(17 lbfft) 35
36
29 Synthetic
grease
25 Nm
(18 lbfft) 30 34 Nm 10
V07K0US
(25 lbfft) 37
VMR2004_149_09_02A.FM 09-02-1
Section 09 BRAKES
Four-Wheel Drive Models
2 1 Nm
23 Nm 15 4 (9 lbfin)
(17 lbfft) 8
3 19
16
6
17
14
34 Nm 24 1
(25 lbfft) 25
5
30 18
13
18 Nm 27
5 Nm (159 lbfin) Synthetic
(44 lbfin) grease
9
17 Nm 26
(13 lbfft) 34
16
33
31
15 12
30
32 34 Nm
35 16
25 Nm 37 (25 lbfft)
(18 lbfft)
9
36
21 19
33
5 Nm 7 Nm
(44 lbfin) 17 Nm (62 lbfin) 32
34 (13 lbfft) 34
9 40
35 17 Nm
5 Nm (13 lbfft)
(44 lbfin) 9 23
Pipe 36
33 11 sealant
32
35 5 Nm 37 25 Nm
(18 lbfft)
(44 lbfin)
23 Nm 22 48 Nm
(17 lbfft) 36 38 39 (35 lbfft)
15
29 Synthetic
30 37 grease
25 Nm 34 Nm 10
V07K0VS
09-02-2 VMR2004_149_09_02A.FM
Section 09 BRAKES
GENERAL PARKING BRAKE MECHANISM

During assembly/installation, use the torque val- Removal
Clean threads before applying a threadlocker. Re- Remove:
fer to SELF-LOCKING FASTENERS and LOCTITE AP- – nut no. 1
PLICATION at the beginning of this manual for com- – screw no. 2
plete procedure.
– spring no. 3
 WARNING – locking mechanism no. 4.
3
Hydraulic Brakes System

The brake system consists of two separate circuits.
Each system has its own master cylinder and res-
ervoir.
Both front and rear brakes are disc type.
 WARNING
Periodically check the brake hoses for damag- V07K07A 4 2 1
es or leaks. Repair any damage before oper- 1. Locking mechanism
ating the vehicle. 2. Spring
3. Screw
4. Nut
Parking Brake Installation

The parking brake operates all brakes. It is activat- For installation, reverse the removal procedure.
ed by a locking mechanism on LH brake lever.
See the following illustration to install the spring
2 1 properly.
V07K08A
V07K02A
1. LH brake lever
2. Locking mechanism
VMR2004_149_09_02A.FM 09-02-3
Section 09 BRAKES
BRAKE LEVER BRAKE FLUID

Removal Recommended Fluid
Remove: Always use brake fluid meeting the specification
– parking brake mechanism (see above) DOT 4 only.
– nut no. 5 CAUTION: Use only DOT 4 brake fluid from a
sealed container.
– screw no. 6
CAUTION: Never use other type of oil, do not mix
– brake lever no. 7. different types of brake fluid.
Fluid Level
With vehicle on a level surface, check brake fluid
1 in reservoir for proper level. It should be above
MIN. mark.
Clean filler cap before removing.
Add fluid as required. Do not overfill.
2
3 CAUTION: Use only DOT 4 brake fluid from a
sealed container.
NOTE: A low level may indicate leaks or worn
brake pads.
Front Brake Fluid Reservoir
Turn steering in the straight-ahead position to en-
sure reservoir is level. Check the brake fluid level,
the reservoir is full when the fluid reaches the top
V07K09A
of window.
1. Brake lever
2. Screw
3. Nut
Inspection
Check brake lever for bending, cracks or other
Installation
V07K0AA
Visually inspect lever boot condition. Check for

cracks, tears, etc. Replace if damaged.
09-02-4 VMR2004_149_09_02A.FM
Section 09 BRAKES
Rear Brake Fluid Reservoir Brake Fluid Filling and Bleeding

Close bleed valves.
Fill reservoirs with DOT 4 brake fluid.
CAUTION: To avoid serious damage to the
brake system, do not use fluids other than the
recommended one, nor mix different fluids for
topping off.
CAUTION: Use only DOT 4 brake fluid from a
sealed container. Do not use brake fluid taken
from old or already opened containers.
Unscrew the bleed valve on the top of rear master
cylinder no. 11 until brake fluid comes out then
close it.
2
V07A0IA
Brake Fluid Replacement

 WARNING
A contaminated brake disc or pad reduces stop-
ping power. Discard contaminated pads and
clean a contaminated disc with a high quality
brake degreasing agent.
V07K0CA 1
CAUTION: Avoid spilling brake fluid on plastic,
rubber or painted parts. Protect these parts 1. Rear master cylinder
2. Bleed valve
with a rag when servicing brake system.
On each caliper, unscrew the bleed valve until the
Brake Fluid Draining
brake fluid comes out then close it.
Remove reservoir cover no. 8 with diaphragm.
Bleed system as per the following procedure.
Connect bleed hose to bleed valve no. 9.
Loosen bleed valve and pump brake lever no. 7 or
brake pedal no. 10 until no more fluid flows out of
bleed valve.
VMR2004_149_09_02A.FM 09-02-5
Section 09 BRAKES
With a Vacuum Pump MASTER CYLINDER

Install the vacuum pump (P/N 529 021 800) to bleed
valve. See the manufacturer’s operating instruc- Removal
tions. Front Master Cylinder
Pump vacuum pump and loosen bleed valve. Close Drain brake fluid.
bleed valve and refill reservoir when the fluid level Remove the handlebar cover.
is low.
Remove reservoir cover with diaphragm and drain
NOTE: Check fluid level often to prevent air from brake fluid from master cylinder no. 14.
being pumped into the system.
CAUTION: Avoid spilling brake fluid on plastic,
Repeat the procedure until no more air bubbles ap- rubber or painted parts. Protect these parts
pear in bleed hose. with a rag when servicing brake system.
NOTE: For the front brake system, switch to LH and Remove banjo bolt no. 15 and sealing washers
RH caliper. Turn handlebar to full RH side when no. 16 retaining brake hose no. 17 to master cyl-
bleeding right caliper no. 12 and turn to the LH inder.
side for the left caliper no. 13. This helps the
bleeder to reach air into the caliper. The front and Remove screws no. 18 from master cylinder hold-
the rear brakes must be bled at the same time. er and remove master cylinder from handlebar.
Close bleed valve and operate brake lever no. 7 or
brake pedal no. 10. If it still feels spongy, bleed
system again.
Repeat the procedures until air bubbles do not ap-
pear in tube and lever or pedal is stiff.
Fill reservoirs to the upper level with DOT 4 brake
fluid.
Install diaphragms and covers on reservoirs.
Without a Vacuum Pump
If vacuum pump is not available, use the following
procedure. V07K0DA
Install a tube to bleed valve.

Rear Master Cylinder
Open bleeder. Fill reservoirs and pump brake lever
or brake pedal until fluid freely flows out of the Drain brake fluid.
tube. Remove LH and RH footwells.
Close bleed valve. Unplug brake switch connectors.
Pump up system pressure with brake lever or brake NOTE: At this time, check hoses and fittings for
pedal until lever or pedal resistance is felt. damages or leaks.
Squeeze brake lever or depress brake pedal, open Disconnect reservoir flexible hose no. 19 and plug
bleed valve and then close it. the end to avoid brake fluid spillage.
NOTE: Do not release brake lever or brake pedal un- Unscrew rear rigid hose no. 20 from master cylin-
til bleed valve has been closed. For the front brake der.
system, switch to LH and RH caliper. Turn handlebar
to full RH side when bleeding right caliper no. 12
and turn to the LH side for the left caliper no. 13.
This helps to reach air into the caliper. The front and
the rear brakes must be bled at the same time.
Release brake lever or brake pedal slowly.
Repeat the procedure until no more air bubbles ap-
pear in tube and lever or pedal is stiff.
09-02-6 VMR2004_149_09_02A.FM
Section 09 BRAKES
1
V07K0WA
1. Brake switch
2. Reservoir hose
3. Rear rigid hose V07K0GA
Unscrew front rigid hose no. 21 from master cyl- Rear Master Cylinder
inder.
Remove:
Unhook push rod from brake pedal no. 22.
– end cap
Remove bolts no. 23 retaining master cylinder to
the frame. – spring
– piston
2
3
1
V07K0XA
1. Front hose
2. Push rod lock
3. Master cylinder bolts
V07K0HA 3 2 1
Disassembly 1. End cap
2. Spring
Front Master Cylinder 3. Piston
Remove brake lever lock no. 4 and brake lever – boot no. 26
no. 7.
– snap ring no. 27
Remove piston boot no. 24, snap ring no. 25,
master piston and spring. – push rod no. 28.
VMR2004_149_09_02A.FM 09-02-7
Section 09 BRAKES
Inspection and Lubrication If push rod yoke no. 22 has been removed, rein-
stall it then adjust push rod length, see the follow-
Discard any remaining fluid inside reservoirs.
ing illustration.
Clean reservoirs, master pistons and master cylin-
ders thoroughly with clean brake fluid.
Check:
– boots for crack
– springs for damage
– piston cups for wear, deterioration or damages
– master cylinders and pistons for scoring, scratches
or other damages.
Change part(s) if necessary.
Check locking pin no. 29 for excessive wear, replace A
if necessary.
Check if the end cap O-ring is brittle, hard or dam-
aged.
NOTE: If master cylinder housing is damaged or
leaking, replace as an assembly.
V07K0IA
Assembly
A. 44 ± 1 mm (1.732 ± .039 in)
Front Master Cylinder
Coat master piston and piston cups with clean brake
Coat master piston and piston cups with clean brake fluid.
fluid.
The spring is conical. Install the smaller end on pis-
Install: ton.
– spring onto master piston Insert piston in the master cylinder.
– master piston into master cylinder
– snap ring into groove in the master cylinder
– boot into master cylinder and the groove in pis-
ton.
Apply silicone grease to the brake lever contacting
surface of the piston.
Install brake lever and locking mechanism.
NOTE: Apply silicone grease on lever pivot bolt.
Rear Master Cylinder
Install: V07K0JA
– push rod no. 28

Install the end cap. Do not forget the O-ring.
– snap ring no. 27
– boot no. 26.
09-02-8 VMR2004_149_09_02A.FM
Section 09 BRAKES
Installation CALIPER
For the installation, reverse the removal procedure,
pay attention to the following details. Removal
Front Brakes Loosen wheel nuts.
Place the brake lever assembly no. 7 on the han- Raise vehicle and support it securely.
dlebar. Remove wheel(s).
Position cylinder holding bracket with the UP mark Drain brake system.
upward.
Install bolts and tighten loosely.
For front wheel(s) caliper(s), remove the screws
With the handlebar in straight ahead position, po- retaining the caliper to the differential.
sition cylinder reservoir parallel to the ground.
Tighten upper bolt first.
V07K0YA
1. Retaining screw
V07K0KA All Models

Connect brake hose to master cylinder with bolt Remove banjo bolt no. 15 with sealing washers
and new sealing washers. no. 16 and detach brake hose from caliper.
Bleed brake system. Catch spilled fluid with a rag. Attach the brake hose
in a position to prevent the fluid from flowing out.
Check for leaks and make sure the brakes operate
normally before driving. Unscrew bolts no. 30 retaining caliper on its sup-
port and remove caliper.
Rear Brake
Install master cylinder to frame.
Hook push rod on brake pedal.
Connect front and rear hoses on master cylinder.
Connect flexible hose from reservoir.
Fill up reservoir with clean brake fluid.
CAUTION: Do not mix different types of brake
fluid. Use only DOT 4 brake fluid.
Bleed brake system. 1
Check for leaks and make sure the brakes operate 2
normally before driving.
V07K0ZA
Connect brake light switch connectors.
1. Remove banjo bolt and washers
2. Unscrew bolts
VMR2004_149_09_02A.FM 09-02-9
Section 09 BRAKES
Disassembly Install caliper in its original position.

Remove brake pads, see the following section. If hose was disconnected, bleed the brakes.
Remove: Check for leaks and make sure the brakes operate
normally before driving.
– slide caliper support no. 31
– pad spring no. 32. BRAKE PADS
Place rag over piston.
Place caliper body with piston down and apply Removal
small squirts of air pressure to the fluid inlet to re- Raise vehicle and support it securely.
move piston.
Remove wheels.
 WARNING Loosen pad pins no. 34.
Do not use high pressure air or bring nozzle too
3
close to inlet.
Remove piston seal.

CAUTION: Be careful not to damage piston
sliding surface.
Clean piston grooves, caliper cylinder and piston
with clean brake fluid.
Clean slide pins with brake cleaner and a rag.
Inspection
If boots no. 33 are deteriorated or hard, replace
with new ones.
Check caliper cylinder for scratches, rust or other
damages. If so, replace caliper.
Check piston for scratches, rust or other damages.
If so, replace piston. V07K0MA 2 1
1. Pad pins
Assembly 2. Caliper
3. Pad
Coat piston seal with clean brake fluid and install
it into piston grooves in caliper. Remove caliper from its support.
Coat piston with clean brake fluid and install into Unscrew pad pins then remove pads no. 35.
cylinder with the closing toward caliper body. CAUTION: Do not let the caliper hang by the
Apply silicone grease into sliding bores and install hose and don’t stretch or twist the hose.
slide pins. Push piston all the way in to allow installation of
NOTE: Make sure that rubber boots are correctly new pads.
installed in slide pins grooves. NOTE: It is very important to clean remaining O.D.
Install pad spring, caliper bracket and pads. of piston out from caliper with clean brake fluid
before pushing the piston back in. Make sure the
Installation piston is free of any contaminant and is shiny.
For the installation, reverse the removal procedure,
pay attention to the following details.
Use new sealing washers when installing banjo bolt
retaining brake hose to caliper.
09-02-10 VMR2004_149_09_02A.FM
Section 09 BRAKES
Inspection Make sure that pad spring no. 32 is in position.

CAUTION: Do not clean brake pads in petro-
leum based solvent. Use brake system cleaner
only. Soiled brake pads must be replaced with
new ones.
Measure brake pad lining thickness.
Brake pads must be replaced when lining is 1 mm
(1/32 in) thick or less, or look the hollow places on
both sides on the pad lining.
There are four hollow places on one set of brake
pads. When the pad wear reaches one of the hol-
low places, the pad must be changed even if the
pad wear does not reach another hollow place. V02K0BA 1 2
1. Pad spring
2. Piston
1
Install new brake pads.
Install new pad pins by pushing in the pads against
pad spring to align pad slots in the pads and caliper
body.
V02K0FA
Install brake caliper so the disc is positioned be-
1. Hollow place tween pads.
NOTE: Be careful not to damage pads and make
BRAKE PAD MINIMUM
1 mm (1/32 in) sure pads are correctly inserted in their location.
THICKNESS
After the job is completed, firmly depress the
brake lever a few times to bring the pads in con-
 WARNING tact with the disc.
Avoid getting oil or grease on brake pads. Con- Check for leaks and make sure the brakes operate
taminated brake pads can affect stopping ca- normally before driving. The pads must rest flat on
pacities. the disk.
CAUTION: Brake pads must always be replaced
in pairs. BRAKE DISC
Installation Inspection
Push caliper pistons inward before installing brake Brake discs no. 36 can be inspected without re-
pads. moving them from the vehicle.
NOTE: Use a C-clamp or another suitable tool. To Raise vehicle and support it securely. Remove
avoid damaging the piston, use an old pad to push wheels and visually inspect disc surfaces for
it into the caliper. scratches or grooves. Make sure to check both
sides of disc.
VMR2004_149_09_02A.FM 09-02-11
Section 09 BRAKES
Measure thickness of the disc. Place the propeller shaft in a vise.

Heat up brake disc around screws to facilitate re-
DISC MINIMUM THICKNESS
moval.
FRONT 3.5 mm (.138 in) Remove brake disc screws no. 37 retaining brake
disc no. 36 to the propeller shaft.
REAR 4.3 mm (.170 in)
Installation
Replace disc if not within specifications.
CAUTION: Brake discs should never be machined.
dure. However, pay attention to the following de-
Turn the disc by hand and check warpage. tails.
DISC WARPAGE (max.) Inspect the brake disc hub at the end of its sup-
port.
FRONT
0.3 mm (.01 in) Two-Wheel Drive Models
REAR Install brake disc on its hub and tighten screws
no. 37 to 34 N•m (25 lbf•ft) in a criss-cross se-
quence.
Removal
Front Brake Disc
Remove:
– appropriate wheel 1 5
– inner fender
3
– wheel hub
4
– front drive shaft (refer to FRONT DRIVE)
2
– lower suspension arm
All Models
– caliper (suspend it out of the way)
CAUTION: Do not let the caliper hang by the
V01K0BB
hose and do not stretch or twist the hose.
TORQUE TO 34 N•m (25 lbf•ft)
– drive shaft.
Place the drive shaft in a vise. Four-Wheel Drive Models
Heat up brake disc around screws and flange on Install brake disc on differential and tighten
drive shaft to facilitate removal. screws no. 37 to 34 N•m (25 lbf•ft) in a criss-cross
sequence.
Remove brake disc screws no. 37 retaining brake
disc no. 36 to the drive shaft.
BRAKE PEDAL
Rear Brake Disc
Remove: Removal
– LH wheel Remove RH footwell.
– caliper (suspend it out of the way) Unhook:
CAUTION: Do not let the caliper hang by the – return spring no. 38
hose and do not stretch or twist the hose. – master cylinder push rod hook no. 22.
– rear propeller shaft (refer to REAR DRIVE).
09-02-12 VMR2004_149_09_02A.FM
Section 09 BRAKES
Removal
NOTE: Before removing any hoses, drain brake
system.
Remove all necessary parts to reach the hoses.
Thoroughly clean the area around the joints that
will be disconnected.
Place a drain pan under the joint that will be dis-
connected.
Disconnect any retaining clips or brackets holding
the hose and remove the defective part(s).
Installation
V07K0NA 3 1 2 Install the new hose.
1. Return spring Make sure the piece will not rub against any other
2. Push rod hook
3. Brake pedal part.
Remove bolt no. 39 retaining the brake pedal no. 10 When there is a banjo bolt securing the hose to
to frame. the caliper or to the front master cylinder, always
replace the sealing washers with new ones.
Inspection
2
Check brake pedal for cracks or distortion.
Installation
BRAKE HOSES
Inspection
Brake hoses should be inspected frequently for
leaks and damages.
Check if the hoses are crushed or damaged. Any
deformation can restrict the proper flow of fluid
and cause braking problems.
Check hoses for cracking or scrapes. This damage
can cause hose failure under pressure.
When hoses are removed or disconnected, clean- V07K0PA 1
liness must be observed. Clean all joints and con- 1. Banjo bolt
nections before disassembly. New hoses should 2. Sealing washers
be cleaned with brake fluid before installation to Install any retaining clips or brackets.
remove any contamination.
Refill and bleed the system.
Replace any defective parts.
VMR2004_149_09_02A.FM 09-02-13
Section 09 BRAKES
BRAKE LIGHT SWITCH

Inspection
Check switch no. 40 for dirt or corrosion. Make
sure it is operating properly.
Depress brake pedal and check for brake light to turn
on. Repeat with the brake lever.
Before replacing the brake light switch, check the
brake light bulb and the wiring harness.
Removal
The rear brake switch is located on the rear master
cylinder.
V07K0QA
The rear brake light switch cannot be adjusted.

Disconnect switch connectors.
Drain brake system.
Unscrew brake light switch from master cylinder.
Catch spilled fluid with a rag.
Installation
NOTE: Apply pipe sealant on threads of brake light
switch.
09-02-14 VMR2004_149_09_02A.FM
Section 10 BODY/FRAME
TABLE OF CONTENTS 0
BODY ...................................................................................................................................... 10-02-1
BODY PARTS (FRONT VIEW) ........................................................................................... 10-02-1
BODY PARTS (REAR VIEW).............................................................................................. 10-02-2
SEAT................................................................................................................................... 10-02-3
GENERAL ........................................................................................................................... 10-02-4
FLAG HOLDER ................................................................................................................... 10-02-4
PASSENGER’S SEAT......................................................................................................... 10-02-4
OPERATOR’S SEAT ........................................................................................................... 10-02-5
STORAGE COVER ............................................................................................................. 10-02-5
SIDE PANEL ....................................................................................................................... 10-02-6
ENGINE COVER ................................................................................................................. 10-02-6
FOOTPEG(S) ...................................................................................................................... 10-02-6
FOOTREST ......................................................................................................................... 10-02-7
CONSOLE........................................................................................................................... 10-02-8
INNER FENDER.................................................................................................................. 10-02-8
FRONT SKID PLATE .......................................................................................................... 10-02-8
FRONT FACIA .................................................................................................................... 10-02-9
LUGGAGE RACK ............................................................................................................... 10-02-9
REAR GRAB HANDLE ....................................................................................................... 10-02-10
FENDER .............................................................................................................................. 10-02-10
TRANSMISSION LEVER INDICATOR ............................................................................... 10-02-11
FUEL VALVE SUPPORT .................................................................................................... 10-02-12
FRONT BUMPER ............................................................................................................... 10-02-12
REAR LOWER BUMPER .................................................................................................... 10-02-13
REAR UPPER BUMPER ..................................................................................................... 10-02-13
FENDER SUPPORT ............................................................................................................ 10-02-14
SEAT COVER REPLACEMENT .......................................................................................... 10-02-15
STORAGE COVER LATCH................................................................................................. 10-02-15
SEAT CLEANING ............................................................................................................... 10-02-15
DECAL ................................................................................................................................ 10-02-15
HITCH/TRAILER BALL ....................................................................................................... 10-02-15
PLASTIC MAINTENANCE ................................................................................................. 10-02-16
MAINTENANCE ................................................................................................................. 10-02-16
PLASTIC REPAIR................................................................................................................ 10-02-16
FRAME ................................................................................................................................... 10-03-1

GENERAL ........................................................................................................................... 10-03-2
FOOTREST SUPPORT ....................................................................................................... 10-03-2
BATTERY RACK ................................................................................................................. 10-03-2
HITCH ................................................................................................................................. 10-03-3
FRAME ............................................................................................................................... 10-03-3
VMR2004_154_10_01ATOC.FM 10-01-1
Subsection 02 (BODY)
BODY 0
BODY PARTS (FRONT VIEW)
7 28
6
27
3.5 Nm 1
(31 lbfin) 17 4.5 Nm
(40 lbfin) 32
31
40
18
39 30
4.5 Nm 31
(40 lbfin) 36 4.5 Nm
27 (40 lbfin)
28
28
33
38
30 30
31 20 Nm
4.5 Nm (15 lbfft) 45
(40 lbfin)
30 30
29
43 30
30
29
19 30
29
23 Nm 1 29
24 Nm
(17 lbfft) 41 (18 lbfft)
45 55
1 1 56
26
41
48 Nm 25 55
(35 lbfft) 24 Nm
2.5 Nm (18 lbfft) 53
26 (22 lbfin)
20
42 44 23
24
44 2.5 Nm 52
8 Nm (22 lbfin) 54
(71 lbfin) 24 Nm
(18 lbfft)
21
V07L2ES
22 50 51
VMR2004_150_10_02A.FM 10-02-1
BODY PARTS (REAR VIEW)

14 12
2.5 Nm
6 (22 lbfin)
7 13
14
16 2.5 Nm
(22 lbfin)
4.5 Nm
(40 lbfin) 3
10 9
11
MAX/MAX XT 2
35
8 37
30
12
13 29
12 20 Nm 46
(15 lbfft)
30
13
30 61
29
30
29 47
15 29 59
60
59
58
57
V07L2FS 57
10-02-2 VMR2004_150_10_02A.FM
SEAT
48
MAX/XT
49
6.5 Nm
(58 lbfin)
V07L2GS
VMR2004_150_10_02A.FM 10-02-3
GENERAL Removal
During assembly/installation, use the torque val- Remove:
ues and service products as in the exploded views. – flag (if so equipped)
Clean threads before applying a threadlocker. Re- – screws no. 3
fer to SELF-LOCKING FASTENERS and LOCTITE AP- – flat bracket no. 4
plete procedure. – flag holder no. 2.
 WARNING Installation
Torque wrench tightening specifications See the following illustration to install the flag
must strictly be adhered to. holder properly.
Plastic Rivet
Plastic rivets no. 1 are used in the riveting of the
various body parts. Plastic rivets can be removed
carefully with pliers (P/N 295 000 070).
NOTE: Reuse the plastic rivets.
V07L2WA
PASSENGER’S SEAT
Outlander MAX/XT Models Only
Removal
Push latch forward while gently lifting rear of seat.
Pull seat rearward. Continue lifting movement un-
til you can release the front retaining device then
completely remove passenger’s seat.
V06L08A 2 1
TYPICAL
1. Pliers (P/N 295 000 070)
2. Plastic rivet
FLAG HOLDER
The flag holder no. 2 is located on the left rear lug-
gage rack.
V07L2HA
1. Passenger’s seat latch
10-02-4 VMR2004_150_10_02A.FM
Installation
Insert front tabs of passenger’s seat under frame
rod. When seat rests in its position, firmly push
seat down to latch.
1
1
V07L2IA
1. Operator’s seat latch — Outlander MAX/XT

2
V07L1PB Installation
1. Insert this tab under rod Insert front tab of seat into frame hook. When seat
2. Rod
rests in its position, firmly push seat down to latch.
OPERATOR’S SEAT 1
Outlander MAX/XT Models
Remove passenger’s seat as mentioned above.
All Models
Removal
To remove seat, push latch no. 5 forward while
gently lifting rear of seat. Continue lifting move-
ment until you can release the front retaining de-
vice, then, completely remove seat.
V07L05A 2
1. Insert this tab in hook
2. Hook
STORAGE COVER
Removal
The storage cover no. 6 is retained by a rubber
latch no. 7.
Unlatch cover, lift then remove cover.
V07L04A 1 Inspection
1. Seat latch — Outlander/XT
Check latch no. 7 for cracks or other damages.
Change if necessary.
VMR2004_150_10_02A.FM 10-02-5
Installation ENGINE COVER

Installation is the reverse order of removal.
Removal
SIDE PANEL Remove screws no. 10 retaining the engine cover
no. 11 to the engine cover supports.
Removal
NOTE: Use the same procedure to remove the LH
Installation
and RH side panels no. 8 and no. 9. The installation is the reverse of removal procedure.
Remove the seat/s (as applicable).
Come off the plastic studs from the grommets.
FOOTPEG(S)
Removal
Remove:
– footpeg(s) bolts no. 12
V07L0HA
Remove plastic rivet from lower tab.

V07L0JA
– footpeg(s) no. 13.
Installation
dure.
NOTE: On Outlander MAX/XT, pay attention to
align passenger’s footpeg with the footrest sup-
port.
V07L0IA
Move the tabs out of their slots.

Remove the side panel completely.
Installation
10-02-6 VMR2004_150_10_02A.FM
FOOTREST
Removal
Remove:
– side panel no. 8 or no. 9
V07L2LA
OUTLANDER MAX/XT ONLY
– all screws no. 14 retaining the footrest no. 15

or no. 16 to fenders.
V07L2JA
– footpeg(s) no. 13
V07L2MA
V07L2KA
OUTLANDER MAX/XT
– footrest support retaining screws
V07L2NA
Pull the footrest out of vehicle.
VMR2004_150_10_02A.FM 10-02-7
Installation Installation
The installation is the reverse of removal procedure. The installation is the reverse of removal procedure.
CONSOLE INNER FENDER

Removal Removal
Remove screws no. 17 retaining console no. 18. Lift the front of vehicle and support it securely.
Remove:
– all fastening hardware
– inner fender no. 19 or no. 20.
NOTE: On RH side, unclip the radiator hose.
Installation
FRONT SKID PLATE

Removal
V07L0LA 1 2
Remove bolts no. 21, no. 22 and no. 23.
1. Console screws
2. Console Outlander XT/MAX XT
Remove plastic rivets no. 1 near handlebar cover. Remove winch hook no. 51 and fairlead no. 50.
2 1
V07A0PA
V07L0MA 2 1 3 1. Winch hook

2. Fairlead
1. Plastic rivets
2. Handlebar cover
3. Console
Lift the console then unplug the ignition switch

and the 12-volt power outlet.
Remove the console.
10-02-8 VMR2004_150_10_02A.FM
All Models
V07L13A
LUGGAGE RACK
NOTE: Use the same procedure for all luggage racks.
V07L0NA
Removal
TYPICAL
Unscrew the protection plugs or screws no. 27
Remove the front skid plate no. 24. and no. 28 (as applicable).
Installation
cedure.
FRONT FACIA
Removal
Unplug headlight connectors.
Remove:
– plastic rivets no. 1 V07L0OA
– bolts no. 23 retaining front facia to front skid Remove:

plate.
– bolts no. 29
Remove front facia no. 25.
– washers no. 30
Installation – nuts no. 31.
The installation is the reverse of removal proce- Pull luggage rack no. 32, no. 33, no. 34 or no. 35
dure. upward.
NOTE: Install a washer no. 26 under each plastic
rivet located at the both ends of facia.
VMR2004_150_10_02A.FM 10-02-9
Installation
NOTE: The short protection plugs no. 27 must be
installed only in the specific locations, refer to the
following illustration.
1
V07L2VA
1. Protection plug
FENDER
Removal
V07L0PA 1 Front Fender
1. Short protection plug location Remove:
– side panels no. 8 and no. 9
REAR GRAB HANDLE – luggage racks no. 32 or no. 33
Outlander MAX/XT Models – plastic rivets no. 1 retaining front fender no. 36
Removal to front facia
Removal of LH and RH side rear grab handle is the

same.
Remove 2 nuts under handle.
V07L0QA
– all screws retaining the footrests to fender
1
V07L2UA
1. Nuts
Remove protection plug and pull out grab handle.
V07L0RA
10-02-10 VMR2004_150_10_02A.FM
– service compartment cover

– tool box
V07L0SA
V07L0MB
– coolant reservoir support
Lift and remove front fender.
Rear Fender
Remove:
– seat
– side panels
– luggage racks no. 34 or no. 35
– all screws retaining the footrests to rear fender
no. 37
V07C0SA
– rear brake fluid reservoir bolt
V07L0KA
– fuel tank cap.

Lift and remove fender.
Installation
V07L0UA
TRANSMISSION LEVER
– inner fenders INDICATOR
– plastic rivets no. 1 retaining front fender to con-
sole. Removal
Remove:
– RH side panel no. 9
VMR2004_150_10_02A.FM 10-02-11
– transmission lever handle FRONT BUMPER

– bolts no. 38.
Removal
Outlander MAX/XT Models Only
Remove:
– bolts no. 53 and no. 54 retaining front bumper
no. 52 to front facia no. 25 and bumper support
no. 56.
V07L0VA
Lift the console to remove the transmission lever

indicator no. 39.
Installation
1
FUEL VALVE SUPPORT V07L2OA
1. Bolts to be removed
Removal
– bumper support no. 56 by removing bolt no. 55
Remove: from the frame.
– seat
All Models
– LH side panel
Remove:
– fuel valve cap
– bolts no. 23 retaining front skid plate no. 24 to
– fuel valve nut front facia no. 25
V07L0XA
V07L0WA
– bolts no. 41 retaining front bumper no. 42 to

– console. fender support no. 43
Unlatch the fuel valve support no. 40.
Installation
10-02-12 VMR2004_150_10_02A.FM
V07L0YA
1
– bolts no. 44 retaining front bumper to frame V07L2ZA
1. Lower bumper retaining bolts
– bolts no. 59 from both sides and lower bumper

no. 58.
V07L0ZA
– front bumper from vehicle.
Installation V07L2RA
The installation is the reverse of removal procedure. 1. Bolt to be removed
REAR LOWER BUMPER Installation

Removal
Outlander XT/MAX XT Models Only REAR UPPER BUMPER
Remove: Removal
– bolts no. 57 retaining lower bumper no. 58 to
hitch Outlander XT/MAX XT Models Only
Remove:
– lower bumper no. 58
(refer to procedure given above)
– bolts no. 60 retaining rear upper bumper no. 61
to fender support no. 47.
VMR2004_150_10_02A.FM 10-02-13
V07L11A
1 Rear Fender Support

V07L2SA
Remove:
1. Bolts
– rear fender
Installation Outlander XT/MAX XT Models Only
The installation is the reverse of removal procedure. – rear lower and upper bumper
– battery rack support
FENDER SUPPORT
Removal
Front Fender Support
Remove:
– front fender
– front facia
– front bumper
– radiator mounting bolts
V07L2TA
V07L10A 1. Battery rack support
– bolts no. 45 retaining the fender support no. 43 All Models

to the frame. – bolts no. 46 retaining the fender support no. 47
to the frame.
10-02-14 VMR2004_150_10_02A.FM
After cover installation cut all around the excess of

material.
STORAGE COVER LATCH

Inspection
Inspect for crack or damage. Change if a any crack
or damage are detected.
V07L12A Removal
Under front fender, pull the storage cover latch.
Installation
Installation
Under front fender, insert the storage cover latch
SEAT COVER REPLACEMENT in the slot. Pull the latch by the top.
Remove the old seat cover no. 48. Check the foam SEAT CLEANING
and replace if necessary.
Install staples with an electric tacker such as Arrow It is recommended to clean the seat with a solution
tacker no. ETN-50 or with a manual tacker such as of warm soapy water, using a soft clean cloth.
Arrow tacker no. T-50. CAUTION: Avoid use of harsh detergents such
NOTE: For an easier installation, it’s highly recom- as strong soaps, degreasing solvents, abrasive
mended to use an electric tacker. cleaners, paint thinners, etc. that may cause dam-
age to the seat cover.
Ensure that the seat rest firmly against a hard sur-
face such as a piece of wood. This is done to get
the staples completely pushed in place.
DECAL
To remove a decal; heat old decal with a heat gun
and peel off slowly.
Using isopropyl alcohol, clean the surface and dry
thoroughly.
Apply liquid soap to new decal and carefully posi-
tion the decal. Using a sponge or a squeegee, re-
move the air bubbles and surplus water working
from the center toward the edges. Allow to air dry.
CAUTION: Do not apply isopropyl alcohol or sol-
vent directly on decals. Use only in a well venti-
lated area.
HITCH/TRAILER BALL
Inspection
The hitch/trailer ball is optional. If the vehicle is
equipped with this option, often check the solidity
1 of the installation.
F01L3YA 2
TYPICAL
1. Piece of wood
2. ETN-50 (electric) or T-50 (manual)
VMR2004_150_10_02A.FM 10-02-15
PLASTIC MAINTENANCE
MAINTENANCE
Clean the vehicle thoroughly, removing all dirt and
grease accumulation.
To clean use a soft clean cloth and either soapy
water or isopropyl alcohol.
To remove grease, oil or glue use isopropyl alcohol.
CAUTION: Do not apply isopropyl alcohol or ac-
etone directly on decals.
CAUTION: The following products must not be
used to clean or wax any of the plastic compo-
nents used on the vehicles:
– gasoline
– brake fluid
– kerosene
– diesel fuel
– lighter fluid
– varsol
– naphtha
– acetone
– strong detergents
– abrasive cleaners
– waxes containing an abrasive or a cleaning agent
in their formula.
PLASTIC REPAIR
No plastic part on the vehicle is repairable. Change
all defective parts.
10-02-16 VMR2004_150_10_02A.FM
Subsection 03 (FRAME)
FRAME 0
8 MAX/MAX XT only
9
9
2 10 Nm 23 Nm
6 (17 lbfft)
3 (89 lbfin)
4 23 Nm 5
(17 lbfft)
1
3
10 Nm
(89 lbfin)
23 Nm 10 Nm
3 (89 lbfin)
(17 lbfft)
4
23 Nm
4 (17 lbfft)
2
3
10 Nm
(89 lbfin)
V07L1RS
VMR2004_151_10_03A.FM 10-03-1
GENERAL
plete procedure.
 WARNING
stalled or replaced with new ones where V07L1SA
specified. If the efficiency of a locking device BOLTS TO BE REMOVED

– footrest support(s).
CAUTION: Before performing electrical welding
anywhere on the vehicle, unplug the electronic Inspection
module connector. Also unplug the negative Check footrest support(s) for cracks, bending or
cable and the voltage regulator. This will protect other damages. Replace if necessary.
the electronic module and battery against
damage caused by flowing current when Installation
welding.
dure.
FOOTREST SUPPORT
NOTE: Use the same procedure for RH or LH foot- BATTERY RACK
rest supports.
Removal
Removal Remove:
For footrest support no. 2, remove: – battery (refer to STARTING SYSTEM)
– footrest (refer to BODY) – bolts no. 6 retaining the battery rack no. 5 to
– bolts no. 3 and no. 4 retaining footrest support frame no. 1
no. 2 to frame no. 1
– footrest support.
Outlander MAX/MAX XT Only
For footrest support no. 8, remove:
– LH and RH side panels (refer to BODY)
– LH and RH side footrests (refer to BODY)
– bolts no. 9 retaining footrest support(s) no. 8 to
frame
V07L0BA
TYPICAL
10-03-2 VMR2004_151_10_03A.FM
– upper differential bolts HITCH

Removal
Remove:
– differential protector (refer to BODY)
Outlander XT/MAX XT Only
– rear lower bumper (refer to BODY)
All Models
– bolts retaining the hitch no. 7 and the rear dif-
ferential to frame.
V07L0CA
TYPICAL — OUTLANDER/OUTLANDER XT
NOTE: Secure aside the support (MAX/MAX XT

models only).
V07L0DA
– hitch.
Inspection
Check hitch for cracks, bending or other damages.
V07L1TA
1. Support Installation
– battery rack. The installation is the reverse of removal procedure.
Inspection FRAME
Check battery rack for cracks or other damages.
Replace if necessary. Cleaning
Clean frame no. 1 with appropriate cleaners and
Installation rinse with high pressure hose.
The installation is the reverse of removal proce- NOTE: Clean the draining holes under frame. The
dure. drain holes are located at the rear of bottom side
of frame.
Touch up all metal spots where paint has been
scratched off. Spray all bare metal parts of vehicle
with metal protector.
VMR2004_151_10_03A.FM 10-03-3
Welding
Steel Frame:
– electric welding
– amperage: 70 - 110 A
– voltage: 20 - 24 V
– rod: E-7014 (3/32 in).
CAUTION: Before performing electrical welding
anywhere on the vehicle, unplug the multiple
connector at the electronic module connector.
Also unplug the negative cable and the voltage
regulator. This will protect the electronic module
and battery against damage caused by flowing
current when welding.
NOTE: Install the ground as close as possible from
the reparation area.
CAUTION: If welding is to be done near plastic
material, it is recommended to either remove the
part from the area or to protect it with aluminum
foil to prevent damage.
10-03-4 VMR2004_151_10_03A.FM
Section 11 TECHNICAL DATA
Subsection 01 (SI METRIC INFORMATION GUIDE)
TECHNICAL DATA 0
SI* METRIC INFORMATION GUIDE
BASE UNITS
DESCRIPTION UNIT SYMBOL
length .................................................................. meter ..................................................... m

mass .................................................................... kilogram ................................................. kg
force .................................................................... newton ................................................... N
liquid .................................................................... liter ......................................................... L
temperature ........................................................ Celsius ................................................... °C
pressure .............................................................. kilo pascal ............................................... kPa
torque .................................................................. newton•meter ....................................... N•m
speed .................................................................. kilometer per hour .................................. km/h
PREFIXES
PREFIX SYMBOL MEANING VALUE
kilo ................................ k ............................... one thousand ......................................... 1 000

centi ............................. c ............................... one hundredth ........................................ 0.01
milli ............................... m .............................. one thousandth ...................................... 0.001
micro ............................ µ ............................... one millionth .......................................... 0.000001
CONVERSION FACTORS
TO CONVERT TO † MULTIPLY BY
in ......................................................................... mm ......................................................... 25.4

in ......................................................................... cm .......................................................... 2.54
in2 ........................................................................ cm2 ......................................................... 6.45
in3 ........................................................................ cm3 ......................................................... 16.39
ft .......................................................................... m ............................................................ 0.3
oz ......................................................................... g ............................................................. 28.35
lb ......................................................................... kg ........................................................... 0.45
lbf ........................................................................ N ............................................................ 4.4
lbf•in ................................................................... N•m ....................................................... 0.11
lbf•ft .................................................................... N•m ....................................................... 1.36
lbf•ft .................................................................... lbf•in ...................................................... 12
PSI (lbf/in2) ........................................................... kPa ......................................................... 6.89
imp. oz ................................................................. U.S. oz .................................................... 0.96
imp. oz ................................................................. mL .......................................................... 28.41
imp. gal ................................................................ U.S. gal ................................................... 1.2
imp. gal ................................................................ L ............................................................. 4.55
U.S. oz ................................................................. mL .......................................................... 29.57
U.S. gal ................................................................ L ............................................................. 3.79
MPH .................................................................... km/h ...................................................... 1.61
Fahrenheit ........................................................... Celsius ................................................... (°F - 32) ÷ 1.8
Celsius ................................................................. Fahrenheit .............................................. (°C x 1.8) + 32
* The international system of units abbreviates SI in all languages.

† To obtain the inverse sequence, divide by the given factor. To convert ’’mm’’ to ’’in’’, divide by 25.4.
NOTE: Conversion factors are rounded off to 2 decimals for easier use.
VMR2004_152_11_01A.FM 11-01-1
Subsection 02 (OUTLANDER 330)
OUTLANDER 330 0
VEHICLE MODEL OUTLANDERTM 330 H.O. 2 X 4 OUTLANDERTM 330 H.O. 4 X 4
ENGINE
BOMBARDIER-ROTAX, 4-stroke,
Engine type Over Head Camshaft (OHC), liquid cooled
Electric start and manual rewind starter.
Starting system
Start in any gear (with brakes applied)
Number of cylinder(s) 1
Number of valves 4 valves (mechanical adjustment)
Decompressor type N.A.
Bore Standard mm (in) 82 (3.23)
Stroke mm (in) 61.5 (2.42)
Displacement cm3 (in3) 325 (19.83)
Compression ratio 10.3:1
Lubrication Wet sump with replaceable oil filter
Oil filter BOMBARDIER-ROTAX
Air filter type 2 stage foam filter
Type Nelson, steel
Exhaust system
Spark arrester USDA Forest Service approved
Intake valve opening 15.00° BTDC
Intake valve closing 45.00° ABDC
Exhaust valve opening 50.00° BBDC
Exhaust valve closing 10.00° ATDC
Chain tensioner plunger protrusion Wear limit mm (in) 20.0 (.7874)
Intake mm (in) 0.06 (.0024) to 0.14 (.0055)
Valve clearance
Exhaust mm (in) 0.11 (.0043) to 0.19 (.0075)
New minimum mm (in) 4.966 (.1955)
Intake New maximum mm (in) 4.980 (.1960)
Wear limit mm (in) 4.930 (.1940)
Valve/valve stem clearance
Exhaust New maximum mm (in) 4.970 (.1957)
Valve guide diameter New maximum mm (in) 5.018 (.1976)
New nominal mm (in) 40.81 (1.607)
Valve spring free length
Service limit mm (in) 39.00 (1.535)
New mm (in) 1.15 to 1.35 (.045 to .053)
Intake
Valve seat contact width
New mm (in) 1.25 to 1.55 (.049 to .061)
Exhaust
Wear limit mm (in) 2 (.078)
Piston measurement New nominal mm (in) 81.950 to 81.966 (3.226 to 3.227)
New nominal mm (in) 0.057 to 0.087 (.0022 to .0034)
Piston/cylinder clearance
Upper compression ring Rectangular
Piston ring type Lower compression ring Taper-face
Oil scraper ring Standard
Upper compression ring mm (in) 0.2 (.008)
Lower compression ring New minimum mm (in) 0.2 (.008)
Oil scraper ring mm (in) 0.2 (.008)
Piston ring end gap Upper compression ring mm (in) 0.40 (.016)
Lower compression ring New maximum mm (in) 0.40 (.016)
All Wear limit mm (in) 1.5 (.06)
VMR2004_152_11_02A.FM 11-02-1

ENGINE
Piston/ring groove clearance Upper compression ring mm (in) 0.070 (.0028)
Rocker arm bore diameter New maximum mm (in) 12.050 (.4744)
Wear limit mm (in) 12.060 (.4748)
Rocker arm shaft diameter New maximum mm (in) 12.018 (.4732)
Wear limit mm (in) 11.990 (.4720)
Cylinder bore New nominal mm (in) 82.023 to 82.037 (3.229 to 3.230)
New maximum mm (in) 0.038 (.001)
Cylinder taper
Cylinder out of round
PTO side New maximum mm (in) 21.980 (.8654)
Wear limit mm (in) 21.950 (.8642)
Camshaft bearing journal
New minimum mm (in) 34.959 (1.3763)
Magneto side New maximum mm (in) 34.975 (1.3770)
Wear limit mm (in) 34.950 (1.3760)
Wear limit mm (in) 22.040 (.8677)
Camshaft bore
Wear limit mm (in) 35.040 (1.3795)
Intake New maximum mm (in) 32.363 (1.2741)
Wear limit mm (in) 32.300 (1.2717)
Cam lobe
Exhaust New maximum mm (in) 32.047 (1.2617)
Wear limit mm (in) 32.000 (1.2598)
Crankshaft axial clearance New minimum mm (in) 0.1 (.0039)
MAG side New nominal mm (in) 0.05 (.0020)
Crankshaft deflection
PTO side New nominal mm (in) 0.05 (.0020)
Crankshaft pin diameter New maximum mm (in) 40.025 (1.5758)
Wear limit mm (in) 39.980 (1.5740)
Crankshaft journal diameter MAG/PTO side New maximum mm (in) 42.040 (1.6551)
Wear limit mm (in) 42.000 (1.6535)
MAG side Wear limit mm (in) 42.070 (1.6563)
Crankcase plain bearing
PTO side Wear limit mm (in) 42.070 (1.6563)
MAG side
Crankshaft radial clearance Service limit mm (in) 0.07 (.0028)
PTO side
Connecting rod big end diameter New maximum mm (in) 40.051 (1.5768)
Connecting rod big end clearance Service limit mm (in) 0.09 (.0035)
11-02-2 VMR2004_152_11_02A.FM

ENGINE
Connecting rod big end axial play New maximum mm (in) 0.352 (.014)
Connecting rod small end diameter New maximum mm (in) 20.02 (.7882)
Piston pin diameter New maximum mm (in) 20.000 (.7874)
Wear limit mm (in) 19.980 (.7867)
Piston pin bore clearance Wear limit mm (in) 0.080 (.0035)
Drive belt
Governor cup roller diameter New maximum mm (in) 13.90 (.547)
Service limit mm (in) 13.20 (.519)
Centrifugal lever pivot bolt diameter New maximum mm (in) 6.100 (.240)
Centrifugal lever bore diameter Service limit mm (in) 6.200 (.244)
Centrifugal lever pivot bolt bore diameter New maximum mm (in) 6.171 (.243)
Drive pulley sliding half large bushing New maximum mm (in) 55.020 (2.166)
Drive pulley sliding half small bushing New maximum mm (in) 30.020 (1.182)
One-way clutch bushing diameter New maximum mm (in) 40.085 (1.578)
Driven pulley sliding half busing diameter New maximum mm (in) 30.020 (1.182)
Driven pulley fixed half busing diameter New maximum mm (in) 30.020 (1.182)
Torque gear on driven pulley Service limit mm (in) 7.500 (.295)
MAG side mm (in) 17.990 (.708)
Main shaft
PTO side mm (in) 24.950 (.982)
Bevel gear shaft PTO side mm (in) 24.990 (.984)
VMR2004_152_11_02A.FM 11-02-3

ELECTRICAL
Magneto/generator 400 W @ 6000 RPM
Ignition system type C.D.I. (Capacitive Discharge Ignition)
Ignition timing Not adjustable
Quantity 1
Spark plug Make and type NGK DCPR8E
Gap mm (in) 0.7 to 0.8 (.028 to .032)
CPS (Crankshaft Position Sensor) Ω 190 – 300
Starter coil Ω 0.4 ± 01 @ 20°C (68°F)
Primary Ω 1.0 ± 0.15 @ 20°C (68°F)
Ignition coil
Secondary kΩ 11.5 ± 2.3 @ 20°C (68°F)
Forward RPM 8000
Engine RPM limiter
Reverse RPM 4000 ± 100
Type Dry battery type
Voltage 12 volts
Battery
Nominal rating 13 A•h
Power starter output 1.2 KW
Headlamp 2 x 30 W, HOBBS 81425
Taillight 8/27 W, 1157
Pilot lamp cluster LEDS, 0.7 V approximately (each)
Accessories 15 A (power outlet and auxiliary supply)
Fan 15 A
Fuses
Main 20 A
Charging system 30 A
CARBURETION
Mikuni constant depression type with manual choke and ECS
Type
Carburetor (Enrichner Coasting System)
Model BSR33
Type Mikuni (Pulsation pump)
Fuel pump
Model External (vacuum-operated)
Idle engine speed RPM 1300 ± 100
Main jet 133.8
Pilot jet 32.5
Needle jet (826) P-4
Jet needle 5 FEY 1
Clip position number 3
Choke plunger position Variable choke
Throttle cable 0.5 mm (.02 in)
Preliminary pilot screw turn 2.5
Adjustment
± 0.5 mm 10.0
Float level
± 0.020 in .390
Type Regular unleaded gasoline
Fuel
Octane no. 87 (Ron + Mon)/2
COOLING
Coolant Ethyl glycol/water mix (50% coolant, 50% water).

Use coolant specifically designed for aluminum engines
Fan Thermostatic
Operating temperature 115°C (239°F)
Coolant temperature switch
Closing temperature 110°C (230°F)
Switch ON 95°C (203°F)
Fan thermostat
Switch OFF 90°C (194°F)
Opening temperature 65°C (149°F)
Engine thermostat
Radiator cap opening pressure 110 kPa (16 PSI)
11-02-4 VMR2004_152_11_02A.FM

LUBRICATION
Oil pressure switch operation 30 to 60 kPa (4.35 to 8.70 PSI)
Engine oil pressure (min.) 350 kPa (51 PSI)

DRIVE TRAIN
CVT (Continuously Variable Transmission).
Transmission Type
Dual range (HI-LO) with park, neutral and reverse
Engagement RPM ± 100 RPM 1450
Front differential Shaft driven/single Auto-lock differential (pump driven)
Front differential ratio 3.6:1
Rear axle Shaft driven/single differential
Rear axle ratio 3.6:1
STEERING
Turning radius 1.83 m (6 ft)
Total toe (vehicle on ground) mm (in) 0 ± 4 (0 ± .157)
Camber angle 0°
Tie-rod maximum length unengaged mm (in) 286.5 ± 5 (11.28 ± 0.197)
SUSPENSION
• FRONT
Suspension type McPherson Strut
Suspension travel mm (in) 178 (7)
Qty 2
Shock absorber
Type Oil
Spring free length mm (in) 354 (14)
Spring color code Blue/Red/Blue
Front preload adjustment N.A.
• REAR
Suspension type Trailing arms
Qty 2
Shock absorber
Type Oil
Spring free length mm (in) 371 (14.6)
Spring color code Blue/Black/Blue
Rear preload adjustment 5 settings
BRAKES
Qty 2
Front brake
Type Hydraulic, discs
Qty 1
Rear brake
Type Hydraulic, disc
Parking brake Hydraulic lock-4 wheels
Caliper Floating
Front Organic
Lining material
Rear Metallic
Minimum pad thickness mm (in) 1 (.04)
mm (in) 3.5 (.138)
Minimum brake disc thickness
mm (in) 4.3 (.17)
Maximum brake disc warpage mm (in) 0.2 (.01)
VMR2004_152_11_02A.FM 11-02-5

TIRES AND WHEELS
• TIRES
Maximum 28 kPa (4 PSI)
Front
Minimum 24 kPa (3.5 PSI)
Pressure
Maximum 31 kPa (4.5 PSI)
Rear
Minimum 28 kPa (4 PSI)
Minimum tire thread depth mm (in) 3 (0.118)
Front 25 x 8 x 12
Size
Rear 25 x 10 x 12
• WHEELS
Front 12 x 6
Size
Rear 12 x 7.5
DIMENSION
Overall length mm (in) 2184 (86)
Overall width mm (in) 1168 (46)
Overall height mm (in) 1143 (45)
Dry weight kg (lb) 250 (550) 272 (598)
Wheel base mm (in) 1244 (49)
Front mm (in) 965 (38)
Wheel track
Rear mm (in) 914 (36)
Front and under engine ground clearance mm (in) 236 (9.3)
Rear rigid axle ground clearance mm (in) 236 (9.3)
CAPACITIES
• LIQUID
Fuel tank 16 L (4.2 U.S. gal)
Fuel tank reserve 2 L (0.6 U.S. gal)
Capacity 3 L (3.17 quarts)
SAE, 4 stroke mineral based oil SG, SH or SJ or
Engine/transmission oil Bombardier synthetic oil 5W40.
Recommended
Refer to the oil viscosity chart in the
MAINTENANCE section
Front N.A. 500 mL (17 U.S. oz)
Capacity
Differential oil Rear 300 mL (10 U.S. oz)
Recommended Synthetic polyolester oil 75W90 (API GL5)
CV joint grease TEXACO, HTBJ grease (M3014), ONLY
Propeller shaft grease SHELL, Alvania EP-2, ONLY
Capacity 250 mL (8.5 U.S. oz)
Hydraulics brakes
Recommended Brake fluid DOT 4, ONLY
Cooling system 2.5 L (2.65 quarts)
• BODY AND FRAME
Weight distribution Front/rear % 49/51
Rear storage box (included with rear rack weight) 10 kg (22 lb)
Front 40 kg (90 lb)
Rack Rear (including rear storage box and
80 kg (175 lb)
tongue weight)
Total vehicle load allowed 230 kg (500 lb)
(including driver, all other loads and added accessories)
Gross vehicle weight rating 460 kg (1014 lb)
Towing 500 kg (1100 lb)
Tongue (included with rear rack weight) 14 kg (30 lb)
11-02-6 VMR2004_152_11_02A.FM

MATERIAL
Material Steel
Frame
Color Black
Material Steel
Wheel
Color Moondust pearl
Material Polypropylene (glass fiber-reinforced)
Front/rear rack
Color Earth gray
Material Aluminum
Front bumper
Color Aluminum
Material High density polyethylene
Front/rear fender
Color Yellow/Laurentian green/Viper red
Fuel tank protector
Color Black
Material Polypropylene
Steering cover
Color Earth grey
Storage compartment cover
Color Earth gray
Front facia
Front skid plate
Color Earth grey
Side panel
Foot rest
Color Black
Console
Air box cover
Color Black
Air box
Color Black
Transmission lever locator
Color Earth grey
A-arm protector
Color Black
Engine cover
Color Earth grey
Seat base
Color Black
Material Thermoformed vinyl
Seat cover
Color Deep earth grey
VMR2004_152_11_02A.FM 11-02-7
VEHICLE MODEL OUTLANDERTM 330 H.O. 2 X 4 OUTLANDERTM 330 H.O. 4 X 4 SERVICE PRODUCT
TORQUE
• ENGINE
Lower engine mounting bracket M8 23 N•m (17 lbf•ft)
Lower engine mounting bolts
M10 48 N•m (35 lbf•ft)
Upper engine support
Spark plug 20 N•m (15 lbf•ft)
Oil filter screw 10 N•m (89 lbf•in)
M6 10 N•m (89 lbf•in) None
Magneto cover bolts
M8 25 N•m (18 lbf•ft)
Starter bolts 10 N•m (89 lbf•in)
Vehicle speed sensor 10 N•m (89 lbf•in)
CPS bolt 10 N•m (89 lbf•in)
Engine cover 5 N•m (44 lbf•in)
Starter RED (+) cable 6 N•m (53 lbf•in) Dielectric grease
Rotor nut 180 N•m (133 lbf•ft)
Loctite 243
Stator bolt 10 N•m (89 lbf•in)
• COOLING
Radiator mount screw/nut 10 N•m (89 lbf•in)
Thermostat housing 7 N•m (62 lbf•in)
Thermostat bleeding screw 5 N•m (44 lbf•in)
Temperature sensor 17 N•m (151 lbf•in) None
Water pump housing 10 N•m (89 lbf•in)
Fan mount screw/nut 7 N•m (62 lbf•in)
Temperature sender on radiator 11 N•m (97 lbf•in)
• EXHAUST
Exhaust nut 11 N•m (97 lbf•in)
Heat shield screws 13 N•m (115 lbf•in) None
Exhaust support 23 N•m (17 lbf•ft)
• LUBRICATION
Engine drain plug 30 N•m (22 lbf•ft)
Engine oil strainer cover 10 N•m (89 lbf•in)
None
Oil pump housing 10 N•m (89 lbf•in)
Oil pressure regulator plug 11 N•m (97 lbf•in)
Oil pressure switch 12 N•m (106 lbf•in) Loctite 243
• CYLINDER AND HEAD
Valve cover 7 N•m (62 lbf•in)
M6 10 N•m (89 lbf•in)
Cylinder head screw First torque 20 N•m (15 lbf•ft) None
M11
Final torque 60 N•m (44 lbf•ft)
Intake adaptor 25 N•m (18 lbf•ft)
Camshaft timing gear 25 N•m (18 lbf•ft)
Chain guide 10 N•m (89 lbf•in) Loctite 243
Chain tensioner housing 8 N•m (71 lbf•in)
Chain tensioner plug 4.5 N•m (40 lbf•in) None
• CRANKSHAFT
M6 10 N•m (89 lbf•in)
Crankcase housing screw
M8 25 N•m (18 lbf•ft)
None
Connecting rod 20 N•m (15 lbf•ft) + 70° rotation
Crankshaft locking access screw 25 N•m (18 lbf•ft)
• GEARBOX
Bearing screw 10 N•m (89 lbf•in)
Index lever 10 N•m (89 lbf•in)
Loctite 243
Starter drive pinion cover 8 N•m (71 lbf•in)
Shifting indicator switch 4 N•m (35 lbf•in)
11-02-8 VMR2004_152_11_02A.FM
TORQUE
• CVT
CVT cover 7 N•m (62 lbf•in)
Centrifugal lever bolt 5 N•m (44 lbf•in)
100 N•m (74 lbf•ft), None
Drive pulley refer to CVT section for proper procedure
Driven pulley 60 N•m (44 lbf•ft)
• FUEL
Carburetor mounting clamp 2.5 N•m (22 lbf•in)
Fuel pump screw 5.5 N•m (49 lbf•in) None
Fuel valve nut 10 N•m (89 lbf•in)
• DRIVE TRAIN
Wheel hub nut 145 N•m (107 lbf•ft) (MINIMUM)
Front differential mounting bolt Front 75 N•m (55 lbf•ft)
Lower 90 N•m (66 lbf•ft)
Rear differential mounting bolt
Upper 90 N•m (66 lbf•ft)
Front propeller shaft screw Differential side 42 N•m (31 lbf•ft)
Engine side 34 N•m (25 lbf•ft) None
Rear propeller shaft screw
Differential side 42 N•m (31 lbf•ft)
Rear differential protector Hexagonal screw 2.5 N•m (22 lbf•in)
Differential oil drain plug Front/rear 13 N•m (115 lbf•in)
Differential filler plug Front/rear 13 N•m (115 lbf•in)
Differential housing Torx screw Front/rear 33 N•m (24 lbf•ft)
Front differential 150 N•m (111 lbf•ft)
Pinion gear nut Loctite 243
Rear differential 150 N•m (111 lbf•ft)
Disconnect unit mounting bolts 24 N•m (18 lbf•ft)
Disconnect unit actuator mounting bolts 18 N•m (13 lbf•ft) None
2 WD/4 WD selector (4 X 4 models only) 18 N•m (13 lbf•ft)
• WHEEL
Wheel nuts 70 N•m (52 lbf•ft) Anti-seize
• STEERING
Tie rod ends 75 N•m (55 lbf•ft)
Steering arm (castellated nut) 75 N•m (55 lbf•ft)
Handlebar screws 24 N•m (18 lbf•ft) None
Steering column half housing bolts 24 N•m (18 lbf•ft)
Handle grip screw 0.5 N•m (4 lbf•in)
Flanged bearing bolts 10 N•m (89 lbf•in) Loctite 243
• SUSPENSION
Trailing arm nut 190 N•m (140 lbf•ft)
Loctite 243
McPershon strut nut 55 N•m (41 lbf•ft)
McPershon strut bolt 80 N•m (59 lbf•ft)
A-arm bolt 48 N•m (35 lbf•ft)
A-arm 23 N•m (17 lbf•ft)
Ball joint
Knuckle 48 N•m (35 lbf•ft)
None
A-arm protector 4 N•m (35 lbf•in)
Rear shock absorber bolt 48 N•m (35 lbf•ft)
120 N•m (89 lbf•ft)
Torsion bar nut refer to REAR SUSPENSION section for proper procedure
VMR2004_152_11_02A.FM 11-02-9
TORQUE
• BRAKE
Front 34 N•m (25 lbf•ft)
Caliper brake screws
Rear 24 N•m (18 lbf•ft)
Brake disc screws
None
Master cylinder bolts 24 N•m (18 lbf•ft)
BANJO bolt 24 N•m (18 lbf•ft)
Caliper bleeder valve 5 N•m (44 lbf•in)
Master cylinder rod nut 5 N•m (44 lbf•in)
Hydraulic brake light switch 7 N•m (62 lbf•in) Pipe sealant
• BODY AND FRAME
M6 2.5 N•m (22 lbf•in)
Front skid plate
M10 8 N•m (71 lbf•in)
M8 24 N•m (18 lbf•ft)
Front bumper
M10 48 N•m (35 lbf•ft)
None
Front/rear racks 4.5 N•m (40 lbf•in)
Footpeg 4.5 N•m (39 lbf•in)
Headlamp housing 1 N•m (9 lbf•in)
Front 18 N•m (13 lbf•ft) MINIMUM
Fender support
Rear 21 N•m (15 lbf•ft) MAXIMUM Loctite 243 (rear only)
11-02-10 VMR2004_152_11_02A.FM
OUTLANDER 400 0
OUTLANDERTM 400 H.O.
VEHICLE MODEL
2X4 4X4 XT
ENGINE
Starting system
Decompressor type Automatic
Stroke mm (in) 61.5 (2.42)
Compression ratio 10.3:1
Type Nelson, steel
Exhaust system
Intake mm (in) 0.06 (.0024) to 0.14 (.0055)
Valve clearance
Exhaust mm (in) 0.11 (.0043) to 0.19 (.0075)
New mm (in) 1.15 to 1.35 (.045 to .053)
Intake
New mm (in) 1.25 to 1.55 (.049 to .061)
Exhaust
VMR2004_152_11_03A.FM 11-03-1

VEHICLE MODEL
2X4 4X4 XT
ENGINE
Piston ring end gap Upper compression ring mm (in) 0.40 (.016)
Wear limit mm (in) 12.060 (.4748)
Wear limit mm (in) 11.990 (.4720)
Cylinder taper
Wear limit mm (in) 21.950 (.8642)
Wear limit mm (in) 34.950 (1.3760)
Wear limit mm (in) 22.040 (.8677)
Camshaft bore
Wear limit mm (in) 35.040 (1.3795)
Wear limit mm (in) 32.300 (1.2717)
Cam lobe
Wear limit mm (in) 32.000 (1.2598)
Wear limit mm (in) 39.980 (1.5740)
Wear limit mm (in) 42.000 (1.6535)
11-03-2 VMR2004_152_11_03A.FM

VEHICLE MODEL
2X4 4X4 XT
ENGINE
Crankshaft radial clearance MAG/PTO side Service limit mm (in) 0.07 (.0028)
Wear limit mm (in) 19.980 (.7867)
Drive belt
MAG side mm (in) 17.990 (.708)
Main shaft
PTO side mm (in) 24.950 (.982)
VMR2004_152_11_03A.FM 11-03-3

VEHICLE MODEL
2X4 4X4 XT
ELECTRICAL
Quantity 1
Gap mm (in) 0.7 to 0.8 (.028 to .032)
Starter coil Ω 0.4 ± 01 @ 20°C (68°F)
Primary Ω 1.0 ± 0.15 @ 20°C (68°F)
Ignition coil
Secondary kΩ 11.5 ± 2.3 @ 20°C (68°F)
Forward RPM 8000
Engine RPM limiter
Voltage 12 volts
Battery
Headlight 2 x 30 W, HOBBS 81425
Fan 15 A
Fuses
Main 20 A
CARBURETION
Type
Model BSR33
Fuel pump
Main jet 133.8
Pilot jet 32.5
Jet needle 5 FEY 1
Adjustment
± 0.5 mm 10.0
Float level
± 0.020 in .390
Fuel
COOLING

Fan Thermostatic
Fan thermostat
Engine thermostat
11-03-4 VMR2004_152_11_03A.FM

VEHICLE MODEL
2X4 4X4 XT
LUBRICATION
DRIVE TRAIN
Transmission Type
STEERING
mm (in)
Total toe (vehicle on ground) 0 ± 4 (0 ± .157)
Camber angle 0°
SUSPENSION
• FRONT
Qty 2
Shock absorber
Type Oil
• REAR
Qty 2
Shock absorber
Type Oil
BRAKES
Qty 2
Front brake
Qty 1
Rear brake
Parking brake Hydraulic lock-4 wheels
Caliper Floating
Front Organic
Lining material
Rear Metallic
mm (in) 3.5 (.138)
Minimum brake disk thickness
mm (in) 4.3 (.17)
Maximum brake disk warpage mm (in) 0.2 (.01)
VMR2004_152_11_03A.FM 11-03-5

VEHICLE MODEL
2X4 4X4 XT
TIRES AND WHEELS
• TIRES
Maximum 28 kPa (4 PSI)
Front
Minimum 24 kPa (3.5 PSI)
Pressure
Maximum 31 kPa (4.5 PSI)
Rear
Minimum 28 kPa (4 PSI)
Front 25 x 8 x 12
Size
Rear 25 x 10 x 12
• WHEELS
Front 12 x 6
Size
Rear 12 x 7.5
DIMENSIONS
Dry weight kg (lb) 250 (550) 269 (592)
Wheel track
Rear mm (in) 914 (36)
CAPACITIES
• LIQUID
Recommended
Refer to the oil viscosity chart in the
MAINTENANCE section
Front N.A. 500 mL (17 U.S. oz)
Capacity
Hydraulics brakes
• BODY AND FRAME
Front 40 kg (90 lb)
Rack Rear (including rear storage box and
80 kg (175 lb)
tongue weight)
Total vehicle load allowed 230 kg (500 lb)
(including driver, all other loads and added accessories)
Gross vehicle weight rating 460 kg (1014 lb)
11-03-6 VMR2004_152_11_03A.FM

VEHICLE MODEL
2X4 4X4 XT
MATERIAL
Material Steel
Frame
Color Black
Material Steel
Wheel
Color Moondust pearl Chrome/Deep Black
Front/rear rack
Color Earth gray
Material Aluminum
Front bumper
Color Aluminum
Front/rear fender Yellow/Laurentian
Color Yellow/Laurentian Green/Viper Red/Camo green/Viper red/
Camo/Sandstone
Fuel tank protector
Color Black
Steering cover
Color Earth grey
Color Earth gray
Front facia Yellow/Laurentian
Color Yellow/Laurentian green/Viper red/Camo green/Viper
red/Sandstone
Front skid plate
Color Earth grey
Yellow/Laurentian
Side panel green/Viper
Color Yellow/Laurentian Green/Viper Red/Camo
red/Camo/
Sandstone
Foot rest
Color Black
Yellow/Laurentian
Console green/Viper
Color Yellow/Laurentian green/Viper red/Camo red/Camo/
Sandstone
Air box cover
Color Black
Air box
Color Black
Color Earth grey
A-arm protector
Color Black
Engine cover
Color Earth grey
Seat base
Color Black
Seat cover
VMR2004_152_11_03A.FM 11-03-7

VEHICLE MODEL SERVICE PRODUCT
2X4 4X4 XT
TORQUE
• ENGINE
M10 48 N•m (35 lbf•ft)
M6 10 N•m (89 lbf•in)
Magneto cover bolts None
M8 25 N•m (18 lbf•ft)
Winch solenoid N.A. 9 N•m (80 lbf•in)
Loctite 243
• COOLING
• EXHAUST
• LUBRICATION
None
M6 10 N•m (89 lbf•in)
M11
Final torque 60 N•m (44 lbf•ft)
11-03-8 VMR2004_152_11_03A.FM

2X4 4X4 XT
TORQUE
• CRANKSHAFT
M6 10 N•m (89 lbf•in)
M8 25 N•m (18 lbf•ft)
None
• GEARBOX
Loctite 243
• CVT
Drive pulley refer to CVT section for proper procedure
• FUEL
• DRIVE TRAIN
Lower 90 N•m (66 lbf•ft)
Rear differential mounting bolt
Upper 90 N•m (66 lbf•ft)
Front differential 150 N•m (111 lbf•ft)
Pinion gear nut Loctite 243
Rear differential 150 N•m (111 lbf•ft)
2 WD/4 WD selector (4 X 4 models only) 18 N•m (13 lbf•ft)
• WHEEL
• STEERING
VMR2004_152_11_03A.FM 11-03-9

2X4 4X4 XT
TORQUE
• SUSPENSION
Loctite 243
Ball joint
Knuckle 48 N•m (35 lbf•ft) None
120 N•m (89 lbf•ft)
Torsion bar nut
refer to REAR SUSPENSION section for proper procedure
• BRAKE
Brake disc screws
None
• BODY AND FRAME
M6 2.5 N•m (22 lbf•in)
Front skid plate
M10 8 N•m (71 lbf•in)
M8 24 N•m (18 lbf•ft)
Front bumper
M10 48 N•m (35 lbf•ft)
Winch plate support N.A. 24 N•m (18 lbf•ft) None
Winch bolts N.A. 15 N•m (133 lbf•in)
Fairlead N.A. 15 N•m (133 lbf•in)
Fender support
11-03-10 VMR2004_152_11_03A.FM
Subsection 04 (OUTLANDER MAX)
OUTLANDER MAX 0
VEHICLE MODEL OUTLANDERTM MAX OUTLANDERTM MAX XT
ENGINE
Starting system
Decompressor type Automatic
Stroke mm (in) 61.5 (2.42)
Compression ratio ± 0.3 10.3:1
Type Nelson, steel
Exhaust system
Intake mm (in) 0.06 (.0024) to 0.14 (.0055)
Valve clearance
Exhaust mm (in) 0.11 (.0043) to 0.19 (.0075)
New mm (in) 1.15 to 1.35 (.045 to .053)
Intake
New mm (in) 1.25 to 1.55 (.049 to .061)
Exhaust
Piston ring end gap Upper compression ring mm (in) 0.40 (.016
VMR2004_152_11_04A.FM 11-04-1

ENGINE
Wear limit mm (in) 12.060 (.4748)
Wear limit mm (in) 11.990 (.4720)
Cylinder taper
Wear limit mm (in) 21.950 (.8642)
Wear limit mm (in) 34.950 (1.3760)
Wear limit mm (in) 22.040 (.8677)
Camshaft bore
Wear limit mm (in) 35.040 (1.3795)
Wear limit mm (in) 32.300 (1.2717)
Cam lobe
Wear limit mm (in) 32.000 (1.2598)
Wear limit mm (in) 39.980 (1.5740)
Wear limit mm (in) 42.000 (1.6535)
MAG side
Crankshaft radial clearance Service limit mm (in) 0.07 (.0028)
PTO side
11-04-2 VMR2004_152_11_04A.FM

ENGINE
Wear limit mm (in) 19.980 (.7867)
Drive belt
MAG side mm (in) 17.990 (.708)
Main shaft
PTO side mm (in) 24.950 (.982)
VMR2004_152_11_04A.FM 11-04-3

ELECTRICAL
Quantity 1
Gap mm (in) 0.7 to 0.8 (.028 to .032)
Starter coil Ω 0.4 ± 01 @ 20°C (68°F)
Primary Ω 1.0 ± 0.15 @ 20°C (68°F)
Ignition coil
Secondary kΩ 11.5 ± 2.3 @ 20°C (68°F)
Forward RPM 8000
Engine RPM limiter
Voltage 12 volts
Battery
Headlight 2 x 30 W, HOBBS 81425
Fan 15 A
Fuses
Main 20 A
CARBURETION
Type
Model BSR33
Fuel pump
Main jet 133.8
Pilot jet 32.5
Jet needle 5 FEY 1
Adjustment
± 0.5 mm 10.0
Float level
± 0.020 in .390
Fuel
COOLING

Fan Thermostatic
Fan thermostat
Engine thermostat
11-04-4 VMR2004_152_11_04A.FM

LUBRICATION
DRIVE TRAIN
Transmission Type
STEERING
mm (in)
Total toe (vehicle on ground) 0 ± 4 (0 ± .157)
Camber angle 0°
SUSPENSION
• FRONT
Qty 2
Shock absorber
Type Oil
• REAR
Qty 2
Shock absorber
Type Oil
BRAKES
Qty 2
Front brake
Qty 1
Rear brake
Parking brake Hydraulic (lock-4 wheels)
Caliper Floating
Front Organic
Lining material
Rear Metallic
mm (in) 3.5 (.138)
Minimum brake disk thickness
mm (in) 4.3 (.17)
Maximum brake disk warpage mm (in) 0.2 (.01)
VMR2004_152_11_04A.FM 11-04-5

TIRES AND WHEELS
• TIRE
34 kPa (5 PSI) MAXIMUM
Front
Up to 31 kPa (4.5 PSI) MINIMUM
Pressure
235 kg (517 lb) 34 kPa (5 PSI) MAXIMUM
Rear
31 kPa (4.5 PSI) MINIMUM
Front 25 x 8 x 12
Size
Rear 25 x 10 x 12
• WHEELS
Front 12 x 6
Size
Rear 12 x 7.5
DIMENSION
Dry weight kg (lb) 272 (598) 293 (645)
Wheel track
Rear mm (in) 914 (36)
CAPACITIES
• LIQUID
Recommended Refer to the oil viscosity chart in the
MAINTENANCE section
Front 500 mL (17 U.S. oz)
Capacity
Hydraulics brakes
• BODY AND FRAME
Front 40 kg (90 lb)
Rack Rear (including rear storage box and 80 kg (175 lb)
tongue weight)
Total vehicle load allowed
(including driver, all other loads and added accessories) 235 kg (517 lb)
Gross vehicle weight rating 460 kg (1014 lb) 554 kg (1219 lb)
11-04-6 VMR2004_152_11_04A.FM

MATERIAL
Material Steel
Frame
Color Black
Material Steel
Wheel
Color Moondust pearl
Front/rear rack
Color Earth gray
Material Aluminum
Front bumper
Color Aluminum
Front/rear fender
Color Laurentian green/Viper red
Fuel tank protector
Color Black
Steering cover
Color Earth grey
Color Earth gray
Front facia
Front skid plate
Color Earth grey
Side panel
Foot rest
Color Black
Console
Air box cover
Color Black
Air box
Color Black
Color Earth grey
A-arm protector
Color Black
Engine cover
Color Earth grey
Seat base
Color Black
Seat cover
VMR2004_152_11_04A.FM 11-04-7
VEHICLE MODEL OUTLANDERTM MAX OUTLANDERTM MAX XT SERVICE PRODUCT

TORQUE
• ENGINE
M10 48 N•m (35 lbf•ft)
M6 10 N•m (89 lbf•in)
Magneto cover bolts None
M8 25 N•m (18 lbf•ft)
Winch solenoid N.A. 9 N•m (80 lbf•in)
Loctite 243
• COOLING
• EXHAUST
• LUBRICATION
None
M6 10 N•m (89 lbf•in)
M11 Final torque 60 N•m (44 lbf•ft)
• CRANKSHAFT
M6 10 N•m (89 lbf•in)
M8 25 N•m (18 lbf•ft)
None
11-04-8 VMR2004_152_11_04A.FM

TORQUE
• GEARBOX
Loctite 243
• CVT
Drive pulley
refer to CVT section for proper procedure
• FUEL
• DRIVE TRAIN
Lower
Rear differential mounting bolt 90 N•m (66 lbf•ft)
Upper
Front differential
Pinion gear nut 150 N•m (111 lbf•ft) Loctite 243
Rear differential
2 WD/4 WD selector 18 N•m (13 lbf•ft)
• WHEEL
• STEERING
VMR2004_152_11_04A.FM 11-04-9

TORQUE
• SUSPENSION
Loctite 243
Ball joint
Knuckle 48 N•m (35 lbf•ft)
None
120 N•m (89 lbf•ft)
Torsion bar nut
refer to REAR SUSPENSION section for proper procedure
• BRAKE
Brake disc screws
None
• BODY AND FRAME
M6 2.5 N•m (22 lbf•in)
Front skid plate
M10 8 N•m (71 lbf•in)
M8 24 N•m (18 lbf•ft)
Front bumper
M10 48 N•m (35 lbf•ft)
Winch plate support N.A. 24 N•m (18 lbf•ft) None
Winch bolts N.A. 15 N•m (133 lbf•in)
Fairlead N.A. 15 N•m (133 lbf•in)
Backrest 24 N•m (18 lbf•ft)
Grab handle 10 N•m (89 lbf•in)
Fender support
11-04-10 VMR2004_152_11_04A.FM
Section 12 WIRING DIAGRAM
Subsection 01 (WIRING DIAGRAM)
WIRING DIAGRAM 0
WIRING CONNECTORS CONNECTOR HOUSING AREA
CODING
XX/XX
 WARNING 1 -02D
Ensure all terminals are properly crimped on
the wires and all connector housings are prop- A00I04C
1
erly fastened.
THE SHADED PART INDICATES THE CONNECTOR HOUSING AREA
XX/XX
1-02D
1
1
A00I04A 2 3 4 5
2
3
1. Wire colors
2. Connector housing area 4
3. Connector number
4. Wire connector location in housing
WIRE COLORS
V07A0HA
It identifies the color of a wire. When a 2-color
scheme is used, the first color is the main color
while the second color is the tracer color. AREA LOCATION
1 Steering area
XX/XX 2 Service compartment
XX/XX 3 Front of vehicle

A00I04B 1-02D 4 Engine area
THE SHADED PART INDICATES THE WIRE COLOR
5 Rear of vehicle
Example: YL/BK is a YELLOW wire with a BLACK
stripe.
VMR2004_153_12_01A.FM 12-01-1
Section 12 WIRING DIAGRAM
Subsection 01 (WIRING DIAGRAM)
CONNECTOR NUMBER
It represents a connector number in the given ar- B
ea. If there are many connectors in the same area, A
it helps identify which wire is in which connector.
B
A
XX/XX
1- 02 -D
V04G04A
02 B B
A A
THE SHADED PART INDICATES A CONNECTOR NUMBER C C
CONNECTOR LOCATION IN
HOUSING
This is the wire position in the connector. The number B B
or letter given refers to the physical identification C C
A A
stamped on the connector.
NOTE: However, if no letters or numbers are indi-
cated on the connectors, see the connector chart
at the end of the OVERVIEW section for proper
D D
connector locations. A A
C C
XX/XX
A00E4WB B B
1-02 D
A00I04D
D TYPICAL
THE SHADED PART INDICATES THE CONNECTOR LOCATION IN

HOUSING
12-01-2 VMR2004_153_12_01A.FM
OUTLANDER
V07Z03

2004 2005 Bombardier Outlander 330 400 SM 03740 (1) 4 ROUES A STEPH

Uploaded by

Copyright:

Available Formats

You might also like

2004 2005 Bombardier Outlander 330 400 SM 03740 (1) 4 ROUES A STEPH

Uploaded by

Document Information

Original Description:

Original Title

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

2004 2005 Bombardier Outlander 330 400 SM 03740 (1) 4 ROUES A STEPH

Uploaded by

Copyright:

Available Formats

2004

This document contains the registered trademarks of the following companies:

SECTION SUBSECTION PAGE

SAFETY NOTICE ................................................................................................................................... III

01 SERVICE TOOLS AND 01 – Table of contents...................................................................... 01-01-1

02 MAINTENANCE 01 – Table of contents...................................................................... 02-01-1

03 ENGINE 01 – Table of contents...................................................................... 03-01-1

04 FUEL SYSTEM 01 – Table of contents...................................................................... 04-01-1

05 ELECTRICAL 01 – Table of contents...................................................................... 05-01-1

06 DRIVE TRAIN 01 – Table of contents...................................................................... 06-01-1

07 STEERING SYSTEM 01 – Table of contents...................................................................... 07-01-1

08 SUSPENSION 01 – Table of contents...................................................................... 08-01-1

09 BRAKES 01 – Table of contents...................................................................... 09-01-1

SECTION SUBSECTION PAGE

10 BODY/FRAME 01 – Table of contents ..................................................................... 10-01-1

11 TECHNICAL DATA 01 – SI metric information guide...................................................... 11-01-1

12 WIRING DIAGRAM 01 – Wiring diagram......................................................................... 12-01-1

ENGINE AND VEHICLE SERIAL LIST OF ABBREVIATIONS USED

BDC bottom dead center

BTDC before top dead center

CDI Capacitor discharge ignition

cm² square centimeter

cm³ cubic centimeter

TYPICAL DC direct current

ARRANGEMENT OF THE fl. oz fluid ounce

lbf pound (force)

MPH mile per hour

N.A. not applicable

O.L. overload (open circuit)

O.D. outside diameter

OHC Over head camshaft

P/N part number

PSI pounds per square inch

PTO power take off

RPM revolution per minute

Sp. Gr. specific gravity

TDC top dead center

U.S. oz ounce (United States)

USFD U.S. Forest Service

Vac volt (alternative current)

This Shop Manual uses technical terms wich may be

TYPICAL PAGE Page heading

REMOVAL AND INSTALLATION Subsection title

Document Bold face number Page numbering system:

Title indicates BEARING STATOR AND TRIGGER COIL

Call-outs for 1. Ball bearing R610motr20A 1 2

Illustrations and photos show the typical construc-

Threadlocker 1. Clean threads (bolt and hole) with solvent.

1. Clean threads (bolt and nut) with solvent.

3. Choose proper strength Loctite threadlocker.

Adjusting Screw NOTE: Retaining compound is always forced out

1. Adjust screw to proper setting.

1. Clean inner housing diameter and outer gasket

TIGHTENING STRENGTH GRADE

6.5 to 8.5 N•m 8 to 12 N•m 10.5 to 15 N•m

Bombardier SERVICE PUBLICATIONS REPORT

Bombardier SERVICE PUBLICATIONS REPORT