SAFETY NOTICE

SAFETY NOTICE
This manual has been prepared as a guide to cor- CAUTION Indicates a hazardous situation
rectly service and repair 2014 Can-Am™ roadsters which, if not avoided, could result in minor or
described in the list in the INTRODUCTION. moderate injury.
This SHOP MANUAL SUPPLEMENT must be NOTICE Indicates an instruction which, if not
used in conjunction with the 2013 CAN-AM
followed, could result in severe damage to ve-
ROADSTER SHOP MANUAL (P/N 219 100 736).
hicle components or other property.
Refer to this manual when a particular system is
not covered in this supplement. NOTE: Indicates supplementary information re-
This edition was primarily published to be used by quired to fully complete an instruction.
technicians who are already familiar with service Although the mere reading of such information
procedures relating to Bombardier Recreational does not eliminate the hazard, your understand-
Products Inc. (BRP) products. Mechanical tech- ing of the information will promote its correct
nicians should attend continuous training courses use. Always use common shop safety practice.
given by B.R.P.T.I.
It is understood that this manual may be trans-
Please note that the instructions will apply only lated into another language. In the event of any
if proper hand tools and special service tools are discrepancy, the English version shall prevail.
used.
BRP disclaims liability for all damages and/or in-
The content depicts parts and procedures appli- juries resulting from the improper use of the con-
cable to the particular product at time of writing. tents. We strongly recommend that any services
SERVICE and WARRANTY BULLETINS may be be carried out and/or verified by a highly skilled
published to update the content of this manual. professional mechanic.
Make sure to read and understand them. Dealer
modifications that were carried out after manufac-
turing of the product, whether or not authorized
by BRP, are not included.
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 ex-
act replicas of the parts.
The use of BRP parts is most strongly recom-
mended when considering replacement of any
component. 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.
It is understood that certain modifications may
render use of the vehicle illegal under existing
federal, provincial and state regulations.
This manual emphasizes particular information de-
noted by the wording and symbols:

WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.

rmr2014-005 I
INTRODUCTION

INTRODUCTION
GENERAL INFORMATION
This Shop Manual covers the following BRP made 2014 Can-Am Roadsters Spyder RT.
MODEL COLOR MODEL NUMBER
Timeless Black A3EB, A3ED, A3EE, A3EF
SM6
White Pearl A3EG
RT
Timeless Black B2EB, B2ED
SE6
White Pearl B2EE
Timeless Black B5EB
White Pearl B5ED
SM6
Circuit Yellow B5EF
Cognac B5EH
RT-S
Timeless Black A4EB
White Pearl A4ED, A4EF, A4EG, A4ER
SE6
Circuit Yellow A4EH
Cognac A4EK, A4EM, A4EN, A4EP
Black Current B9EB, B9ED
B9EE, B9EG, B9EH, B9EJ, B9EK,
RT Limited SE6 Silver Platinum
B9EL, B9EN
Cognac B9ER, B9ET, B9EU, B9EV

The information and component/system descriptions contained in this manual are correct at time of writ-
ing. BRP however, maintains a policy of continuous improvement of its products without imposing upon
itself any obligation to install them on products previously manufactured.
Due to late changes, there may be some differences between the manufactured product and the de-
scription and/or specifications in this document.
BRP reserves the right at any time to discontinue or change specifications, designs, features, models or
equipment without incurring obligation.

II rmr2014-005
 INTRODUCTION

VEHICLE INFORMATION
VEHICLE IDENTIFICATION
NUMBER (V.I.N.)

1 2
rmo2008-001-091_a

TYPICAL — VEHICLE SERIAL NUMBER LABEL

1. VIN (Vehicle Identification Number)
2. Model number

rmo2014-005-008_a

1. Engine Identification Number (EIN) location

EPA COMPLIANCE LABEL

rmo2013-003-037_a

TYPICAL - LOCATION OF VIN

1. Swing arm (VIN label)
2. Lower frame (VIN stamped on left side) rmo2008-001-094

ENGINE IDENTIFICATION
NUMBER (EIN)
The engine identification number is located on the
left rear of engine, near the alternator.

rmo2008-001-044_b

TYPICAL
1. EPA exhaust emission label located under seat

rmr2014-005 III
 Subsection 01 (MAINTENANCE SCHEDULE)

MAINTENANCE SCHEDULE
Maintenance is very important for keeping your vehicle in safe operating condition. Proper maintenance
is the owner's responsibility. Perform periodic checks and follow the maintenance schedule. The main-
tenance schedule does not exempt the pre-ride inspection.

WARNING
Failure to properly maintain the vehicle according to the maintenance schedule and procedures
can make it unsafe to operate.

BREAK-IN INSPECTION - 5 000 KM (3,000 MI)

Using BRP Utility and Diagnostic Software (B.U.D.S.), check fault codes and install required updates.
Replace engine oil and oil filter.
Check clutch fluid level (SM6 model only).
Check brake fluid level.
Check reverse mechanism operation.
Check engine coolant level.
Inspect throttle twist grip operation.
Check lighting system (brake light, hazard warning light, turn signal lights, position lights, license plate light).
Clean brake light switch.
Check operation of control switches.
Inspect the drive belt condition and its tension. Adjust if required.
Check tightening torque of the front wheels lug nuts.
Check tightening torque of the rear wheel axle nut.
Check parking brake operation. Adjust as required.
Check wheels wear. Align front wheels if required.
Check tires pressure. Adjust as required.
Check brake pads and discs condition.
Check passenger handholds looseness.
Check footrests looseness.
Check body panels looseness.
Check operation of storage compartment latches, hinges and key barrels.
Check and retighten exhaust pipe, clamping rings, joints, and gaskets condition.

rmr2014-006 1
Subsection 01 (MAINTENANCE SCHEDULE)

EVERY 15 000 KM (9,300 MI) OR 1 YEAR (WHICHEVER COMES FIRST)

Using BRP Utility and Diagnostic Software (B.U.D.S.), check fault codes and install required updates.
Replace engine oil and oil filter.
Check clutch fluid level (SM6 model only).
Check brake fluid level. Replace every 2 years.
Check brake hoses
Check reverse mechanism operation.
Check radiator, hoses and water pump.
Check engine coolant level.
Perform a pressure test of cooling system.
Inspect throttle twist grip operation.
Check lighting system (brake light, hazard warning light, turn signal lights, position lights, license plate light).
Clean brake light switch.
Check operation of control switches and passenger switches.
Check condition of fuel hoses, fuel evaporation lines and canister.
Check battery connections tightening.
Inspect the drive belt condition and its tension. Adjust if required.
Check and retighten exhaust pipe, clamping rings, joints, and gaskets condition.
Check steering for abnormal play.
Check tie-rods condition.
Check shock absorbers for leaks or other damages.
Check tightening torque of the front wheels lug nuts.
Check tightening torque of the rear wheel axle nut.
Check ball joints condition.
Check front wheel bearings condition.
Check parking brake operation. Adjust as required.
Check wheels wear. Align front wheels if required.
Check tires pressure. Adjust as required.
Check brake pads and discs condition.
Check passenger handholds looseness.
Check footrests looseness.
Check body panels looseness.
Check operation of storage compartment latches, hinges and key barrels.

EVERY 30 000 KM (19,000 MI)

Replace air filter and clean air filter housing.
Replace clutch fluid (SM6 model only).
Replace the fuel filter (or every 5 years).

2 rmr2014-006
 Subsection 01 (MAINTENANCE SCHEDULE)

EVERY 45 000 KM (28,000 MI)

Replace the Hydraulic Control Module (HCM) oil filter (SE6 model only).
Replace the canister pre-filter.
Replace engine coolant (or every 5 years).
Replace the spark plugs.
Check front suspension arms rubber bushings.

rmr2014-006 3
 Subsection XX (PRESEASON PREPARATION)

PRESEASON PREPARATION
Prior to use the vehicle, proper preparation is re-
quired after the storage period.
Any worn, broken or damaged parts found during
the storage procedure should have been replaced.
If not, proceed with the replacement.
PROCEDURES
5. Check that the engine stop button is working
properly.
6. Start engine, release parking brake and ensure
parking brake indicator is off on the multifunc-
tion gauge cluster.
7. Drive forward slowly a few feet then apply
brake to test.

VEHICLE PREPARED AS PER VEHICLE NOT PREPARED AS PER

STORAGE PROCEDURE STORAGE PROCEDURE
Remove vehicle protective cover, muffler protec- Proceed with the same steps as specified in VE-
tive bag and clean the vehicle. HICLES PREPARED AS PER STORAGE PROCE-
Charge battery as required. Refer to CHARGING DURE above.
SYSTEM. Carry out these additional steps:
Check the following items: – Check the level of engine coolant. Refer to
– Tires: Look for damage, incorrect inflation and COOLING SYSTEM subsection.
excessive tread wear. – Check the brake fluid level. Refer to BRAKES
– Wheels and lug nuts: Look for damage. subsection.
Check front wheel lug nuts if they are properly – Lubricate the front suspension arms. Refer to
tighten. Be sure the rear wheel axle nut and FRONT SUSPENSION subsection.
cotter pin are in place. – Replace engine oil and filter. Refer to LUBRICA-
– Drive belt: Look for fraying, cuts, punctures TION SYSTEM subsection.
and missing teeth. Verify alignment. For addi- – Replace HCM oil filter (SE5 model). Refer to
tional information, refer to DRIVE BELT AND HYDRAULIC CONTROL MODULE (SE5) sub-
REAR WHEEL subsection. section.
– Leaks: Look under the vehicle for any leaks. – Models with a flat footrest: Release the latch
– Brake pedal: Press and make sure you feel underneath footrest. Pivot footrest by pushing
firm resistance. Pedal must fully return when down its front part. Flip back the footrest until
released. it latches. The mechanism must work freely.
– Throttle handle: Twist a few times. Be sure
it operates freely and returns to idle position
when released.
– Clutch lever (SM5 model): Squeeze to be
sure it operates easily and fully returns when
released. Adjust if needed. Refer to CLUTCH
(SM5) subsection.
– Clutch oil level (SM5 model): Check clutch
fluid level. Refer to CLUTCH (SM5) subsection.
– Gearshift selector (SE5 model): Be sure
gearshift selector operates normally in both di-
rections and returns to center when released.
Turn ignition key ON:
1. Check the gauges, indicator lamps, and mes-
sages on the multifunction gauge cluster.
2. Ensure headlights, taillight, brake light, turn sig-
nals, and hazards are working properly.
3. Ensure horn is working properly.
4. Start engine and verify steering operates freely.

rmr2013-005 1
 Subsection 02 (STORAGE PROCEDURE)

STORAGE PROCEDURE
SERVICE PRODUCTS
Description Part Number Page
LONG LIFE ANTIFREEZE .............................................................. 219 702 685 ........................................... 1
XPS FUEL STABILIZER.................................................................. 413 408 601 ........................................... 1
XPS ROADSTER WASH ................................................................ 219 701 703 ........................................... 2
XPS STORAGE OIL (EXCEPT U.S. COUNTRY) ............................. 413 711 600 ........................................... 1
XPS STORAGE OIL (U.S. COUNTRY ONLY) ................................. 413 711 900 ........................................... 1

GENERAL body (5 seconds in each openings) while crank-

If the vehicle is not ridden for at least 4 months,
such as during the winter, proper storage is nec-
essary to keep the vehicle in good condition.
PROCEDURES
FUEL SYSTEM
Fuel System Protection
With the new fuel additives, it is critical to use the
XPS FUEL STABILIZER (P/N 413 408 601) or an equiv-
alent to prevent fuel deterioration and fuel system
gumming. Follow the manufacturer's instructions
for proper use.
Pour fuel stabilizer in fuel tank. Fill up fuel tank.
NOTICE Engine should be run after fuel sta-
bilizer is added to ensure fuel system compo-
nents protection against varnish deposits.
Do not drain fuel system.
ENGINE
Engine Oil and Filter Replacement
Change engine oil and filter. Refer to LUBRICA-
TION SYSTEM subsection.
Engine Internal Lubrication
Engine internal parts should be lubricated to pro-
tect them from rust formation during the storage
period.
Proceed as follows:
1. Remove air filter housing cover. Refer to AIR
INTAKE SYSTEM subsection.
2. Spray XPS STORAGE OIL (EXCEPT U.S. COUN-
TRY) (P/N 413 711 600) or XPS STORAGE OIL (U.S.
COUNTRY ONLY) (P/N 413 711 900) into throttle
ing in drowned mode (throttle wide open and
depress start button).
3. Reinstall air filter housing cover.
NOTE: Do not run engine during storage period.
CLUTCH SYSTEM (SM6)
Clutch Fluid Level Inspection
Check clutch fluid level. Refill if necessary.
COOLING SYSTEM
Coolant Inspection
Check coolant level.
Test coolant density using an antifreeze hydrome-
ter.
NOTE: Follow manufacturer's instructions for
proper use.
Use LONG LIFE ANTIFREEZE (P/N 219 702 685) or a
blend of 50% antifreeze with 50% distilled water
to provide the optimum cooling, corrosion protec-
tion and antifreeze protection.
NOTICE Do not use tap water, straight an-
tifreeze 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 an-
tifreeze will cause system temperature prob-
lems.
Change coolant if necessary. Refer to COOLING
SYSTEM subsection.
ELECTRICAL SYSTEM
Battery Charging
Slow charge the battery once a month at the rec-
ommended charging rate of 2 A. It is not neces-
sary to remove the battery.

rmr2014-007 1
Subsection 02 (STORAGE PROCEDURE)

WHEELS AND TIRES
Tire Pressure
Inflate all tires to their recommended pressure.
BRAKE SYSTEM
Brake Fluid Level Inspection
Check brake fluid level. Refill if necessary.
Brake System Lubrication
Clean and lubricate mechanism of parking brake.
Lubricate parking brake cable.
Lubricate pivoting point of brake pedal.
3. While washing the vehicle, check for grease or
oil. You can use XPS ROADSTER WASH (P/N 219
701 703) or a mild automotive degreaser. Thor-
oughly follow the manufacturer's instructions.
4. Dry the vehicle with a chamois or a soft towel.
Vehicle Waxing
Apply non-abrasive wax to plastic parts.
NOTICE Do not wax or polish matte surfaces.
SURFACE PRODUCT/PRECAUTION
Glossy Apply only non-abrasive wax, safe
finishes for clear coat paints
Matte finishes Do not apply wax

SUSPENSION NOTICE Do not polish windshield with any

Suspension Lubrication plastic cleaner/polisher.
Lubricate front suspension arms. Refer to FRONT WARNING
SUSPENSION subsection.
Do not apply a vinyl or plastic protector on
the seat as the surface will become slippery
VEHICLE and the operator or the passenger may slip
Vehicle Cleaning off the vehicle.
To clean the vehicle, do not use high-pressure Vehicle Protection
washers (like the ones found in car washes) as
they may damage certain parts of the vehicle. Touch up all metal spots where paint has been
scratched off.
NOTICE Do not clean the windshield with al-
Install a plastic bag over muffler outlet to prevent
kaline or acid cleaner, gasoline or solvent to moisture from entering it.
avoid windshield damage.
Cover the vehicle with a permeable material.
NOTICE For Matte finishes, do not use wax, Avoid using plastic or similar non-breathing,
detail spray, or other products used on regular coated materials that restrict air flow and allow
paint. Do not wash with abrasive materials. Do heat and moisture to accumulate.
not use mechanical cleaners or polishers, and Store vehicle in a dry unheated area, away from
do not rub the surfaces vigorously. sunlight, with a small amount of daily temperature
To clean the vehicle: variation.
1. Rinse the vehicle thoroughly with water to re-
move loose dirt.
2. Using a soft, clean cloth, wash the vehicle with
water mixed with a mild detergent, such as
soap specially formulated for motorcycles or
automobiles.
NOTE: Using warm water works well to remove
bugs in the windshield and front panels.
NOTE: For Matte finishes, hand-wash with a soft
wash mitt and a mild cleaning product safe for
matte paint. To remove foreign substances such
as insects, use a soft applicator and a mild sol-
vent. Saturate and soak area before cleaning. Rub
lightly.

2 rmr2014-007
 Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

ENGINE REMOVAL AND INSTALLATION

SERVICE TOOLS
Description Part Number Page
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ............................................. 8
ENGINE LIFTING TOOL ................................................................ 529 036 300 ............................................. 5

10 ± 2 N•m
(89 ± 18 lbf•in)

31.5 ± 3.5 N•m

(23 ± 3 lbf•ft)

10 ± 2 N•m
(89 ± 18 lbf•in)
48 ± 6 N•m
(35 ± 4 lbf•ft)

30 ± 2 N•m 61 ± 9 N•m
(22 ± 1 lbf•ft) (45 ± 7 lbf•ft)
10 ± 2 N•m
(89 ± 18 lbf•in)

48 ± 6 N•m
(35 ± 4 lbf•ft)
61 ± 9 N•m
(45 ± 7 lbf•ft) 30 ± 2 N•m
(22 ± 1 lbf•ft)

rmr2014-008-100_a

rmr2014-008 1
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

GENERAL Remove exhaust clamp from manifold to front

pipe. Refer to EXHAUST SYSTEM subsection.
CAUTION To avoid potential burns, let en-
On Right Side of Vehicle:
gine and exhaust system cool down.
1. Disconnect the coolant hoses.
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed must be re-
placed (e.g.: locking tabs, elastic stop nuts,
cotter pins, etc.).

rmr2014-008-011_a
NOTICE Hoses, cables or locking ties re- COOLANT HOSES
moved during the procedure must be rein-
stalled as per factory standard.

PROCEDURES
ENGINE
Preparation for Engine Removal
Place vehicle on a workstation that will have ac-
cess to an engine-lifting hoist.
Refer to BODY subsection to remove the follow-
ing:
– Both mirrors
– Both middle side panels
– Both top side panels
– Both rear panels
– Both bottom side panels (rear and front)
– Front storage compartment
– Glove box
– Acoustic panels.
Disconnect the BLACK (-) cable from battery, then
the RED (+) cable.

WARNING
Always disconnect battery cables exactly in
the specified order, the BLACK (-) cable first.
It is recommended to disconnect electrical
connections prior to disconnecting fuel lines.

Drain engine coolant. Refer to COOLING SYS-

TEM subsection.

2 rmr2014-008
 Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

2. Make sure the following components are disconnected.

rmr2014-008-008_a

RH VIEW - SOME COMPONENTS REMOVED FOR CLARITY

1. Evap canister purge hose
2. Secondary air box
3. Fuel pressure hose
4. Valve cover breather hose
5. Front HCM connector (SE6 models only)
6. Ambient air temperature sensor
7. Clutch vent (SM6 only)

3. Cut locking ties and free no. 6 wire for removal with engine.
On Left Side of Vehicle:
1. Remove the LH foot rest support.
Release drive belt tension. Refer to DRIVE BELT AND REAR WHEEL subsection.
2. Remove front sprocket.

rmr2014-008 3
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

3. Make sure the following components are disconnected.

rmr2014-008-004_a

LH VIEW - SOME COMPONENTS REMOVED FOR CLARITY

1. Harness inter-connect. (HIC)
2. RED (+) starter cable
3. BLACK (-) engine ground cable
4. Evap purge valve connector
5. RED (+) alternator cable
6. Alternator connector
7. ECM connectors
8. Reverse lock actuator cable
9. Clutch hose

4. Remove left hand lateral support with ECM. Refer to FRAME subsection.
5. Remove primary air box. Refer to AIR INTAKE SYSTEM subsection.

4 rmr2014-008
 Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

Lifting Engine
1. Remove fasteners indicated in the following illustration.
NOTICE Never unscrew stabilizer rod jam nuts unless the rod needs to be changed.

rmr2014-008-200_a

2. Install ENGINE LIFTING TOOL (P/N 529 036 300) on points indicated by no. 1.

529036300

rmr2014-008 5
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

rmr2014-008-201_a

NOTICE Clearance is tight, be very careful not to damage components.

3. Lift engine slowly and remove it from vehicle on the LH side.

Engine Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
NOTE: Prior to installing engine, inspect condition
of engine mounts.
NOTE: Unless link rod dimensions were
changed, or link rod replaced, no engine align-
ment is necessary. Otherwise proceed with
engine alignment. Refer to ENGINE ALIGNMENT rmr2014-008-010_a

in this subsection. FRONT LINK ROD

Install all mounting bolts and mounting nuts.
Torque bolts to specifications.
Install all other removed parts.
Complete final assembly. Refer to FINAL ASSEM-
BLY in this subsection.

Engine Alignment
1. Pre-adjust front link rod as illustrated.

rmr2014-008-009_a

FRONT LINK ROD

1. LH thread
2. RH thread
A. 120.1 mm (4.73 in)

2. Tighten fasteners as per sequence in illustra-

tion.

6 rmr2014-008
 Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

NOTE: Depending on operation performed, additional fasteners may require tightening. These fasteners
do not affect engine alignment and should be tightened after illustrated sequence.

10 ± 2 N•m
(89 ± 18 lbf•in)

5
5 31.5 ± 3.5 N•m
(23 ± 3 lbf•ft)

10 ± 2 N•m
(89 ± 18 lbf•in)
48 ± 6 N•m
(35 ± 4 lbf•ft)

30 ± 2 N•m 61 ± 9 N•m
(22 ± 1 lbf•ft) 2 (45 ± 7 lbf•ft)
3
10 ± 2 N•m 6
(89 ± 18 lbf•in)

7
48 ± 6 N•m
(35 ± 4 lbf•ft)
4
1 61 ± 9 N•m
30 ± 2 N•m
(45 ± 7 lbf•ft)
(22 ± 1 lbf•ft)

rmr2014-008-100_e

ENGINE ALIGNMENT TIGHTENING SEQUENCE

Final Assembly ENGINE MOUNTS

Make sure oil drain plugs are reinstalled and tight. Engine Mounts Removal
Fill cooling system. Refer to COOLING SYSTEM
subsection. Front Rubber Mount
Check oil level. Refer to LUBRICATION SYSTEM Refer to BODY subsection to remove the follow-
subsection. ing parts:
– Both mirrors
Reconnect battery.
– Both middle side panels
WARNING – Both top side panels
Connect RED (+) cable then BLACK (-) cable. – Both rear panels
Always connect RED (+) cable in first. – Both bottom side panels (rear and front)
– Front storage compartment
Start engine and let it reach its operating temper- – Glove box
ature. – Acoustic panels.
Stop engine and check coolant and oil levels. Re- Remove front pipe.
fill as necessary.
Align and adjust tension of drive belt. Refer to
DRIVE BELT AND REAR WHEEL subsection.
Test drive vehicle to confirm proper operation.

rmr2014-008 7
Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

Rear Rubber Mounts

Remove engine. Refer to ENGINE REMOVAL in
this subsection.
Remove rear engine mount from vehicle.
Using the BLIND HOLE BEARING PULLER SET
(P/N 529 036 117), remove rear rubber mounts.

rmr2014-010-011_a

1. Front pipe
2. Springs securing front pipe to catalytic converter
3. Oxygen sensor
4. Front pipe retaining clamp

Remove no. 1 in image below. 529036117

Place a bottle jack under engine.

Engine Mount Installation
Using a piece of wood, slightly raise and support
the engine. Front Rubber Mounts
Remove no. 2 in image below. The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
NOTE: Unless link rod dimensions were
changed, or link rod replaced, no engine align-
ment is necessary.
Adjust drive belt tension. Refer to DRIVE BELT
AND REAR WHEEL subsection.
Install all removed parts.
Rear Rubber Mounts
Insert rubber mount into tube and align the tab
with the recess on tube.

rmr2014-008-006_a

REAR RUBBER MOUNT

1. Tab to recess on tube alignment

rmr2014-008-202_a
Using a plastic hammer, insert rubber mount into
tube.
Remove front rubber mount. Install engine. Refer to ENGINE INSTALLATION in
this subsection.
8 rmr2014-008
 Subsection 01 (ENGINE REMOVAL AND INSTALLATION)

Complete final assembly. Refer to FINAL ASSEM-

BLY in this subsection.
NOTE: Unless link rod dimensions were
changed, or link rod replaced, no engine align-
ment is necessary.
Adjust drive belt tension. Refer to DRIVE BELT
AND REAR WHEEL subsection.
Install all removed parts.

rmr2014-008 9
 Subsection 02 (AIR INTAKE SYSTEM)

AIR INTAKE SYSTEM

INTAKE MANIFOLD

11 ± 1 N•m
(97 ± 9 lbf•in)

Engine oil

See ELECTRONIC FUEL

INJECTION (EFI)

6 ± 0,7 N•m
(53 ± 6 lbf•in) Engine oil

Engine oil
See ELECTRONIC FUEL
INJECTION (EFI) 6 ± 0,7 N•m
NEW (53 ± 6 lbf•in)

See ELECTRONIC FUEL

Engine oil INJECTION (EFI)

SE6
models

11 ± 1 N•m
(97 ± 9 lbf•in)
See tightening
11 ± 1 N•m sequence
(97 ± 9 lbf•in)

NEW

NEW = Component must be replaced when removed.

rmr2014-009-001_a

rmr2014-009 1
Subsection 02 (AIR INTAKE SYSTEM)

AIR INTAKE SILENCER

2,5 ± 0,5 N•m

(22 ± 4 lbf•in)

SE6
4 ± 1 N•m
2,5 ± 0,5 N•m (35 ± 9 lbf•in)
(22 ± 4 lbf•in)

SM6

1,7 ± 0,2 N•m

(15 ± 1,8 lbf•in)

NEW

4,5 ± 0,5 N•m

(40 ± 4 lbf•in)
NEW

2,5 ± 0,5 N•m

(22 ± 4 lbf•in)

NEW

10 ± 2 N•m
(89 ± 18 lbf•in)

rmr2014-009-100_a

2 rmr2014-009
 Subsection 02 (AIR INTAKE SYSTEM)

PROCEDURES Air Filter Cleaning

Inspect air filter for cleanliness and damage.
AIR FILTER NOTICE It is not recommended to blow com-
Air Filter Removal pressed air on the paper filter. This could dam-
1. Refer to BODY subsection and removed the fol- age the paper fibers and reduce its filtration
lowing parts: ability when used in dusty environments.
– LH middle side panel NOTICE Do not wash the paper filter with any
– LH top side panel cleaning solution.
– LH acoustic panel. NOTICE Inspect primary air intake silencer
2. Remove the 3 retaining screws securing air fil- and remove any dust or debris taking care not
ter cover to primary air intake silencer. to blow or move anything inside the clean side
of the air inlet (passed air filter).
NOTICE Remove any dust or debris that may
have moved or shifted inside the clean side of
the air intake silencer (passed air filter). Clean
by pulling on the dust and not pushing it inside.
Replace air filter as necessary according to recom-
mended maintenance schedule and particular use
(especially in dusty environments).

Air Filter Installation

rmr2014-009-201_a
PARTS REMOVED FOR CLARITY
1. Air filter cover
2. Retaining screws to remove
3. Remove air filter from primary air intake si-
lencer.
NOTICE Remove air filter slowly to keep dust
and debris from falling into the clean area of
the air intake silencer (passed air filter).
Installation is the reverse of removal however pay
attention to the following:
Make sure the ring on which the air filter sits is flat
and well positioned before seating the air filter.
Make sure the air filter is positioned in the correct
orientation.
NOTE: A special area is present on the filter for
writing down date and mileage at which new filter
was installed.
Position air filter cover onto primary air intake si-
lencer.
TIGHTENING TORQUE
Air filter cover retaining 4 N•m ± 1 N•m
screws (35 lbf•in ± 9 lbf•in)

PRIMARY AIR INLET

Primary Air Inlet Removal
1. Refer to BODY subsection and remove :
– Front body module
2. Remove LH radiator air intakes.
3. Remove front panel.
4. Remove plastic rivets securing air inlet valve to
rmr2014-009-202_a
vehicle.
PARTS REMOVED FOR CLARITY
1. Air filter

rmr2014-009 3
Subsection 02 (AIR INTAKE SYSTEM)

PRIMARY AIR INTAKE SILENCER

Primary Air Intake Silencer Removal
1. Refer to BODY subsection and remove :
– Middle side panel
– Top side panel.
2. Remove LH acoustic panels.

rmr2014-009-220_a

TYPICAL
1. Plastic rivets
2. Air inlet valve

5. Loosen clamp securing air inlet adapter to pri-

mary air intake silencer and remove air inlet
adapter.

rmr2014-009-222_a

1. Acoustic panel

3. Remove retaining screws securing air intake si-

lencer support into place.

rmr2014-009-215_a

TYPICAL
rmr2014-009-216_a
1. Clamp securing air inlet adapter to primary air intake silencer
2. Air inlet adapter RH SIDE SHOWN
3. Air inlet adapter 1. Retaining screw to remove
2. Air intake silencer support
Primary Air Inlet Installation
Installation is the reverse of removal. However
pay attention to the following.
TIGHTENING TORQUE
2.5 N•m ± 0.5 N•m
Air inlet adapter clamp
(22 lbf•in ± 4 lbf•in)

4 rmr2014-009
 Subsection 02 (AIR INTAKE SYSTEM)

6. Remove ring securing central air intake adapter

into primary air intake silencer.
6.1 When looking inside primary air intake si-
lencer, turn counter clockwise by approxi-
mately 30°.
6.2 Pull ring gently out of primary air intake si-
lencer
NOTE: The alignment arrow is at 6 o'clock.

rmr2014-009-217_a

LH SIDE SHOWN
1. Retaining screw to remove
2. Air intake silencer support

4. Remove air filter. Refer to AIR FILTER RE-

MOVAL in this subsection.

rmr2014-009-232_a

TYPICAL - PRIMARY AIR INTAKE SILENCER COVER REMOVED

FOR CLARITY
1. Ring to rotate and remove
2. Alignment arrow

7. Remove central air intake adapter from primary

rmr2014-009-230_a air silencer.
PARTS REMOVED FOR CLARITY
1. Air filter cover

5. Remove retaining screw securing lower part of

primary air intake silencer to vehicle.

rmr2014-009-242_a

1. Central air intake adapter

Primary Air Intake Silencer Installation

rmr2014-009-241_a Installation is the reverse of the removal proce-
PARTS REMOVED FOR CLARITY dure. However pay attention to the following:
1. Retaining screw to remove

rmr2014-009 5
Subsection 02 (AIR INTAKE SYSTEM)

NOTICE Make sure primary and secondary

air intake silencers are clean and that no debris
or dust are in the silencers before installation.
Ring installation for central adapter:
Turn ring clockwise by approximately 30° until a
snap is felt and then until the ring bottoms (is fully
locked into place).
NOTE: Arrow is at 6 o'clock once ring is installed
in its final position.
NOTICE Make sure the air filter seat (where rmr2014-009-216_a

air filter seals with central adapter) is correctly RH SIDE SHOWN

positioned and oriented before installing the 1. Retaining screw to remove
2. Air intake silencer support
filter.
NOTE: Central adapter and primary air intake si-
lencer need to be aligned together. A rib helps to
align both parts together and keeps them in posi-
tion on the vehicle.
TIGHTENING TORQUE
2.5 N•m ± 0.5 N•m
Air inlet adapter clamp
(22 lbf•in ± 4 lbf•in)
Primary air intake 4.5 N•m ± 0.5 N•m
silencer retaining screw (40 lbf•in ± 4 lbf•in)
rmr2014-009-217_a

SECONDARY AIR INTAKE LH SIDE SHOWN

1. Retaining screw to remove
SILENCER 2. Air intake silencer support

Secondary Air Intake Silencer Removal SE6 Models

1. Refer to BODY subsection and remove : Check secondary air intake silencer plug for dam-
– Middle side panels age replace if needed. Do NOT remove plug ex-
cept for replacement.
– Top side panels.
2. Remove acoustic panels.

rmr2014-009-212_a

1. Secondary air intake silencer plug

2. Secondary air intake silencer plug clip
rmr2014-009-208_a

SM6 Models
3. Remove retaining screws securing air intake si-
lencer support into place. Cut Oetiker clamp securing solenoid valve hose to
secondary air intake silencer.

6 rmr2014-009
 Subsection 02 (AIR INTAKE SYSTEM)

6. Remove secondary air intake silencer from ve-

hicle.
7. Loosen clamp securing air intake manifold
adapter to throttle body and remove air intake
manifold adapter.
NOTICE Appropriate care should be taken af-
ter primary and secondary air intake silencers
removal to prevent dust or debris from falling
in the engine.

rmr2014-009-240_a

1. Solenoid valve hose

2. Oetiker clamp

All Models
4. Cut locking tie securing multifunction switch
harness to secondary air intake silencer and
move harnesses aside.

rmr2014-009-214_a

1. Clamp to loosen
2. Air intake manifold adapter

Secondary Air Intake Silencer

Installation
Installation is the reverse of the removal proce-
dure. However pay attention to the following.
NOTICE Make sure primary and secondary
air intake silencers are clean and that no debris
or dust are in the silencers before installation.
rmr2014-009-211_a

1. Locking tie to cut SM6 Models

5. Remove retaining screw securing secondary air Reconnect solenoid valve hose to secondary air
intake silencer to vehicle. intake silencer and secure it using a NEW Oetiker
clamp.
TIGHTENING TORQUE
2.5 N•m ± 0.5 N•m
Air inlet adapter clamp
(22 lbf•in ± 4 lbf•in)
Secondary air intake 4.5 N•m ± 0.5 N•m
silencer retaining screw (40 lbf•in ± 4 lbf•in)

INTAKE MANIFOLD
Intake Manifold Access
Refer to BODY subsection and remove:
– Console module
rmr2014-009-221_a

1. Retaining screw to remove Remove lateral frame supports.

rmr2014-009 7
Subsection 02 (AIR INTAKE SYSTEM)

Remove TCM.Refer to ELECTRONIC SHIFT SYS- Remove screw securing the engine wiring har-
TEM (SE6) subsection. ness cable clamp to the cylinder head.
Remove ECM. Refer to ELECTRONIC FUEL IN-
JECTION subsection.
Intake Manifold Removal
Cut locking ties of:
– fuel injector harness
– Purge valve connector cable
– stick coil cables
– Clutch low pressure hose (SM6 only) and sen-
sor harness.

rmr2014-009-005_a

1. Screw
2. Clamp
3. Cylinder head

Disconnect manifold absolute pressure and tem-

rmr2014-009-003_a
perature sensor (MAPTS).
1. Locking ties

Cut locking tie securing camshaft position sensor

(CAPS) harness to intake manifold.

rmr2014-009-006_a

1. MAPTS connector

Disconnect throttle body connector.

rmr2014-009-004_a

1. Locking tie
2. Camshaft position sensor (CAPS)
3. Throttle body

8 rmr2014-009
 Subsection 02 (AIR INTAKE SYSTEM)

rmr2014-009-224_a

1. Purge valve hose

2. Clamp

rmr2014-009-007_a
Remove clamp and intake hose from throttle
1. Throttle body connector
body.

Remove clamp securing the OPS wire to the oil

tank.

rmr2014-009-225_a

1. Throttle body
2. Clamp
3. Intake hose

Carefully disconnect fuel hose from fuel rail. Refer

to ELECTRONIC FUEL INJECTION subsection.

rmr2014-009-004_b

1. Clamp
2. Oil tank

Disconnect purge valve hose from intake mani-

fold.

rmr2014-009 9
Subsection 02 (AIR INTAKE SYSTEM)

rmr2014-009-223_a

PARTS REMOVED FOR CLARITY

1. Fuel hose
2. Fuel rail
rmr2014-009-010_a
Disconnect: 1. Oil dip stick
– fuel injector connectors 2. Spring clip
3. Oil filler tube upper part
– ignition coil connectors.
Remove lock nut and screw of intake manifold
support.

rmr2014-009-009_a

1. Injector connectors rmr2014-009-011_a

2. Ignition coil connectors
1. Lock nut
2. Screw
Remove: 3. Intake manifold support
– Oil dip stick
Remove screws securing intake manifold to cylin-
– Spring clip der head.
– Oil filler tube upper part.

10 rmr2014-009
 Subsection 02 (AIR INTAKE SYSTEM)

rmr2014-009-012_a rmr2014-009-014_a

FOR CLARITY SOME PARTS REMOVED 1. Silent block of intake manifold support
1. Intake manifold screws 2. MAPTS
3. Fuel rail with injectors
NOTICE Before removing intake manifold, 4. Throttle body

make sure area is cleaned so that no debris or

dust fall in the engine.
Remove intake manifold from engine.
NOTICE Appropriate care should be taken af-
ter intake manifold removal to make sure that
no debris or dust falls in the engine.
Remove and discard intake manifold gaskets.

rmr2014-009-243_a

1. Silent block of oil filler tube upper part

2. Purge valve hose nipple with O-ring

rmr2014-009-013_a

1. Intake manifold
2. Gaskets

If required, remove the following parts from intake

manifold:
– Silent block of oil filler tube upper part
– Silent block of intake manifold support
– Purge valve hose nipple with O-ring
– MAPTS. Refer to ELECTRONIC FUEL INJEC-
TION (EFI) subsection.
– Fuel rail with injectors. Refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.
– Throttle body. Refer to ELECTRONIC FUEL IN-
JECTION (EFI) subsection. rmr2014-009-016_a

SM6 ONLY
– Clutch solenoid and low pressure hose (SM6 1. Clutch solenoid
only). Refer to CLUTCH (SM6) subsection. 2. Low pressure hose

rmr2014-009 11
Subsection 02 (AIR INTAKE SYSTEM)

Intake Manifold Inspection – Throttle body

Check intake manifold for cracks, warping at – Fuel rail with injectors.
flanges or any other visible damages. Replace if Install NEW lock nut and tighten screw of intake
required. manifold support to specification.
Drain intake manifold if any liquids accumulated. LOCK NUT
Flush intake manifold with a solvent and let it dry
11 N•m ± 1 N•m
out. Tightening torque
(97 lbf•in ± 9 lbf•in)
Intake Manifold Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install NEW gaskets with tab properly inserted
into notch.

rmr2014-009-011_a

1. Lock nut
2. Screw
3. Intake manifold support

Tighten engine wiring harness cable clamp screw

to specification.
rmr2014-009-013_b

1. Gaskets tab properly inserted CABLE CLAMP SCREW

11 N•m ± 1 N•m
Tighten intake manifold screws to specification as Tightening torque
(97 lbf•in ± 9 lbf•in)
per the following sequence.
INTAKE MANIFOLD SCREWS
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

rmr2014-009-012_b

TIGHTENING SEQUENCE - FOR CLARITY SOME PARTS

rmr2014-009-005_a
REMOVED
1. Screw
2. Clamp
Refer to ELECTRONIC FUEL INJECTION (EFI) 3. Cylinder head
subsection to install:
– MAPTS Tighten OPS wire clamp to specification.

12 rmr2014-009
 Subsection 02 (AIR INTAKE SYSTEM)

CABLE CLAMP SCREW

6 N•m ± 0.7 N•m
Tightening torque
(53 lbf•in ± 6 lbf•in)

rmr2014-009-004_b

1. OPS wire clamp

2. Oil tank

Install all other remaining parts.

rmr2014-009 13
 Subsection 03 (EXHAUST SYSTEM)

EXHAUST SYSTEM
SERVICE TOOLS
Description Part Number Page
SPRING INSTALLER/REMOVER ................................................... 529 035 983 ..................................... 3, 8–9

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 5

rmr2014-010 1
Subsection 03 (EXHAUST SYSTEM)

NEW
24.5 ± 3.5 N•m 5 ± 0.5 N•m
Loctite 243 (18 ± 2 lbf•ft) (44 ± 4.5 lbf•in)
5 ± 0.5 N•m Loctite 243
(44 ± 4.5 lbf•in)

NEW

35 ± 2 N•m
(25 ± 1.5 lbf•ft)
Loctite 243 NEW
5 ± 0.5 N•m
(44 ± 4.5 lbf•in)

7 ± 1 N•m
7 ± 1 N•m (61 ± 9 lbf•in)
(61 ± 9 lbf•in)

37.5 ± 2.5 N•m Loctite 767

(25.5 ± 1.8 lbf•ft) 50 ± 10 N•m
(37 ± 7 lbf•ft)
See ELECTRONIC FUEL
INJECTION (EFI)

NEW

Loctite 243
35 ± 2 N•m 5 ± 0.5 N•m
(25 ± 1.5 lbf•ft) (44 ± 4.5 lbf•in)
NEW

Loctite 243
5 ± 0.5 N•m
(44 ± 4.5 lbf•in)

Loctite 243
5 ± 0.5 N•m
(44 ± 4.5 lbf•in)
5 ± 0.5 N•m
(44 ± 4.5 lbf•in)
NEW = Component must be replaced when removed. Loctite 243
rmr2014-010-100_a

2 rmr2014-010
 Subsection 03 (EXHAUST SYSTEM)

GENERAL MAINTENANCE
WARNING CATALYTIC CONVERTER GASKET
To avoid potential burns, never touch ex- REPLACEMENT
haust system components immediately after
the engine has been run as these compo- 1. Open the seat.
nents are very hot. Let engine and exhaust 2. Remove both mirrors, refer to BODY subsec-
system cool down before performing any tion.
servicing.
3. Remove the following body panels, refer to
BODY subsection:
WARNING – LH and RH middle side panels
Torque wrench tightening specifications – LH and RH wind deflectors
must be strictly adhered to. Locking de-
vices must be replaced when removed (e.g.: – LH and RH top side panels
locking tabs, elastic stop nuts, self-locking – LH bottom front side panel
fasteners, cotter pins, etc.). – LH bottom rear side panel.
4. Remove the oxygen sensor from the head pipe,
Hoses, cables or locking ties removed during a refer to HEATED OXYGEN SENSOR (HO2S) in
procedure must be reinstalled as per factory stan- the ELECTRONIC FUEL INJECTION (EFI) sub-
dards. section.
5. Remove clamp retaining front pipe to exhaust
EXHAUST SYSTEM manifold.
INSTALLATION SEQUENCE
NOTE: When installing exhaust system compo-
nents, use new gaskets, new spherical clamps
and new hardware as applicable. Apply specified
torques. Refer to the exploded view.
1. Install all exhaust system components loosely
to ease adjustment of components.
2. Measure and adjust all gaps to properly position
all exhaust components.
3. Torque exhaust system components in the fol-
lowing order. Adjust sequence as required ac-
cording to parts removal and installation to en-
sure proper clearances are obtained.
EXHAUST SYSTEM TORQUE SEQUENCE rmr2014-010-003_a

TYPICAL - FRONT PIPE TO EXHAUST MANIFOLD

1. Exhaust manifold to cylinder head 1. Exhaust clamp to remove

2. Front pipe to exhaust manifold 6. Remove spring and clamp retaining catalytic
3. Catalytic converter support bracket to frame converter to front pipe.
mount
REQUIRED TOOL
5. Front pipe to catalytic converter (gasket and
SPRING INSTALLER/REMOVER (P/N 529 035 983)
springs)
6. Muffler to catalytic converter clamp
7. Muffler mounting bolt

rmr2014-010 3
Subsection 03 (EXHAUST SYSTEM)

rmr2014-010-002_a
rmr2014-010-304_a
TYPICAL - FRONT FRONT PIPE TO CATALYTIC CONVERTER
1. Exhaust springs to remove A. Minimum distance between front pipe and frame member
2. Front pipe
3. Catalytic converter MINIMUM DISTANCE BETWEEN FRONT
PIPE AND FRAME MEMBER
7. Disconnect and lower front section of front
head pipe from exhaust manifold. 24 mm ± 3 mm (15/16 in ± 1/8 in)
8. Disconnect front pipe from catalytic converter.
13. Install all remaining removed parts. Refer to
9. Remove exhaust gasket from front pipe. BODY subsection.
10. Install a NEW exhaust gasket on front pipe.
11. Install NEW spherical clamp and install previ- INSPECTION
ously removed exhaust components. Always inspect exhaust system parts for the fol-
NOTE: Make sure spherical clamp is parallel to lowing defects or damages:
pipe joint. – Cracks
– Tearing
– Bending
– Dents
– Corrosion
– Leaks
A – And any other damage or defect which could
affect system performance.
Replace as required.

rmr2014-010-306_a

A. 90°± 5°

12. Verify the following measurement:

4 rmr2014-010
 Subsection 03 (EXHAUST SYSTEM)

PROCEDURES
MUFFLER HEAT SHIELDS
Heat Shields Removal

rmr2014-010-008_a

PARTS REMOVED FOR CLARITY

1. Front muffler shield mounting screw
2. Front muffler shield

Heat Shield Installation

rmr2014-010-006_a 1. Clean muffler retaining bolt threads and apply
1. Muffler LOCTITE 243 (BLUE) (P/N 293 800 060) to the
2. Rear muffler shield
3. Front muffler shield threads of the mounting screws.
Remove the three screws mounting the rear heat 2. Position rear heat shield on muffler, install and
shield to the front end of the muffler. torque the three mounting screws.
3. Position front heat shield on muffler, install and
torque the three mounting screws.
MUFFLER SHIELD SCREW TORQUE
5.5 N•m (49 lbf•ft)

MUFFLER
Muffler Removal
1. Remove clamp sealing muffler with catalytic
converter.

rmr2014-010-007_a

1. Rear muffler shield mounting screw

2. Rear muffler shield

Remove the three screws mounting the front heat

shield to the front section of the muffler.

rmr2014-010-009_a

1. Clamp sealing muffler with catalytic converter

2. While supporting muffler, remove the muffler

mounting hexagonal screw, seal, rubber seal
and washer from the muffler support.

rmr2014-010 5
Subsection 03 (EXHAUST SYSTEM)

rmr2008-030-009

TYPICAL - LIFT BY THE FRAME

rmr2014-010-005_a
6. Set initial alignment of muffler by ensuring the
1. Muffler
2. Muffler retaining bolt to remove catalytic converter outlet pipe, the spherical
clamp and the muffler inlet pipe are all aligned
NOTICE Insert padding between muffler and as depicted.
park brake mechanism on rear wheel axle to
prevent contact between parts and damage to
the muffler.

Muffler Installation A
NOTICE Insert padding between muffler and
park brake mechanism on rear wheel axle to
prevent contact between parts and damage to
the muffler.
1. Position muffler spherical clamp onto muffler
flared pipe.
2. Position muffler flared pipe over catalytic con-
verter pipe . rmr2014-010-307_a

3. Install muffler retaining bolt on muffler support A. 90°± 5°

and loosely install nut. Do not torque yet. Verify the following measurements:
NOTE: Push onto muffler spherical joint when
tightening muffler support retaining bolt.
4. Loosely install muffler spherical clamp with
clamp bolt parallel to the ground/frame, and
with threads pointing rearwards over pipe junc- B
tion and tighten just enough for them to remain
in position. Do not torque yet. A
5. Lift rear of vehicle by the frame until rear wheel
is off the ground.
NOTICE Do not lift under rear shock ab-
sorber. Always lift by the frame. Refer to
illustration. C
rmr2014-010-301_a

A. Minimum distance between inner saddlebag cover and muffler

heat shield
B. Minimum distance between rear fender and exhaust pipe cover
C. Minimum distance between muffler and parking brake bracket

6 rmr2014-010
 Subsection 03 (EXHAUST SYSTEM)

MINIMUM DISTANCE BETWEEN INNER MINIMUM DISTANCE BETWEEN EXTERNAL

SADDLEBAG COVER AND MUFFLER SECTION OF CATALYTIC CONVERTER
HEAT SHIELD AND EXTERNAL SIDE OF SWING ARM
(RH SIDE OF VEHICLE)
15 mm (19/32 in)
16 mm ± 3 mm (5/8 in ± 1/8 in)
MINIMUM DISTANCE BETWEEN REAR FENDER
AND EXHAUST PIPE COVER MINIMUM DISTANCE BETWEEN CATALYTIC
CONVERTER OUTER WELD AND DRIVE BELT
25 mm (1 in)
13 mm (1/2 in)
MINIMUM DISTANCE BETWEEN MUFFLER
AND PARKING BRAKE BRACKET 7. Tighten according to the following sequence:
19 mm ± 6 mm (3/4 in ± 1/4 in) NOTE: Before applying torque, make sure sleeve
is pushed forward.

1
A

rmr2014-010-303_a
rmr2014-010-302_a
A. Minimum distance between catalytic converter outlet pipe and
swing arm in full extension 1. Sleeve to push forward

MINIMUM DISTANCE BETWEEN CATALYTIC MUFFLER TORQUE SEQUENCE

CONVERTER OUTLET PIPE AND SWING
ARM IN FULL EXTENSION Muffler spherical 35 N•m ± 2 N•m
STEP 1
clamp (26 lbf•ft ± 1 lbf•ft)
49.5 mm ± 3 mm (1-15/16 in ± 1/8 in)
37 N•m ± 2.5 N•m
STEP 2 Muffler retaining nut
(27 lbf•ft ± 2 lbf•ft)

NOTE: For proper installation muffler clamp bolt

A must be parallel to the ground, parallel to the
frame, and with the bolt threads pointing rear-
wards.
NOTICE Recheck clearance when all compo-
nents are torqued. Adjust as needed.
8. Remove padding previously inserter between
muffler and park brake mechanism.
9. Start engine and ensure the muffler gasket ring
B is not leaking.
rmr2014-010-305_a

VIEWED FROM REAR OF VEHICLE

A. Minimum distance where catalytic converter side overtakes CATALYTIC CONVERTER
swing arm
B. Minimum distance between catalytic converter outer weld and
drive belt
Catalytic Converter Removal
1. Open the seat.
2. Remove both mirrors, refer to BODY subsec-
tion.

rmr2014-010 7
Subsection 03 (EXHAUST SYSTEM)

3. Remove the following body panels, refer to 4. Install the head pipe springs using same tool as
BODY subsection: for removal.
– LH and RH middle side panels 5. Verify the following measurements.
– LH and RH wind deflectors
– LH and RH top side panels
– LH bottom front side panel
A
– LH bottom rear side panel.
4. Remove the MUFFLER, see procedure in this
subsection.
5. Remove the springs retaining the catalytic con-
verter to the front pipe.
REQUIRED TOOL
SPRING INSTALLER/REMOVER (P/N 529 035 983)
B
rmr2014-010-305_a

VIEWED FROM REAR OF VEHICLE

A. Minimum distance where catalytic converter side overtakes
swing arm
B. Minimum distance between catalytic converter outer weld adn
6. Pull the catalytic converter towards rear of ve- drive belt
hicle.
MINIMUM DISTANCE BETWEEN EXTERNAL
7. As you support the catalytic converter, unhook SECTION OF CATALYTIC CONVERTER
the rubber support above the converter. AND EXTERNAL SIDE OF SWING ARM
(RH SIDE OF VEHICLE)
16 mm ± 3 mm (5/8 in ± 1/8 in)

MINIMUM DISTANCE BETWEEN CATALYTIC

CONVERTER OUTER WELD AND DRIVE BELT
13 mm (1/2 in)

A
rmr2014-010-010_a

1. Springs
2. Rubber support
3. Catalytic converter
4. Aft rubber support screw

8. Carefully pull down on catalytic converter ex-

haust pipe to disconnect from front pipe.
rmr2014-010-304_a

Catalytic Converter Installation A. Minimum distance between front pipe and frame member

1. Install NEW gasket and NEW spherical clamp MINIMUM DISTANCE BETWEEN FRONT
on front pipe. PIPE AND FRAME MEMBER
2. Slide converter support hooks (2) into support 24 mm ± 3 mm (15/16 in ± 1/8 in)
bracket grommets and insert the catalytic con-
verter pipe over the head pipe. 6. Install muffler and ensure proper exhaust sys-
3. Insert the support hook above the catalytic con- tem clearance gaps are obtained. Refer to
verter into its rubber support. MUFFLER INSTALLATION at the beginning of
this subsection.
8 rmr2014-010
 Subsection 03 (EXHAUST SYSTEM)

NOTICE Recheck clearance when all compo-
nents are torqued. Adjust as needed.
7. Install all remaining removed parts and panels.
FRONT PIPE
Front Pipe Removal
1. Open the seat and both rear side cargo com-
partments.
2. Remove both mirrors, refer to BODY subsec-
tion.
3. Remove the following body panels, refer to
BODY subsection:
– LH and RH middle side panels
– LH and RH wind deflectors
– LH and RH top side panels
– LH bottom front side panel
– LH bottom rear side panel.
4. Remove the oxygen sensor from the head pipe,
refer to HEATED OXYGEN SENSOR (HO2S) in
the ELECTRONIC FUEL INJECTION (EFI) sub-
section.
5. Remove clamp sealing front pipe to exhaust
manifold.
6. Remove spring and front pipe spherical clamp
retaining catalytic converter to front pipe.
REQUIRED TOOL
SPRING INSTALLER/REMOVER (P/N 529 035 983)
7. Remove front pipe by pulling it from under ve-
hicle.
8. Disconnect and lower front section of front
head pipe from exhaust manifold.
9. Disconnect front pipe from catalytic converter.
10. Remove exhaust gasket from front pipe.
Front Pipe Installation
1. Install NEW gasket between catalytic converter
and front pipe.
2. Install oxygen sensor, refer to HEATED OXY-
GEN SENSOR (HO2S) in the ELECTRONIC
FUEL INJECTION (EFI) subsection.
3. Install NEW spherical clamp and install remain-
ing exhaust system components.
NOTE: Make sure front pipe spherical clamp is
parallel to pipe joint.
A
rmr2014-010-306_a

A. 90°± 5°

4. Verify the following measurement:

rmr2014-010-304_a

rmr2014-010-011_a
A. Minimum distance between front pipe and frame member
1. Front pipe
2. Springs securing front pipe to catalytic converter
3. Oxygen sensor
4. Front pipe spherical clamp

rmr2014-010 9
Subsection 03 (EXHAUST SYSTEM)

MINIMUM DISTANCE BETWEEN FRONT

PIPE AND FRAME MEMBER
24 mm ± 3 mm (15/16 in ± 1/8 in)

Install all remaining removed parts and panels.

Refer to BODY subsection.

10 rmr2014-010
 Subsection 04 (LUBRICATION SYSTEM)

LUBRICATION SYSTEM
SERVICE TOOLS
Description Part Number Page
ADAPTER HOSE ........................................................................... 529 035 652 ............................................. 8
ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 10
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ........................................... 10
PRESSURE GAUGE....................................................................... 529 035 709 ............................................. 8

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ....................................... 8, 11
LOCTITE 5910 ............................................................................... 293 800 081 ........................................... 30
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ........................................... 30
XPS 4-STROKE SYNTH. BLEND OIL (SUMMER) ......................... 293 600 121 ............................................. 5

rmr2014-011 1
Subsection 04 (LUBRICATION SYSTEM)

25 ± 3 N•m
6 ± 0,7 N•m (18 ± 2 lbf•ft)
Engine oil
(53 ± 6 lbf•in)

NEW

6 ± 0,7 N•m
See tightening (53 ± 6 lbf•in)
procedure
Engine oil
11 ± 1 N•m
(97 ± 9 lbf•in)
NEW Loctite 243
NEW
NEW
See tightening Engine oil
procedure
NEW 17 ± 1 N•m
(150 ± 9 lbf•in)

NEW

Loctite 243 NEW

12 ± 1 N•m NEW
(106 ± 9 lbf•in) Engine oil 11 ± 1 N•m
(97 ± 9 lbf•in)

15 ± 1 N•m Engine oil

(133 ± 9 lbf•in)

Engine oil
Engine oil

NEW
Loctite 5910
Engine oil
Loctite 243
11 ± 1 N•m
28 ± 2 N•m (97 ± 9 lbf•in)
See tightening procedure (21 ± 1 lbf•ft)

28 ± 2 N•m NEW
(21 ± 1 lbf•ft)

NEW = Component must be replaced when removed.

rmr2014-011-002_a

2 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

11 ± 1 N•m
(97 ± 9 lbf•in)

28 ± 2 N•m
(21 ± 1 lbf•ft)
11 ± 1 N•m
(97 ± 9 lbf•in)
Loctite 243
28 ± 2 N•m
NEW (21 ± 1 lbf•ft)

Loctite 243

Engine oil

11 ± 1 N•m
(97 ± 9 lbf•in) 11 ± 1 N•m
(97 ± 9 lbf•in)
Loctite 243 NEW

6 ± 0,7 N•m
(53 ± 6 lbf•in) NEW
NEW

20 ± 2 N•m
(15 ± 1 lbf•ft) Engine oil

11 ± 1 N•m
(97 ± 9 lbf•in)

NEW = Component must be replaced when removed.

rmr2014-011-003_a

rmr2014-011 3
Subsection 04 (LUBRICATION SYSTEM)

11 ± 1 N•m
19 ± 1 N•m (97 ± 9 lbf•in)
(168 ± 9 lbf•in)

NEW

NEW

11 ± 1 N•m
(97 ± 9 lbf•in)

Engine oil

11 ± 1 N•m
(97 ± 9 lbf•in)
11 ± 1 N•m
NEW (97 ± 9 lbf•in)

NEW

Engine oil
20 ± 2 N•m
(15 ± 1 lbf•ft) Engine oil

11 ± 1 N•m
(97 ± 9 lbf•in)

NEW = Component must be replaced when removed.

rmr2014-011-004_a

4 rmr2014-011

GENERAL
SYSTEM DESCRIPTION
This engine has dry sump lubrication system with
an integrated oil tank.
It consists of 3 scavenge oil pumps and 1 pressure
oil pump.
SE6 Models
SE6 engine has one pressure pump with 2 rotors
for the hydraulic control module (HCM) which ac-
tivates the semi automatic gear shifting process.
The hydraulic control module (HCM) uses engine
oil coming from the oil tank.
Pressure Pump Circuit
The pressure pump is located on the PTO side (left
engine side) and sucks engine oil through an oil
sieve in the bottom of the oil tank.
The oil pressure is regulated by a spring loaded
pressure regulator valve which starts opening at
400 kPa (58 PSI)and releases pressure oil back to
the suction side of the pressure pump through a
by-pass bore.
The pressure oil passes at first an oil radiator
which cools down the oil and then it goes to the
engine oil filter in the oil tank.
After passing the oil filter the oil goes through a
retaining valve and then pressure oil is distributed
to the lubricating points in the crankshaft, balance
shaft, cylinder head with camshafts, gearbox and
clutch.
The retaining valve prevents that a certain amount
of engine oil is leaking from the oil tank to inside
of the engine when the engine does not run.
Scavenge pump circuit
The inner (width 16 mm (.63 in)) of the 2 PTO side
scavenge pumps returns engine oil from a portion
of the cylinder head, timing chain chamber and
valve train cover into the oil tank via the left side
venting tube.
The larger outer PTO side scavenge pump (width
26 mm (1.024 in)) returns engine oil from the
crankshaft chest to the oil tank via the same left
venting tube.
The engine oil coming from the gearbox and
clutch as well as a portion of the cylinder head
return oil is pumped by the clutch side scavenge
pump (width 19 mm (.748 in)) via the right venting
tube into the oil tank.
rmr2014-011
Subsection 04 (LUBRICATION SYSTEM)
All 3 scavenge pumps have oil strainers, 2 are lo-
cated in the oil pan and 1 is located in the clutch
cover behind the oil duct cover.
The oil pan has an additional third oil strainer which
filters the engine oil entering the HCU oil pump for
the SE6 engine.
MAINTENANCE
ENGINE OIL
Recommended Engine Oil
RECOMMENDED ENGINE OIL
XPS 4-STROKE SYNTH. BLEND OIL (SUMMER)
(P/N 293 600 121)
NOTE: The XPS oil is specially formulated and
tested for the severe requirements of this engine.
If not available, use a 5W 40 semi-synthetic (min-
imum) or synthetic motorcycle oil meeting the re-
quirements for API service SL, SJ, SH or SG clas-
sification. Always check the API service label on
the oil container.
The same oil is used for the engine, gearbox,
clutch and hydraulic control module (HCM) in the
SE6 models.
NOTICE To avoid damaging the clutch, do
not use a motor oil meeting the API service SM
or ILSAC GF-4 classification. Clutch slippage
will occur.
Engine Oil Level Verification
NOTICE To obtain a precise reading of the
engine oil level, follow this procedure and
make sure engine is at normal operating tem-
perature.
1. Park the vehicle on a level surface.
2. Open seat.
3. With the engine already at normal operating
temperature, start engine and let it run at idle
for at least 30 seconds.
NOTE: Running engine for at least 30 seconds al-
lows the scavenge oil pumps to drain the oil from
the engine back into the oil tank. Not carrying out
this step could result in overfilling the engine oil.
4. Stop engine.
5. Unscrew and remove the oil dipstick.
5
Subsection 04 (LUBRICATION SYSTEM)

Engine Oil and Oil Filter Change

1. Prior to changing the oil, ensure vehicle is on a
level surface.
NOTICE The engine oil and the engine oil fil-
ter must be replaced at the same time. The oil
change should be carried out with a warm en-
gine.

CAUTION Engine oil can be very hot.

2. Remove the following RH body panels, refer to
BODY subsection:
rmo2014-005-015_a
– Middle side panel
1. Oil dipstick
2. Oil filler tube – Top side panel
– Acoustic panel
6. Wipe off the dipstick.
3. Clean area around drain plug under oil sump
7. Reinsert and completely screw in the dipstick cover.
to assure an accurate reading.
4. Place an appropriate drain pan under oil sump
8. Unscrew and remove the dipstick. cover.
9. Check the oil level on the dipstick; it should be 5. Remove the drain plug and discard the sealing
near or equal to the upper mark. washer and O-rings.

rmr2014-011-080_a

1. MAX rmr2014-011-301_a
2. MIN
3. Operating range, 0.5 L (.5 qt (U.S. liq.)) TYPICAL - SE6 MODEL SHOWN
1. Engine oil drain plug
Oil Level is at or near MAXMark
6. Remove the dipstick.
1. Properly insert and tighten dipstick.
7. Allow sufficient time for oil to completely drain.
2. Close seat.
8. Clean area around magnetic drain plug in the
Oil Level under MIN Mark clutch cover.
1. Add a small amount of recommended oil. 9. Place an appropriate drain pan under the clutch
NOTE: The oil quantity between MIN and MAX cover.
mark is 0.5 L (.5 qt (U.S. liq.)). 10. Remove the magnetic oil drain plug and dis-
2. Recheck oil level. card the sealing ring.
3. Repeat the above steps until oil level reaches
the dipsticks upper MAX mark. Do not overfill.
4. Properly insert and tighten dipstick.
5. Close seat.

6 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

14. Check and clean oil filter cavity for dirt and con-
tamination.
15. Clean the magnet on the magnetic drain plug.
16. Using NEW sealing washers and O-rings and
install both drain plugs.
NOTICE Never reuse the drain plug sealing
washers and O-rings. Always replace it with a
new one.
17. Tighten drain plugs as specified.
DRAIN PLUG (OIL SUMP COVER)
rmr2014-011-301_b
Sealing ring NEW
TYPICAL - SE6 MODEL SHOWN
1. Clutch cover magnetic drain plug O-rings NEW
28 N•m ± 2 N•m
Tightening torque
(21 lbf•ft ± 1 lbf•ft)

MAGNETIC DRAIN PLUG (CLUTCH COVER)

Sealing ring NEW
20 N•m ± 1 N•m
Tightening torque
(15 lbf•ft ± 1 lbf•ft)

18. Insert NEW engine oil filter.

19. Install NEW O-rings on oil filter cover.
20. Install oil filter cover and tighten to specifica-
tion.
rmr2014-011-302_a OIL FILTER COVER
TYPICAL - SM6 MODEL SHOWN
1. Clutch cover magnetic drain plug O-rings NEW

11. Remove oil filter cover and discard its O-rings. 25 N•m ± 3 N•m
Tightening torque
(18 lbf•ft ± 2 lbf•ft)
12. Remove and discard oil filter.
21. Pour following amount of the recommended
oil into the oil tank.
OIL QUANTITIES
MODEL QUANTITY
Engine oil and
5.3 L
engine oil filter
(5.6 qt (U.S. liq.))
replacement
SE6 Engine oil,
engine oil
5.6 L
filter and HCM
(5.9 qt (U.S. liq.))
surface filter
replacement
rmr2014-011-081_a

1. Oil filter cover Engine oil and

4.9 L
2. O-rings SM6 engine oil filter
3. Oil filter (5.2 qt (U.S. liq.))
replacement
13. Allow sufficient time for oil to completely drain
22. Start engine and let idle for two minutes.
from clutch cover.

rmr2014-011 7
Subsection 04 (LUBRICATION SYSTEM)

IMPORTANT NOTICE
Do not rev up engine during idling period as this
may cause permanent engine damage.

NOTICE Ensure oil pressure warning lamp

goes out within 5 seconds from engine start. If
oil pressure warning lamp stays ON for more
than 5 seconds, STOP ENGINE and recheck oil
level.
23. Ensure engine oil filter cover, magnetic drain
plug (clutch cover) and drain plug (oil sump
cover) are not leaking.
24. Stop engine. rmr2014-011-005_a

ENGINE EXHAUST SIDE, CLUTCH SIDE

NOTE: The oil level dipstick is accurate when the 1. Plug screw
oil temperature is at 80°C (176°F). 2. Electric starter

NOTE: The quantity between MIN and MAX 4. Install the hose adapter into the plug screw
marks on oil dip stick is 0.5 L (.5 qt (U.S. liq.)). port.
25. Check oil level immediately and adjust if re- 5. Start engine and check the oil pressure.
quired.
ENGINE OIL PRESSURE @ 80°C (176°F)
26. Reinstall all removed body panels.
ENGINE SPEED MINIMUM PRESSURE
27. Dispose of used oil as per your local environ-
mental regulations. Idle (900 RPM) 60 kPa (8.7 PSI)
4000 RPM 400 kPa (58 PSI)
INSPECTION
If the engine oil pressure is out of specification,
ENGINE OIL PRESSURE refer to TROUBLESHOOTING in this subsection.
NOTE: The engine oil pressure test should be car- 6. Remove engine oil pressure test tools.
ried out with a warm engine (80°C (176°F) engine 7. Install plug screw and tighten to specification.
oil temperature) and with the RECOMMENDED
PLUG SCREW
ENGINE OIL at the appropriate level.
1. Refer to BODY and remove the following parts LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
on the RH side:
– Middle side panel 28 N•m ± 2 N•m
Tightening torque
(21 lbf•ft ± 1 lbf•ft)
– Radiator trim.
2. Connect the pressure gauge to adapter hose. 8. Reinstall all removed parts.
REQUIRED TOOL
TROUBLESHOOTING
ADAPTER HOSE (P/N 529
035 652) Always check for fault codes. If a fault code is de-
tected, service the fault code first.
PRESSURE GAUGE (P/N 529 LOW OR NO ENGINE OIL PRESSURE
035 709)
1. Oil level is too low.
- Refill engine oil.
3. Remove the plug screw from cylinder block up-
per half. - Check for high oil consumption. See below.
- Check for oil leaks (gaskets, oil seal or O-rings).
NOTE: Place a container to retrieve engine oil that Repair or replace.
may flow out of engine.
2. Defective or clogged oil filter.
- Replace engine oil and filter.

8 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

3. Use of a bad grade oil. PROCEDURES

- Replace engine oil with BRP recommended oil.
4. Oil pressure regulator valve sticks open, or OIL PRESSURE SWITCH (OPS)
spring load is insufficient.
OPS Activation
- Clean oil regulator piston and its bore. Replace if
necessary. The oil pressure switch activates when the engine
oil pressure is lower than following specified pres-
5. Oil pump(s) worn or damaged. sure range.
- Check if oil pump drive gears are damaged. Re-
place if necessary. OIL PRESSURE SWITCH ACTIVATION RANGE
- Check oil pump rotors and its bore for wear limits. 20 kPa and 40 kPa (2.9 PSI and 5.8 PSI)
Replace if out of specification.
6. Engine oil strainers are clogged. OPS Access
- Remove and clean engine oil strainers. Refer to BODY and remove the following parts on
7. Heavy wear on plain bearings. the RH side:
- Check radial clearance of plain bearings. Replace – Middle side panel
if out of specification. – Top side panel
– Rear side panel
HIGH OIL CONSUMPTION
– Acoustic panel.
1. Oil in breathing system.
- Check if breather V-ring is brittle, hard or dam- OPS Inspection
aged. Replace V-ring. First, ensure oil pressure is adequate. Refer to
- Check if blow—by connector is damaged or miss- ENGINE OIL PRESSURE.
ing.
If the oil pressure is good, check the resistance of
2. Valve stem seals worn or damaged. the oil pressure switch.
- Replace valve stem seals.
OPS Resistance Test
3. Piston rings worn out (blue colored exhaust
smoke). The engine must be warm to check the oil pres-
- Replace piston rings. sure switch properly.

OIL CONTAMINATION WARNING

(WHITE APPEARANCE) Be careful when working near hot part. To
avoid potential burns, never touch exhaust
1. Oil seal and rotary seal on water pump shaft
leaking.
system components immediately after the
engine has been running as these compo-
- Replace water pump module. Change engine oil. nents are very hot. Always use long sleeves
2. Cylinder head gasket leaking. and gloves.
- Replace cylinder head gasket. Change engine oil.
1. Disconnect the OPS connector.
3. Cylinder head screws not properly tightened.
- Retighten screws with recommended torque.
Change engine oil.
4. Oil cooler gasket leaking.
- Replace gasket. Change engine oil.

rmr2014-011 9
Subsection 04 (LUBRICATION SYSTEM)

REQUIRED TOOL

ECM ADAPTER TOOL

(P/N 529 036 166)

3. Disconnect the OPS connector.

rmr2014-011-006_a

1. OPS connector

2. Check the oil pressure switch resistance.

REQUIRED TOOL

FLUKE 115 MULTIMETER

(P/N 529 035 868)
rmr2014-011-006_a

1. OPS connector
3. Read result and compare to table.
4. Check continuity as follows.
RESISTANCE ( )
REQUIRED TOOL
ENGINE NOT RUNNING
Close to 0 FLUKE 115 MULTIMETER
OPS pin 1 OPS pin 2 (normally (P/N 529 035 868)
closed switch)
CIRCUIT CONTINUITY
If resistance is out of specification, replace the oil
pressure switch. OPS pin 1 ECM A pin J4 Close to 0
If the resistance is correct, continue procedure. It OPS pin 2 ECM A pin E3 Close to 0
will be necessary to use jumper wires.
4. Start engine. If the continuity is good and all other tests, try a
NEW ECM.
5. Read result and compare to table.
If the continuity is bad, repair or replace defective
RESISTANCE ( ) wire or connectors.
ENGINE RUNNING
OPS Removal
Infinitely high
OPS pin 1 OPS pin 2
(OL)
1. Unplug the OPS switch connector.

If resistance is out of specification, replace the oil

pressure switch.
If the resistance is correct, check the oil pressure
switch circuit continuity.

OPS Circuit Continuity Test

1. Disconnect ECM connector A. Refer to ECM
CONNECTOR ACCESS in ELECTRONIC FUEL
INJECTION subsection.
2. Install connector A to the ECM adapter.

10 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

– Acoustic panel
– Fuel tank reservoir cover.

Oil Filler Tube Removal

1. Drain engine oil, refer to ENGINE OIL in this
subsection.
2. Remove:
– Oil dip stick
– Spring clip
– Oil filler tube upper part.

rmr2014-011-006_a

1. OPS connector

2. Unscrew and remove the OPS.

rmr2014-009-010_a

1. Oil dipstick
2. Spring clip
rmr2014-011-007_a
3. Oil filler tube upper part
1. Oil pressure switch
3. Remove the oil filler tube retaining screws.
OPS Installation
Install oil pressure switch as per the following in-
formations.
OIL PRESSURE SWITCH
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
17 N•m ± 1 N•m
Tightening torque
(150 lbf•in ± 9 lbf•in)

Install all other removed parts.

OIL FILLER TUBE

Oil Filler Tube Access rmr2014-011-008_a

Refer to BODY and remove the following RH 1. Retaining screws

2. Oil filler tube lower part
parts:
– Top side panel 4. Pull filler tube lower part out of the oil tank
– Rear side panel cover.
5. Remove and discard O-rings of oil filler tube.

rmr2014-011 11
Subsection 04 (LUBRICATION SYSTEM)

Oil Filler Tube Installation

1. Install NEW O-rings on the oil filler tube lower
part.

rmr2014-009-010_b

rmr2014-011-009_a
1. Ol filler tube lower part
1. Oil filler tube O-rings 2. Ol filler tube upper part
3. Silent block
4. Spring clip
2. Lubricate the oil tank cover bore with engine oil. 5. Oil dipstick

9. Install all other removed parts.

10. Refill engine oil and check engine oil level. Re-
fer to ENGINE OIL in this subsection.

OIL TANK COVER

Oil Tank Cover Removal
1. Drain engine oil. Refer to ENGINE OIL in this
subsection.
2. Remove the engine from vehicle. Refer to EN-
GINE REMOVAL AND INSTALLATION subsec-
tion.
3. Remove intake manifold. Refer to AIR INTAKE
rmr2014-011-010_a
SYSTEM subsection.
1. Lubricate the oil tank cover bore
4. Refer to procedures in this subsection to re-
3. Install the oil filler tube lower part. move:
4. Tighten retaining screw to the specified torque. – Oil filter cover and discard O-rings
– Oil filler tube.
OIL FILLER TUBE SCREW
.
6 N•m ± 0.7 N•m 5. Remove alternator and alternator shaft. Refer
Tightening torque
(53 lbf•in ± 6 lbf•in)
to ALTERNATOR subsection.
5. Lubricate oil filler tube upper part with engine 6. Place a drain pan underneath oil tank cover.
oil. 7. Unscrew oil tank cover retaining screws.
6. Fit the oil filler tube upper part in the lower part
and insert the support into the silent block on
the intake manifold.
7. Install spring clip.
8. Install oil dipstick.

12 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

rmr2014-011-012_a rmr2014-011-014_a

RETAINING SCREWS 1. Venting tube screws

1. Oil tank cover 2. Venting tubes
3. Baffle insert
4. Baffle insert screw
8. Remove oil tank cover from the engine.
9. Remove and discard tank cover O-ring and gas- Oil Tank Cover Inspection
ket.
Remove and clean oil strainer with compressed
air.
Make sure venting tube of oil tank cover is not
clogged.. Clean with compressed air.
Check oil strainer for damage and replace if nec-
essary.
Clean all oil tank cover cavities and oil bores in oil
tank cover and clean oil cavity in cylinder block.
Check oil tank cover for cracks, warping at sealing
surface or any other visible damages. Replace if
required.

rmr2014-011-011_a

1. Oil tank cover

2. O-ring
3. Gasket

10. If necessary remove venting tubes with baffle

insert from engine:
10.1 Remove venting tube screws.
10.2 Withdraw venting tubes together with
baffle insert.
10.3 Remove screw retaining the baffle insert
to the venting tube.
10.4 Remove and discard venting tube rmr2014-011-021_a

O-rings. 1. Oil bores

2. Venting tube
3. Oil strainer
4. Oil tank cover

Retaining Valve Inspection

NOTE: Remove retaining valve only after engine
damage with result of contamination.

rmr2014-011 13
Subsection 04 (LUBRICATION SYSTEM)

Carefully pull off the retaining bracket and remove

retaining valve spring and retaining valve from oil
tank cover.

rmr2014-011-017_a

1. Sealing surface
2. Oil tank cover

Oil Tank Cover Installation

rmr2014-011-013_a

1. Retaining bracket 1. Install:

2. Valve spring – Retaining valve
3. Retaining valve
– Valve spring
Check sealing lip of retaining valve for damages. – Retaining bracket.
Replace oil tank cover assembly if necessary.
NOTE: The guiding pins must be correctly posi-
tioned in the bore. Do not engage a guiding pin
in the recess of the retaining valve bore.

rmr2014-011-016_a

1. Sealing lip
2. Retaining valve
rmr2014-011-018_a
Inspect sealing surface of retaining valve in oil 1. Retaining valve
tank cover. Replace oil tank cover assembly if 2. Valve spring
3. Retaining bracket
necessary. 4. Guiding pin
5. Recess in retaining valve bore

2. Insert oil strainer back into oil tank cover.

14 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

8. Install the oil tank cover on the engine as fol-

lows:
8.1 Align centering pin of oil tank cover into
right center hole of the cylinder block.
8.2 Then push tube into cylinder block bore at
the left side.
NOTICE Be sure that all retaining screws
of the oil tank cover do not protrude the
sealing surface during assembly.

rmr2014-011-015_a

1. Oil strainer
2. Oil tank cover

3. Install NEW O-rings on venting tubes.

4. Assemble baffle insert on venting tube.
BAFFLE INSERT SCREW
6 N•m ± 0.7 N•m
Tightening torque
(53 lbf•in ± 6 lbf•in)

5. Install both venting tubes with baffle insert on

cylinder block.
6. Tighten venting tube retaining screws to speci-
fication.
VENTING TUBE RETAINING SCREWS
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

rmr2014-011-019_a

1. Centering pin
2. Tube
3. Oil tank cover
4. Right center hole
5. Bore , left side
6. Cylinder block

9. Tighten screws to the specified torque and se-

quence.
rmr2014-011-014_a OIL TANK COVER SCREWS
1. Venting tube screws
2. Venting tubes 11 N•m ± 1 N•m
Tightening torque
3. Baffle insert (97 lbf•in ± 9 lbf•in)
4. Baffle insert screw

7. Install NEW gasket.

rmr2014-011 15
Subsection 04 (LUBRICATION SYSTEM)

rmr2014-011-012_b rmr2014-011-025_a

TIGHTENING SEQUENCE 1. Retaining screws

2. Oil cooler
10. Install oil filler tube. Refer to OIL FILLER TUBE
in this subsection. 4. Place rags or towels under oil cooler to catch
remaining oil and coolant.
11. Wipe off any oil spillage.
5. Remove oil cooler and its gaskets.
12. Install NEW oil filter and oil filter cover, refer
to ENGINE OIL in this subsection.
13. Install the engine in the vehicle. Refer to EN-
GINE REMOVAL AND INSTALLATION subsec-
tion.
14. Install intake manifold. Refer to AIR INTAKE
SYSTEM subsection.
15. Fill up oil tank and check oil level. Refer to EN-
GINE OIL in this subsection.

OIL COOLER
Oil Cooler Access
Refer to BODY and remove the following parts on
the RH side: rmr2014-011-026_a

– Middle side panel 1. Screws

2. Oil cooler
– Top side panel 3. Gaskets
– Rear side panel.
Oil Cooler Inspection
On SE6 models, move TCM out of the way.
Check oil cooler for cracks and other damage.
Oil Cooler Removal
1. Drain engine oil. Refer to ENGINE OIL in this
subsection.
2. Drain cooling system. Refer to COOLING SYS-
TEM subsection.
3. Remove oil cooler retaining screws.

16 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

OIL PUMP DRIVE GEARS

Oil Pump Drive Gear Location
The oil pump gears are located on the PTO side,
behind the valve train cover.

rmr2014-011-027_a

1. Check for cracks

Replace parts as necessary.

Oil Cooler Installation

For installation, reverse the removal procedure. rmr2014-011-028_a
However, pay attention to the following. 1. Balancer gear on crankshaft (behind sprag clutch gear)
Tighten oil cooler screws in two steps to the spec- 2. Oil pump intermediate gear
3. Oil pressure pump gear
ified torque following the illustrated sequence. 4. Oil scavenge pump gear

OIL COOLER SCREWS TIGHTENING SEQUENCE Oil Pump Drive Gear Removal
Step 1. Drain engine oil. Refer to ENGINE OIL in this
3 N•m ± 0.3 N•m (27 lbf•in ± 3 lbf•in)
A subsection.
Step 2. Remove valve train cover. Refer to VALVE
11 N•m ± 1 N•m (97 lbf•in ± 9 lbf•in)
B TRAIN COVER in the ELECTRIC STARTER
AND STARTER DRIVE subsection.
3. Remove:
– Oil pump gears
– Needle pins.

rmr2014-011-025_b

TIGHTENING SEQUENCE OIL-COOLER

Wipe off any oil and coolant spillage.

Fill up oil tank and check oil level. Refer to EN- rmr2014-011-029_a

GINE OIL in this subsection. 1. Oil pump gears

2. Needle pins
Refill and bleed cooling system. Refer to COOL-
ING SYSTEM subsection. 4. Remove:
– Pin
– Oil pump intermediate gear.

rmr2014-011 17
Subsection 04 (LUBRICATION SYSTEM)

rmr2014-011-030_a rmr2014-011-030_b

1. Pin 1. Oil pump intermediate gear

2. Oil pump intermediate gear 2. Pin

Oil Pump Drive Gear Inspection 3. Install needle pins in oil pump shafts and clip on
both oil pump gears completely.
Inspect gears for:
– wear
– cracks
– damage
– worn pin slots.
Replace if necessary.
Inspect pin and both needle bearings of interme-
diate gear for wear or pitting.
Replace parts as necessary.

Oil Pump Drive Gear Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
rmr2014-011-029_b
1. Apply engine oil on: 1. Needle pins
– Pin 2. Oil pump gears

– Needle bearing in oil pump intermediate 4. Install all other removed parts.
gear.
5. Fill up oil tank and check oil level. Refer to EN-
2. Install: GINE OIL in this subsection.
– Oil pump intermediate gear
– Pin. ENGINE OIL PRESSURE
REGULATOR AND OIL
PRESSURE PUMP
Oil Pressure Regulator and Oil
Pressure Pump Location
The engine oil pressure regulator and oil pressure
pump are located behind the valve train cover.

18 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

rmr2014-011-031_a rmr2014-011-033_a

FOR CLARITY VALVE TRAIN COVER AND OIL PUMP DRIVE 1. Oil pump shaft with inner rotor
GEARS REMOVED 2. Outer rotor
1. Oil pump cover 3. Oil pressure regulator valve
2. Location of engine oil pressure regulator 4. O-ring

Oil Pressure Regulator and Oil Oil Pressure Regulator Inspection

Pressure Pump Removal
1. Drain engine oil. Refer to ENGINE OIL in this
subsection.
2. Refer to OIL PUMP DRIVE GEARS in this sub-
section to remove:
– Oil pump drive gear of oil pressure pump
– Oil pump drive gear of oil scavenge pump
– Pins
– Oil pump intermediate gear.
3. Remove oil pump cover.
Clean oil regulator bore in the cylinder block from
any contamination.
Inspect oil pressure regulator piston and its bore
in cylinder block for scoring or other damages.
Press piston in to check if it moves easily in oil
pressure regulator.
Replace oil pressure regulator if piston does not
move easily.

rmr2014-011-034_a

1. Piston
2. Oil pressure regulator
rmr2014-011-032_a

1. Retaining screws Replace worn or damaged components.

2. Oil pump cover

4. Remove:
Oil Pressure Pump Inspection
– Oil pump shaft with inner rotor Clean oil pressure pump bore in the cylinder block
from any contamination.
– Outer rotor
– Oil pressure regulator valve assembly. Inspect oil pump and oil pump cover bore for
marks, scratches or other damage. Replace any
5. Remove and discard O-ring of oil pressure reg- damaged parts.
ulator valve
Check oil pump cover for damages and for surface
straightness with a straight edge.
rmr2014-011 19
Subsection 04 (LUBRICATION SYSTEM)

Check inner rotor for corrosion, worn pin slots or

other damages. If so, replace inner and outer rotor
at the same time.

rmr2008-011-020

OUTER ROTOR THICKNESS

Using a depth gauge, measure the depth of oil

pump bore in the lower cylinder block.

rmr2014-011-035_a

1. Pitting on the teeth

Radial Clearance
Using a feeler gauge, measure the clearance of
outer rotor and inner rotor where shown with the
arrows.

rmr2014-011-037

OIL PUMP BORE DEPTH (CYLINDER BLOCK)

Substract bore depth from rotor thickness to ob-

tain axial clearance.
OIL PUMP AXIAL CLEARANCE
SERVICE LIMIT 0.15 mm (.0059 in)
rmr2014-011-036_a
NOTE: When the axial clearance of the oil pump
OIL PUMP RADIAL CLEARANCE assembly increases, the oil pressure decreases.

SERVICE LIMIT 0.25 mm (.0098 in)
NOTE: If clearance of inner and outer rotors ex-
ceeds the tolerance, replace oil pump.
Axial Clearance
Measure outer rotor thickness with a micrometer.
Oil Pressure Regulator and Oil
Pressure Pump Installation
For installation, reverse the removal procedure,
however, pay attention to the following.
1. Lubricate outer rotor with engine oil.
2. Install outer rotor into cylinder block oil pump
bore.
NOTICE Mark on outer rotor must show to in-
side the engine.

20 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

rmr2014-011-038_a rmr2014-011-040_a

1. Marks on inner and outer rotor TIGHTENING SEQUENCE

3. Install oil pump shaft with inner rotor.
4. Install NEW O-ring on oil pressure regulator.
5. Apply engine oil on:
– Oil pressure regulator
– Oil pressure regulator bore in the cylinder
block
– Oil pump shaft.
1. Oil pump cover
OIL PUMP COVER RETAINING SCREWS
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)
After installation check for smooth operation of
the oil pump assembly and axial play of the oil
pump shaft.
7. Install all other removed parts.
8. Fill up oil tank and check oil level. Refer to EN-
GINE OIL in this subsection.
Start engine and make sure oil pressure is within
specifications (refer to ENGINE OIL PRESSURE in
this subsection).

OIL SCAVENGE PUMP MODULE

(PTO SIDE)
Oil Scavenge Pump Module Location
The oil scavenge pump module is located behind
rmr2014-011-039_a
the valve train cover.
1. Oil pressure regulator
2. Outer rotor
3. Oil pump shaft with inner rotor

6. Install oil pump cover and tighten retaining

screws as per following sequence.

rmr2014-011-041_a

1. Oil scavenge pump module (PTO side)

rmr2014-011 21
Subsection 04 (LUBRICATION SYSTEM)

Oil Scavenge Pump Module

Disassembly
1. Drain engine oil. Refer to ENGINE OIL in this
subsection.
2. Refer to OIL PUMP DRIVE GEARS in this sub-
section to remove:
– Oil pump drive gear of oil pressure pump
– Oil pump drive gear of oil scavenge pump
– Pins
– Oil pump intermediate gear.
3. Remove oil pump module cover.
rmr2014-011-044_a

1. Oil pump cover

2. Oil pump shaft
3. Needle pin
4. Inner rotor
5. Outer rotor

6. Remove and discard the oil pump cover O-ring.

rmr2014-011-042_a

1. Oil pump module cover

2. Retaining screws

4. Disassemble the large oil scavenge pump as

shown.
rmr2014-011-045_a

1. Oil pump cover O-ring

Oil Scavenge Pumps Inspection

The inspection of both oil scavenge pumps is the
same as for the oil pressure pump. Refer to OIL
PRESSURE PUMP in this subsection.
Oil Scavenge Pump Module Assembly
For installation, reverse the removal procedure,
however, pay attention to the following.
1. Lubricate small oil scavenge pump outer rotor
rmr2014-011-043_a with engine oil.
1. Inner rotor
2. Needle pin NOTICE When installing the smaller oil
3. Outer rotor pump rotors, make sure both marks are point-
5. Disassemble the small oil scavenge pump as ing toward the inside of the cylinder block.
shown.

22 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

rmr2014-011-048_a
rmr2014-011-046_a

1. Mark on inner rotor 1. Needle pin

2. Mark on outer rotor 2. Oil pump shaft
3. Short length side of oil pump shaft
4. Small scavenge pump inner rotor
2. Install small oil scavenge pump outer rotor into
cylinder block oil pump bore. 4. Lubricate oil pump shaft and inner rotor with
engine oil.
5. Install oil pump shaft assembly into the cylinder
block.

rmr2014-011-047_a

1. Small oil scavenge pump outer rotor

3. Install needle pin in bore of the oil pump shaft

rmr2014-011-049_a
short length side and place the small inner rotor
1. Oil pump shaft with small oil scavenge pump
on the shaft.
NOTICE The oil pump shaft is not symmetri- 6. Install a NEW oil pump cover O-ring.
cal. The shorter side must be installed inwards.

rmr2014-011-050_a

1. Oil pump cover O-ring

rmr2014-011 23
Subsection 04 (LUBRICATION SYSTEM)

7. Lubricate both sides of the oil pump cover with

engine oil.
8. Align tab of the oil pump cover with the upper
recess in the cylinder block. Push cover in until
a click is heard, indicating the cover is properly
installed.

rmr2014-011-053_a

TIGHTENING SEQUENCE
1. Oil pump cover

OIL PUMP COVER RETAINING SCREWS

11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

rmr2014-011-051_a 13. Install other removed parts.

1. Oil pump cover tab properly positioned
9. Install large oil scavenge pump needle pin.
10. Install oil scavenge pump inner rotor and outer
rotor with the marks outwards.
After installation is complete, check for smooth
operation of the oil pump assembly and axial play
of the oil pump shaft.
14. Fill up oil tank and check oil level. Refer to EN-
GINE OIL in this subsection.
Start engine and make sure oil pressure is within
specifications (refer to ENGINE OIL PRESSURE in
this subsection).

OIL SCAVENGE PUMP (CLUTCH

SIDE)
Oil Scavenge Pump Location
The oil scavenge pump is located behind the
clutch cover.

rmr2014-011-052_a

1. Marks on inner and outer rotor

11. Lubricate large oil scavenge pump parts with

engine oil.
12. Install oil pump cover and tighten retaining
screws as per following sequence.

rmr2014-011-054_a

SE6
1. Oil scavenge pump module (Clutch side) integrated in HCM
module
2. Hydraulic control module (HCM)
3. Clutch cover

24 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

Remove following parts from HCM housing bore:

– Inner rotor
– Outer rotor
– Needle pin.

rmr2014-011-022_a

SM6
1. Oil scavenge pump module (Clutch side)
2. Clutch cover

Oil Scavenge Pump Removal

Drain engine oil. Refer to ENGINE OIL in this sub- rmr2014-011-055_a
section. 1. Inner rotor
Remove: 2. Outer rotor
3. Needle pin
– Oil duct cover
– Gasket and discard it If necessary remove oil guiding plate and O-ring
(discard it) from clutch cover.
– Oil strainer.

rmr2014-011-066_a
rmr2014-011-065_a
1. Retaining screws
TYPICAL - SE6 SHOWN 2. Oil guiding plate
1. Retaining screws 3. O-ring (discard it)
2. Oil duct cover 4. Clutch cover
3. Gasket
4. Oil strainer
SM6 Models
SE6 Models Refer to CLUTCH (SM6) subsection to remove:
Disconnect the oil pressure sensor and HCM con- – Vacuum hose from diaphragm cover
nector. Refer to CLUTCH (SE6) subsection. – Diaphragm cover
Remove clutch cover. Refer to CLUTCH (SE6) – Diaphragm
subsection. – Clutch cover.
Remove hydraulic control module (HCM). Refer to
NOTICE Do not let the diaphragm cover hang
HYDRAULIC CONTROL MODULE (SE6) subsec-
tion. from the vacuum hose and do not stretch or
twist the vacuum hose.

rmr2014-011 25
Subsection 04 (LUBRICATION SYSTEM)

Remove oil pump housing with scavenge pump

from clutch cover.

rmr2014-011-067_a

1. Retaining screws
2. Oil guiding plate
3. O-ring (discard it)
rmr2014-011-056_a
4. Clutch cover
1. Retaining screws
2. Oil pump housing with scavenge pump
3. Clutch cover Oil Scavenge Pump Inspection
Remove following parts from oil pump housing: Clutch Cover and Oil Pump Bore
– Inner rotor Clean clutch cover and oil pump bore.
– Outer rotor Check clutch cover and oil pump housing (SM6) or
– Needle pin HCM housing (SE6) for cracks, warping at sealing
– Oil pump shaft. surface or any other visible damages.

rmr2014-011-058_a

rmr2014-011-057_a SE6
1. Inner rotor 1. Oil pump bore
2. Outer rotor 2. Sealing surface
3. Needle pin 3. HCM housing
4. Oil pump shaft
5. Oil pump housing

If necessary remove oil guiding plate and O-ring

(discard it) from clutch cover.

26 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

Oil Guiding Plate

Clean oil guiding plate and check for cracks or any
other visible damages.
Replace if necessary.

Oil Scavenge Pump Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
Apply engine oil on:
– Inner rotor
– Outer rotor
rmr2014-011-059_a – Oil pump shaft.
SM6
1. Oil pump bore SE6 Models
2. Sealing surface
3. Oil pump housing Install needle pin in bore of oil pump shaft.
Insert inner and then outer rotor into the HCM
Blow out the oil bores in the clutch cover us-
housing.
ing compressed air and make sure they are not
clogged. NOTICE Marks on inner and outer rotor must
show towards the clutch cover.

rmr2014-011-060_a

TYPICAL - SE6 SHOWN rmr2014-011-061_a

1. Oil bores
2. Sealing surface 1. Oil pump shaft
3. Clutch cover 2. Needle pin
3. Inner rotor
4. Outer rotor
Replace parts as required. 5. Marks on inner and outer rotor

Oil Scavenge Pump Install hydraulic control module. Refer to HY-

Check axial and radial clearance of scavenge DRAULIC CONTROL MODULE (SE6) subsection.
pump. For the appropriate procedure refer to OIL SM6 Models
PRESSURE PUMP in this subsection.
Install needle pin in bore of oil pump shaft and
Oil Duct Cover place oil pump shaft into the bearing bore in the
Clean oil duct cover and check for cracks, warping clutch cover.
at sealing surface or any other visible damages.
Replace if necessary.
Oil Strainer
Clean oil strainer with compressed air and check
for any other visible damages.
Replace if necessary.

rmr2014-011 27
Subsection 04 (LUBRICATION SYSTEM)

rmr2014-011-062_a rmr2014-011-064_a

1. Needle pin 1. Oil pump shaft

2. Oil pump shaft 2. Oil pump housing
3. Clutch cover 3. Needle pins

Install inner rotor and outer onto oil pump shaft. Tighten oil pump housing to specification.
NOTICE Mark on inner and outer rotor must OIL PUMP HOUSING RETAINING SCREWS
show towards the oil pump housing. 11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

All Models
Install oil guiding plate with NEW O-ring in clutch
cover and tighten retaining screws to specifica-
tion.
OIL GUIDING PLATE RETAINING SCREWS
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

Install oil strainer in clutch cover.

Install oil duct cover on clutch cover. For tight-
ening procedure refer to CLUTCH COVER in the
rmr2014-011-063_a CLUTCH (SE6) or CLUTCH (SM6) subsection.
1. Inner rotor
2. Outer rotor Install other removed parts. Refer to CLUTCH
3. Oil pump shaft (SE6) or CLUTCH (SM6) subsection.
4. Marks on inner and outer rotor
Fill up oil tank and check oil level. Refer to EN-
Install oil pump housing onto the oil pump shaft GINE OIL in this subsection.
and then onto the outer rotor.
Turn oil pump shaft to align the oil pump hous- OIL SUMP COVER
ing the needle pins. Then press oil pump housing
completely onto the clutch cover. Oil Sump Cover Location
The oil sump cover is located on the engine bot-
tom.

28 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

rmr2014-011-070_a rmr2014-011-071_a

BOTTOM OF ENGINE 1. Retaining screws

1. Oil sump cover 2. Oil sump cover
3. Gasket (discard it)
Oil Sump Cover Access 5. Remove and clean engine oil strainers.
Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION subsection.
Oil Sump Cover Removal
1. Drain engine oil, refer to ENGINE OIL in this
subsection.
2. Remove cable clamp securing the GBPS wire.

rmr2014-011-072_a

1. Engine oil strainers

2. Oil sump cover

Oil Sump Cover Inspection

Clean oil sump cover and engine oil strainers with
a part cleaner, then use an air gun to dry it.
rmr2014-011-070_b
Blow out the oil drain bores and check if they are
1. Cable clamp not clogged.
2. GBPS wire
3. Oil sump cover

3. Unscrew oil sump cover retaining screws.

4. Remove oil sump cover. Discard gasket.

rmr2014-011-073_a

1. Oil drain bores

rmr2014-011 29
Subsection 04 (LUBRICATION SYSTEM)

Check oil sump cover for cracks or other damage.

Check oil sump cover for flatness with straight
edge.
Replace oil sump cover if necessary.
Check engine oil strainers for damage and change
if necessary.

Oil Sump Cover Installation

1. Install the strainers in oil sump cover.

F12R17A

IMPORTANT: When beginning the application of

the 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.
NOTICE Ensure not to apply too much
sealant, as it will spread out inside cylinder
block.
rmr2014-011-074_a

1. Engine oil strainers 4. Install the oil sump cover on the engine and
2. Oil sump cover tighten screws as per following sequence.
2. Clean oil sump cover sealing surface and cylin-
der block sealing surface using a combination
of LOCTITE CHISEL (GASKET REMOVER) (P/N 413
708 500) and a brass brush. First brush in one
direction then make the final brushing perpen-
dicularly (90°) to the first pass.
3. Install a NEW oil sump cover gasket.
Apply sealant on both sides of oil sump cover gas-
ket.
OIL SUMP COVER GASKET
LOCTITE 5910 (P/N 293
Service product
800 081) rmr2014-011-075_a

TIGHTENING SEQUENCE
Use a plexiglass plate and apply some sealant on
it. Use a soft rubber roller 50mm - 75mm (2 in - OIL SUMP COVER RETAINING SCREWS
3 in), available in arts products suppliers for print- 11 N•m ± 1 N•m
ing, and roll the sealant to get a thin uniform coat Tightening torque
(97 lbf•in ± 9 lbf•in)
on the plate (spread as necessary). When ready,
apply the sealant on oil sump cover gasket. 5. Reinstall oil drain plugs using NEW sealing
washer and O-rings. Refer to ENGINE OIL in
this subsection.
6. Fill up oil tank and check oil level. Refer to EN-
GINE OIL in this subsection.

30 rmr2014-011
 Subsection 04 (LUBRICATION SYSTEM)

OIL NOZZLES If the oil nozzles are damaged or bent during work
in the cylinder block, they must be replaced imme-
Oil Nozzle Location diately.
The oil nozzles are located inside the cylinder Check if ball inside Banjo bolt moves freely.
block upper half.

mmr2009-111-049_a
rmr2014-011-085_a
1. Ball
1. Oil nozzles 2. Spring
2. Cylinder block upper half 3. Banjo bolt
4. Oil nozzle
NOTE: If the engine has to be dismantled within
the scope of repair work, take this opportunity to Oil Nozzle Installation
clean the oil nozzles.
CAUTION At assembly make sure the
Oil Nozzle Removal contact surface of the oil nozzles are well fitted
Separate cylinder block halves. Refer to CYLIN- onto the cylinder block. If this is not ensured,
DER BLOCK subsection. the oil spray direction will change, causing
potential engine damage.
Remove banjo bolt retaining the oil nozzle to cylin-
der block.

rmr2014-011-087_a

1. Oil nozzle
rmr2014-011-086_a 2. Corner in cylinder block
1. Banjo bolt
2. Oil nozzle Tighten banjo bolts to the specified torque.
3. Cylinder block upper half
BANJO BOLT
Oil Nozzle Cleaning and Inspection
15 N•m ± 1 N•m
Clean oil nozzle with a parts cleaner, then use an Tightening torque
(133 lbf•in ± 9 lbf•in)
air gun and dry the parts.

WARNING
Always wear eye protector. Chemicals can
cause a rash break out and injure your eyes.
rmr2014-011 31
 Subsection 05 (COOLING SYSTEM)

COOLING SYSTEM
SERVICE TOOLS
Description Part Number Page
OETIKER PLIERS........................................................................... 295 000 070 ........................................... 9
TEST CAP ...................................................................................... 529 035 991 ........................................... 8
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ........................................... 8

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ........................................... 14
LONG LIFE ANTIFREEZE .............................................................. 219 702 685 ........................................... 6

rmr2014-012 1
Subsection 05 (COOLING SYSTEM)

COOLING SYSTEM (CLOSED LOOP)

1
2

rmr2014-012-100_a

1. Expansion coolant bottle

2. Coolant returns from radiators
3. RH Radiator
4. LH Radiator
5. Coolant flows to radiators

2 rmr2014-012
 Subsection 05 (COOLING SYSTEM)

COOLING SYSTEM COMPONENTS

10 ± 2 N•m
(89 ± 18 lbf•in)

10 ± 2 N•m
(89 ± 18 lbf•in)

10 ± 2 N•m
(89 ± 18 lbf•in)

NEW

27 ± 3,5 N•m 10 ± 2 N•m

(20 ± 2,5 lbf•ft) (89 ± 18 lbf•in)

NEW

NEW

NEW

NEW
NEW

10 ± 2 N•m
(89 ± 18 lbf•in)

NEW NEW
NEW

1,7 ± 0,2 N•m

(15 ± 1,8 lbf•in) NEW
NEW
NEW = Component must be replaced when removed.
rmr2014-012-101_a

rmr2014-012 3
Subsection 05 (COOLING SYSTEM)

COOLING SYSTEM COMPONENTS (ENGINE)

11 ± 1 N•m
(97 ± 9 lbf•in)

53 ± 2 N•m
(39 ± 1 lbf•ft)

Engine oil Loctite 648

17 ± 1 N•m
(150 ± 9 lbf•in)

Engine oil

13 ± 1 N•m
(115 ± 9 lbf•in)

NEW = Component must be replaced when removed.

rmr2014-012-025_a

4 rmr2014-012
 Subsection 05 (COOLING SYSTEM)

ENGINE COOLING CIRCUIT

7
1

5
6

4
8

rmr2014-012-026_a

1. Water pump module, including thermostat

2. Coolant flows into oil radiator for cooling engine oil
3. Coolant temperature sensor (CTS)
4. Coolant flows to radiator
5. Coolant returns from radiator
6. Expansion coolant tank connection
7. Bleed hose nipple (to expansion coolant tank)
8. Bleeder screw

rmr2014-012 5
Subsection 05 (COOLING SYSTEM)

GENERAL Coolant temperature sensor is located on the

cylinder head.
SYSTEM DESCRIPTION
CAUTION Always disconnect battery be-
fore servicing the cooling system. Cooling fans
may start without warning even when engine
and start key are turned OFF.
NOTICE Never start engine without coolant.
Engine parts like the rotary seal of the water
pump shaft can be damaged.
The cooling system keeps the temperature con-
stant.
A separate coolant tank ensures that enough en-
gine coolant is in the circuit during any operating
condition.
The coolant flow comes from the water pump
rmr2014-012-003_a
module and goes into the cylinder head. After- 1. Coolant temperature sensor (CTS)
wards coolant is directed to the oil radiator for 2. Intake manifold
cooling the engine oil, and to the cylinder block. In
the cylinder head the water channels flow around NOTICE Never modify cooling system ar-
the exhaust and then the intake valves. From rangement, otherwise serious engine damage
there the coolant goes back to the water pump could occur.
module. At cold engine coolant flows through a
bypass channel to the thermostat directly back to MAINTENANCE
the water pump impeller and back into the engine.
When engine has reached operating temperature ENGINE COOLANT
the thermostat opens completely and closes the
bypass channel completely. Then coolant takes WARNING
the way through the radiator. To avoid potential burns, do not remove the
The cylinder head and water pump are self bleed- coolant tank cap or any fastener from the
ing via a hose nipple on the water pump module. cooling system if the engine is hot.

Recommended Coolant
COOLANT
BRP recommended LONG LIFE ANTIFREEZE
product (P/N 219 702 685)
A blend of 50%
Alternative antifreeze with 50%
distilled water

NOTICE A blend of 50% antifreeze with 50%

distilled water will improve the cooling effi-
ciency. Using water tap instead of distilled
water, would contribute to make deposits in
cooling system and to reduce antifreeze effi-
ciency. This could lead to engine overheating.
rmr2014-012-005_a
To prevent antifreeze deterioration, always use
1. Bleed hose nipple the same brand. Never mix different brands un-
2. Water pump module
less cooling system is completely flushed and
refilled.

6 rmr2014-012
 Subsection 05 (COOLING SYSTEM)

NOTICE To prevent rust formation or freezing

condition in cold areas, always replenish the
system with 50% antifreeze and 50% distilled
water. Pure antifreeze will freeze at a higher
temperature than the optimal water/antifreeze
mix. Always use ethylene glycol antifreeze
containing corrosion inhibitors specifically
recommended for aluminum engines.

Draining the System

WARNING
Never drain or refill cooling system when en-
gine is hot.
rmr2014-012-202_a
Refer to BODY subsection and remove front body 1. Coolant level when hot
module. 2. Coolant level when cold

Install a drain pan underneath radiators. Do not install pressure cap at this time.
Cut oetiker clamp connecting coolant hose to RH
radiator.

rmr2014-012-203_a

1. This hose becomes hot when thermostat opens

rmr2014-012-201_a

REAR OF RH RADIATOR SHOWN - PARTS REMOVED FOR
CLARITY
1. Coolant hose
2. Oetiker clamp
Remove the coolant tank cap.
Dispose coolant as per local regulations.
Position NEW Oetiker clamp onto coolant hose
and secure coolant hose to radiator.
Refilling the System
Vehicle should be level and engine cold for refill-
ing.
Pour antifreeze into coolant tank until the level
reaches the COLD mark.
Start engine and let vehicle run until engine is hot
(fan starts).
When engine has completely cooled down,
recheck coolant level and top up if necessary.
Install pressure cap.
Install all previously removed parts.
INSPECTION
COOLING SYSTEM LEAK TEST
WARNING
To avoid potential burns, do not remove the
coolant tank cap or any fastener from the
cooling system if the engine is hot.

Open or remove seat.

rmr2014-012 7
Subsection 05 (COOLING SYSTEM)

NOTE: It is not necessary to install a hose pincher ENGINE OVERHEATING

on overflow hose.
1. Low coolant level.
Pressurize system through coolant tank. - Refill and check for leaks (coolant leaking out
REQUIRED TOOL of engine leak indicator hole, hoses or clamps
missing/defective, cylinder head gaskets leaks,
ride plate leaking, etc.). Repair or replace.
TEST CAP (P/N 529 035 991)
2. Air in cooling system
- Refill and bleed cooling system.
VACUUM/PRESSURE PUMP - Check bleeding nozzles in water pump module
(P/N 529 021 800) and cylinder head if they are clogged.
3. Thermostat defective (does not open when en-
COOLING SYSTEM LEAK TEST gine gets hot)
- Replace water pump module.
100 kPa (15 PSI)
4. Water pump failure
Check all hoses, engine and oil cooler for coolant - Inspect water pump drive gears.
leaks. Spray a soap and water solution and look - Inspect and replace defective components.
for air bubbles.
5. Water temperature sensor defective
Check the leak indicator hole: If there are signs
of oil or coolant on cylinder head and/or cylinder - Check or replace. Refer to ELECTRONIC FUEL
INJECTION (EFI).
block replace water pump module.
6. Radiator or hoses damaged
- Check or replace damaged components.
7. Internal passage blocked in cooling system
- Inspect and clean.

PROCEDURES
COOLANT TEMPERATURE
SENSOR (CTS)
Refer to ELECTRONIC FUEL INJECTION (EFI)sub-
section.

rmr2014-012-015_b

1. Check for oil/coolant contamination

TROUBLESHOOTING
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and
it should not be assumed to list all possible prob-
lems.
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to DIAG-
NOSTIC AND FAULT CODES subsection. rmr2014-012-003_a

1. Coolant temperature sensor (CTS)

2. Intake manifold

8 rmr2014-012
 Subsection 05 (COOLING SYSTEM)

PRESSURE CAP WATER PUMP MODULE

Pressure Cap Inspection
Using a pressure cap tester, check cap opening
pressure. If opening pressure is out of range, in-
stall a new pressure cap.
CAP OPENING PRESSURE
90 kPa ± 10 kPa
Opening range
(13 PSI ± 1.5 PSI)

CLAMPS
Clamp Replacement
REQUIRED TOOL

OETIKER PLIERS (P/N 295

000 070)
rmr2014-012-005_b

1. Water pump module

Water Pump Module Access

Refer to BODY subsection and remove :
– RH Top side panel
– RH Middle side panel
– Central panel
1 – RH rear side panel
– RH Light trim

Water Pump Module Removal

Disconnect radiator hoses from water pump mod-
ule.
2
F01B2KA

1. Cutting clamp
2. Securing clamp

NOTE: Always check general condition of hoses

and clamp tightness.

rmr2014-012-204_a

RH SIDE OF VEHICLE- PARTS REMOVED FOR CLARITY

1. Radiator outlet hose
2. Radiator inlet hose
3. Bleeder hose
4. Coolant tank hose

Remove water pump module retaining screws.

rmr2014-012 9
Subsection 05 (COOLING SYSTEM)

rmr2014-012-006_a rmr2014-012-008_a

1. Retaining screws 1. Needle pin

2. Water pump module 2. Thrust washers
3. Axial needle bearing
4. Water pump shaft
Pull the water pump module to remove it.
Remove water pump gear from water pump shaft. Water Pump Module Inspection
NOTE: Water pump gear may remain in cylinder Check if gasket and O-ring are brittle, hard or dam-
head. aged and replace as necessary.

rmr2014-012-007_a
rmr2014-012-010_a
1. Water pump gear
2. Water pump shaft 1. Gasket
3. Water pump module 2. O-ring

Pull out needle pin and withdraw thrust washers Apply pressurized air at bleed hose nipple to
with axial needle bearing from water pump shaft. check self-bleeding system of water pump mod-
ule. Clean if necessary.

rmr2014-012-011_a

1. Bleed hose nipple

2. Bleeding connection bore to Cylinder head

10 rmr2014-012
 Subsection 05 (COOLING SYSTEM)

Check bleeding nozzle in cylinder head if it is WATER PUMP MODULE SCREWS

clogged. Clean if necessary.
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

rmr2014-012-012_a

1. Bleeding nozzle
2. Cylinder head rmr2014-012-006_b

TIGHTENING SEQUENCE
Check if thermostat is in good condition. Refer to
THERMOSTAT in this subsection.
THERMOSTAT
Water Pump Module Installation The thermostat is included in water pump module.
The installation is the opposite of the removal pro-
cedure. However, pay attention to the following.
Before installation lubricate:
– Water pump shaft
– Washers
– Axial needle bearing
– O-ring.
WATER PUMP PARTS LUBRICATION
Service product Engine oil

rmr2014-012-015_a

1. Thermostat
2. Water pump module

rmr2014-012-008_b
1. Lubricate water pump parts
NOTICE To prevent leaking, take care that the
gaskets are exactly in groove when you rein-
stall the water pump module.
Tighten screws to specification using the follow-
ing sequence.
Thermostat Test
Water pump module installed in vehicle
Start engine and let engine heat up to operating
temperature (higher than 80°C (176°F)).
Check if the main supply hose from radiator to wa-
ter pump module heats up with engine at operat-
ing temperature.

rmr2014-012 11
Subsection 05 (COOLING SYSTEM)

If main supply hose does not heat proceed with
THERMOSTAT REMOVAL and perform THERMO-
STAT TEST - WATER PUMP MODULE REMOVED.
Thermostat Removal
Remove the WATER PUMP MODULE, see proce-
dure in this subsection.
Thermostat Test
Water pump module removed from engine
To check the operation of the thermostat, put it in
water and heat water.
Look inside the radiator inlet hose connection to
see the movement of the thermostat.
WATER PUMP SEALS
Water Pump Seals Inspection
Check cylinder head and cylinder block for signs
of oil or coolant:
– Leaking coolant from leak indicator hole indi-
cates a damaged rotary seal on water pump
side.
– Leaking oil indicates a damaged oil seal on en-
gine side.

rmr2014-012-015_b

1. Check for oil/coolant contamination

rmr2014-012-016_a

1. Radiator inlet hose connection

2. Thermostat
3. Water pump module

THERMOSTAT OPERATING TEMPERATURE

Starts to open 80°C (176°F)
Fully open 94°C (201°F)

If there is no operation, replace the water pump

module.

Thermostat Installation rmr2014-012-011_b

Refer to WATER PUMP MODULE in this subsec- 1. Leak indicator hole

tion. If either seal is leaking, replace water pump mod-

ule.

Water Pump Seals Replacement

Replace water pump module.

12 rmr2014-012
 Subsection 05 (COOLING SYSTEM)

WATER PUMP GEARS

Water Pump Gears Location
The water pump gear is located underneath the
water pump module.

rmr2014-012-007_a

1. Water pump gear

2. Water pump shaft
3. Water pump module

Remove exhaust camshaft, refer to CYLINDER

rmr2014-012-020_a
HEAD subsection.
1. Water pump gear Clamp exhaust camshaft at the hexagon in a vice.
2. Water pump module
Remove:
The water pump drive gear is located on the ex- – Flat head screw
haust camshaft.
– Water pump drive gear.
NOTICE To avoid timing chain overstress it is
not allowed to remove or tighten the flat head
screw when camshaft is installed in the engine.

rmr2014-012-021_a

FOR CLARITY VALVE COVER REMOVED

1. Water pump drive gear
2. Exhaust camshaft

Water Pump Gears Removal

Remove water pump module, refer to WATER
PUMP MODULE in this subsection.
Withdraw water pump gear from water pump
shaft.

rmr2014-012 13
Subsection 05 (COOLING SYSTEM)

rmr2014-012-022_a

1. Flat head screw

2. Water pump drive gear
3. Exhaust camshaft
4. Vice

Water Pump Gears Inspection

Check water pump gears for wear or broken
teeth. Replace if damaged.

Water Pump Gears Installation

Install water pump drive gear and tighten flat head
screw to specification.
WATER PUMP DRIVE GEAR FLAT HEAD SCREW
LOCTITE 648 (GREEN)
Service product
(P/N 413 711 400)
50 N•m to 55 N•m
Tightening torque
(37 lbf•ft to 41 lbf•ft)

14 rmr2014-012
 Subsection 06 (ELECTRIC STARTER AND STARTER DRIVE)

ELECTRIC STARTER AND STARTER

DRIVE
SERVICE PRODUCTS
Description Part Number Page
DIELECTRIC GREASE ................................................................... 293 550 004 ........................................... 8
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 7

rmr2014-013 1
Subsection 06 (ELECTRIC STARTER AND STARTER DRIVE)

Loctite 243
30 ± 3 N•m
(22 ± 2 lbf•ft)

NEW
Engine oil
Engine oil
Engine oil

11 ± 1 N•m
(97 ± 9 lbf•in)

Engine oil

11 ± 1 N•m 3 ± 0,3 N•m

(97 ± 9 lbf•in) (27 ± 3 lbf•in)
See tightening
sequence

NEW = Component must be replaced when removed.

rmr2014-013-001_a

2 rmr2014-013
 Subsection 06 (ELECTRIC STARTER AND STARTER DRIVE)

GENERAL Valve Train Cover Access

NOTE: To carry out the following instructions, it is Remove the following LH body panels, refer to the
not necessary to remove the engine from the ve- BODY subsection:
hicle. For a better understanding, many of the fol- – Middle Side Panel
lowing illustrations are produced with the engine – Top Side Panel
removed from the vehicle. – Acoustic panel
Always disconnect the negative wire from the bat- – Bottom Rear Side Panel
tery before working on the engine. – Bottom Front Side Panel
– Rear Side Panel.
WARNING
Remove LH middle side panel support.
Always disconnect the BLACK (-) cable first
and reconnect last. Valve Train Cover Removal
Remove magnetic drain plug at clutch cover to
WARNING drain engine oil.
Before carrying out any inspection or main-
tenance procedure on the vehicle, wait until NOTE: Clean drain plug area before removal.
the engine and exhaust system have cooled
down to avoid potential burns.

Always carry out electrical tests on components

before removing or installing them to ensure their
state of operation.
During assembly/installation, use the torque val-
ues and service products as specified in the ex-
ploded view.
Clean threads before applying threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure. rmr2014-013-004_a

SE6
WARNING 1. Clutch cover
2. Sealing washer
Torque wrench tightening specifications 3. Magnetic drain plug
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners,
cotter pins, etc.) must be replaced with new
ones.

NOTICE Hoses, cables and locking ties re-

moved during a procedure must be reinstalled
as per factory standards.

PROCEDURES
rmr2014-013-007_a

VALVE TRAIN COVER SM6

The valve train cover can be removed without re-
moving the engine from the vehicle.
1. Clutch cover
2. Sealing washer
3. Magnetic drain plug
Place an oil pan under the valve train cover.
Remove valve train cover retaining screws and
pull valve train cover from engine.

rmr2014-013 3
Subsection 06 (ELECTRIC STARTER AND STARTER DRIVE)

rmr2014-013-002_a

1. Valve train cover rmr2014-013-004_a

2. Retaining screws
SE6
1. Clutch cover
Remove and discard gasket. 2. Sealing washer
3. Magnetic drain plug
Valve Train Inspection
Clean valve train cover and check for cracks or
other damages. Replace if necessary.

Valve Train Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
Install a NEW valve train cover gasket.
Tighten valve train cover retaining screws to spec-
ification as per the following sequence.
VALVE TRAIN COVER RETAINING SCREWS rmr2014-013-007_a

11 N•m ± 1 N•m SM6

Tightening torque 1. Clutch cover
(97 lbf•in ± 9 lbf•in) 2. Sealing washer
3. Magnetic drain plug

Refill engine with recommended oil and check

engine oil level. Refer to LUBRICATION SYSTEM
subsection.

STARTER DRIVE GEARS

Starter Drive Gears Location
The starter drive gears are located on the engine
LH side behind the valve train cover.

rmr2014-013-003_a

TIGHTENING SEQUENCE

Install NEW sealing washer and tighten magnetic

drain plug to specification.
MAGNETIC DRAIN PLUG
Sealing washer NEW
20 N•m ± 2 N•m
Tightening torque
(15 lbf•ft ± 1 lbf•ft)

4 rmr2014-013
 Subsection 06 (ELECTRIC STARTER AND STARTER DRIVE)

rmr2014-013-005_a rmr2014-013-006_a

STARTER DRIVE GEARS 1. Retaining ring

1. Intermediate gear 2. Thrust washer
2. Starter double gear 3. Sprag clutch gear
3. Starter gear 4. Crankshaft
4. Location pins
Sprag Clutch Gear Inspection
Starter Drive Gears Removal
Inspect gear, especially teeth and sprag clutch col-
Remove VALVE TRAIN COVER, see procedure in lar, for wear and other damages.
this subsection.
Check needle bearing condition. Replace sprag
Remove the intermediate gear. clutch gear if necessary.
Remove the starter double gear.

Starter Drive Gears Inspection

Inspect the gears for wear, pitting, cracks,
chipped or broken teeth, and any other dam-
ages.
Replace parts as necessary.

Starter Drive Gears Installation

The installation is the reverse of the removal pro-
cedure. Pay attention to the following details.
Apply engine oil on the location pins before in-
stalling the starter double and intermediate gears.

SPRAG CLUTCH GEAR vmr2006-041-016_a

Sprag Clutch Gear Removal INSPECT

1. Teeth
Remove the VALVE TRAIN COVER, see procedure 2. Collar
3. Needle bearing
in this subsection.
Remove: Sprag Clutch Gear Installation
– Retaining ring The installation is the reverse of the removal pro-
– Thrust washer cedure. However, pay attention to the following.
– Sprag clutch gear. Apply engine oil on needle bearing and collar of
the sprag clutch gear.

rmr2014-013 5
Subsection 06 (ELECTRIC STARTER AND STARTER DRIVE)

Sprag Clutch Operation Test

For sprag clutch operation test remove intermedi-
ate gear of starter drive.
Using clamp, rotate sprag clutch gear as follows:
– Must lock in the counterclockwise direction
– Must release in the clockwise direction.
NOTE: Check function of sprag in several angular
positions, as it may skip only in certain areas

CAUTION Never place your fingers in

gear train as serious injury may occur.

vmr2006-041-016_b

LUBRICATE
1. Collar
2. Needle bearing

SPRAG CLUTCH
Sprag Clutch Removal
NOTICE Before removing the sprag clutch
gear check sprag clutch operation. Refer to
SPRAG CLUTCH INSPECTION.
rmr2014-013-009_a

Remove sprag clutch gear, see procedure in this SPRAG CLUTCH FUNCTIONAL TEST
subsection. 1. Must lock in the counterclockwise direction

Remove: NOTE: If defective replace the following parts as

– Sprag clutch housing screws a set:
– Sprag clutch housing – Sprag clutch
– Sprag clutch. – Sprag clutch housing
– Sprag clutch gear.

Sprag Clutch Installation

For installation, reverse the removal procedure.
Pay attention to the following details.
Apply engine oil on the sprag clutch and on the
inside surface of the sprag clutch housing.

rmr2014-013-008_a

1. Sprag clutch housing screws

2. Sprag clutch housing
3. Sprag clutch

Sprag Clutch Inspection

Inspect sprag clutch and sprag clutch housing for
wear and other damages.
Check the collar of the sprag clutch gear.

6 rmr2014-013
 Subsection 06 (ELECTRIC STARTER AND STARTER DRIVE)

Remove starter retaining screws.

rmr2014-013-010_a

LUBRICATE
1. Sprag clutch
2. Sprag clutch housing rmr2014-013-011_a
3. Apply engine oil here
1. Starter (+) terminal
2. Retaining screws
Fit sprag clutch into sprag clutch housing and in-
stall it on the crankshaft. Starter Installation
Tighten sprag clutch housing screws to specifica- Installation is the reverse of the removal proce-
tion. dure. However, pay particular attention to the fol-
SPRAG CLUTCH HOUSING SCREWS lowing.
LOCTITE 243 (BLUE) Make sure that starter and engine mating surfaces
Service product are free of debris.
(P/N 293 800 060)
30 N•m ± 3 N•m NOTICE Premature wear may arise if the
Tightening torque
(22 lbf•ft ± 2 lbf•ft) starter is not properly aligned.
Lubricate starter boss and starter O-ring.
ELECTRIC STARTER STARTER BOSS AND STARTER O-RING
Starter Test Service product Engine oil
Refer to the STARTING SYSTEM subsection to
validate starter operation.

Starter Troubleshooting Tips

If starter is noisy, check the condition of the
starter and the starter gears.
If starter is noisy and skipping, check the sprag
clutch.

Starter Access
Remove the following body panels, refer to BODY
subsection:
– LH bottom plate panel rmr2014-013-012_a

LUBRICATE
Disconnect the battery. 1. Starter boss
2. Starter O-ring
NOTICE Always disconnect BLACK (–) cable
first and reconnect last. Tighten starter retaining screws to specification.
STARTER RETAINING SCREWS
Starter Removal
Remove the RED rubber protector from the Tightening torque 11 N•m ± 1 N•m
starter terminal and disconnect the (+) cable from (97 lbf•in ± 9 lbf•in)
the starter terminal.
NOTE: Starter is case grounded. Connect the RED (+) cable to the starter and
torque nut to specification.
rmr2014-013 7
Subsection 06 (ELECTRIC STARTER AND STARTER DRIVE)

STARTER CABLE NUT

Tightening torque 5.5 N•m ± .5 N•m

(49 lbf•in ± 4 lbf•in)

Apply DIELECTRIC GREASE (P/N 293 550 004) on ter-

minal and nut.
Reconnect the battery.

WARNING
Whenever connecting the RED (+) cable to
the starter motor, make sure the battery ca-
bles are disconnected to prevent electrical
shock. Always connect RED (+) battery cable
first then BLACK (-) cable last.

Test starter operation.

8 rmr2014-013
 Subsection 07 (ALTERNATOR)

ALTERNATOR
SERVICE TOOLS
Description Part Number Page
ALTERNATOR SHAFT ADAPTER .................................................. 529 036 299 ........................................... 10
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 3–4
GENERATOR SHAFT HOLDER ..................................................... 529 036 298 ........................................... 10
OIL SEAL INSTALLER ................................................................... 529 036 297 ........................................... 12

SERVICE PRODUCTS
Description Part Number Page
COPASLIP...................................................................................... 420 297 430 ....................................... 6, 10
LOCTITE 5910 ............................................................................... 293 800 081 ............................................. 7
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ............................................. 7

rmr2014-014 1
Subsection 07 (ALTERNATOR)

11 ± 1 N•m
(97 ± 9 lbf•in)

Engine oil

NEW
Engine oil

Loctite 5910
Engine oil

11 ± 1 N•m
(97 ± 9 lbf•in)
Copaslip
6g (.2oz)

Copaslip

11 ± 1 N•m
(97 ± 9 lbf•in)

NEW = Component must be replaced when removed.

rmr2014-014-001_a

2 rmr2014-014
 Subsection 07 (ALTERNATOR)

GENERAL
WARNING
Always disconnect battery prior to working
on the fuel system. Always disconnect bat-
tery exactly in the specified order. BLACK (-)
cable first.

PROCEDURES
rmr2014-014-021_a

ALTERNATOR 1.
2.
Battery
Ammeter (clamp type)
3. Voltmeter (digital)
Alternator Output Line Voltage Drop 4. Alternator
Test 5. B terminal

This test determines whether the wiring from the 4. Start engine.
alternator "B" terminal to the battery (+) terminal 5. With engine running at 2500 rpm, turn the
(including fuse) is in a good condition or not. headlamps and other lamps on and off until the
NOTICE Before performing the voltage drop ammeter is slightly above 30 A.
test check the following: 6. Decrease engine speed until ammeter displays
– Fuse 30 A.
– Abnormal noise from alternator while en- 7. Check reading of multimeter.
gine is running.
VOLTAGE OUTPUT AT 30 A
1. Turn ignition switch off. SERVICE LIMIT Max. 0.1 V
2. Attach an clamp-type ammeter onto the alter-
nator wire. NOTE: When the alternator output is high and
3. Set multimeter to Vdc and connect it between the value displayed on the ammeter does not
the alternator "B" terminal and the battery (+) decrease until 30 A, set the value to 40 A. Read
terminal. the value displayed on the voltmeter at this time.
When the value range is 40 A, the limit is also
Connect multimeter: max. 0.1 V.
– (+) lead to the alternator "B" terminal 8. If the value displayed on the voltmeter is above
– (-) lead to the battery (+) cable. the limit value, there is probably a malfunction
REQUIRED TOOL in the alternator output wire, so check the
wiring between the alternator "B" terminal and
FLUKE 115 MULTIMETER the battery (+) terminal (including fuse). If a ter-
(P/N 529 035 868) minal is not sufficiently tight or if the harness
has become discolored due to overheating,
Clamp-type ammeter Not illustrated repair and then test again.
9. After the test, run the engine at idle.
10. Turn off all lamps and the ignition switch.
11. Remove clamp-type ammeter and multimeter.

Alternator Output Current Test

This test determines whether the alternator out-
put current is normal.

rmr2014-014 3
Subsection 07 (ALTERNATOR)

NOTICE Before performing the current test 5. Immediately after setting the headlamps to
check the following: high beam, increase engine speed to 2500 rpm
– Alternator installation and read the maximum current output value
– Battery displayed on the ammeter.
– Fuse CURRENT OUTPUT
– Abnormal noise from alternator while en- SERVICE LIMIT minimum 20 A
gine is running.
NOTE: The battery should slightly be discharged. 6. The reading on the ammeter should be above
The load needed by a full-charged battery is insuf- the limit value. If the reading is below the limit
ficient for accurate test. To discharge the battery value and the alternator output wire is normal,
fast and in a controlled manner, start and quickly remove the alternator from the engine and re-
turn OFF the engine several times. If battery is place alternator.
fully charged, it may take multiple start sequences NOTICE
before discharge. – Because the current from the alternator will
1. Turn the ignition switch off. drop soon after the engine is started, the
2. Attach an clamp-type ammeter onto the alter- above step should be carried out as quickly
nator output wire. as possible in order to obtain the maximum
current output value.
3. Set multimeter to Vdc and connect it between
the alternator "B" terminal and the ground. – If the electrical load is small while testing,
the specified level of current may not be out-
Connect multimeter: put even tough the alternator is normal. In
– (+) lead to the alternator "B" terminal such cases, increase the electrical load by
– (-) lead to the ground. leaving the headlamps turned on for some
time to discharge the battery and then test
REQUIRED TOOL again.
FLUKE 115 MULTIMETER 7. Check if reading is higher than battery voltage:
(P/N 529 035 868)
7.1 Initial battery voltage should be 12 volts +/-
Clamp-type ammeter Not illustrated
0.5 volt.
7.2 Battery voltage, 5 seconds after engine
has reached idle should be greater than
initial voltage by at least 1.5 volts
NOTICE This reading should be higher than
the initial battery voltage measured between
step 7.1 and 7.2. If reading is not higher than
battery voltage the battery is not charging.
Check alternator connector and wiring har-
ness. If a terminal is not sufficiently tight or
if the harness has become discolored due to
overheating, repair and then test again.
8. Run the engine at idle after the test.
9. Turn ignition switch off.
rmr2014-014-022_a

1. Battery 10. Remove clamp-type ammeter and multimeter.

2. Load
3.
4.
Ammeter (clamp type)
Voltmeter (digital)
Alternator Access
5. Alternator Refer to BODY and remove the following parts:
6. B terminal
– Top side panel
4. Start the engine. – Rear side panel
– Middle side panel
– Accoustic panel.
Remove frame membrane.
4 rmr2014-014
 Subsection 07 (ALTERNATOR)

Alternator Removal
Disconnect BLACK negative cable from battery.

WARNING
Battery BLACK negative cable must always
be disconnected first and connected last.

Disconnect RED cable from alternator.

Disconnect alternator connector.
Remove:
– Lock nut (discard it)
– Screw.

rmr2014-014-004_a

1. Retaining screws
2. Alternator flange
3. Alternator

Withdraw alternator together with alternator

flange and alternator shaft.

rmr2014-009-011_a

1. Lock nut
2. Screw
3. Intake manifold support

Remove retaining screws of alternator support.

rmr2014-014-005_a

1. Alternator shaft
2. Alternator flange
3. Alternator

Remove alternator shaft and alternator flange

from alternator.

rmr2014-014-003_a

1. Retaining screws
2. Alternator support
3. Alternator

Remove screws retaining the alternator and alter-

nator flange.

rmr2014-014 5
Subsection 07 (ALTERNATOR)

ALTERNATOR SHAFT BORE

COPASLIP (P/N 420
Service product
297 430)

rmr2014-014-006_a

1. Alternator shaft
2. Alternator flange
3. Alternator

Alternator Inspection
Check if alternator O-ring is brittle, hard or dam- rmr2014-014-010_a
aged. Replace if necessary. FOR CLARITY ONLY THE SHAFT IS SHOWN
1. Splines
2. Backfill room behind splines
3. Alternator shaft

Apply specified grease on splines and O-ring of

alternator output shaft.
ALTERNATOR OUTPUT SHAFT SPLINE
AND O-RING
COPASLIP (P/N 420
Service product
297 430)

rmr2014-014-007_a

1. O-ring
2. Alternator

NOTE: The alternator does not require any main-

tenance and must not be opened for repair work.
Inspect the alternator housing and ball bearings
for damage or wear. In case of damage, the alter-
nator must be replaced.

Alternator Installation rmr2014-014-007_b

The installation is the reverse of removal proce- 1. Splines

dure. Pay attention to the following details. 2. Alternator output shaft
3. O-ring
Inspect grease filling inside alternator shaft bore.
Backfill the whole cavity behind the alternator Clean alternator flange mating surface to alterna-
shaft splines with 6 g (.2 oz) of specified grease. tor.

6 rmr2014-014
 Subsection 07 (ALTERNATOR)

rmr2014-014-009_a

1. Mating surface to alternator

2. Oil seal
3. Alternator flange F12R17A

ALTERNATOR FLANGE MATING SURFACE Do not apply in excess as it will spread out inside
CLEANING
cavity.
LOCTITE CHISEL NOTE: It is recommended to apply this specific
Service product (GASKET REMOVER) sealant as described here to get a uniform appli-
(P/N 413 708 500)
cation without lumps. If you do not use the roller
Using a brass brush in one direction then make method, you may use your finger to uniformly dis-
the final brushing perpendicularly (90°) to the first tribute the sealant (using a finger will not affect
pass. the adhesion).
Apply engine oil on oil seal sealing lip and install
NOTICE Do not wipe with rags. Use a new alternator shaft in alternator flange.
clean hand towel only.
Fit alternator flange with shaft on alternator.
Apply sealant on mating surface. Apply engine oil on:
ALTERNATOR FLANGE MATING SURFACE – plain bearing in gearbox housing
SEALANT – alternator shaft journal.
LOCTITE 5910 (P/N 293
Service product
800 081)

IMPORTANT: When beginning the application of

the sealant, the assembly and the first torquing
should be done within 10 minutes. It is suggested
to have all you need on hand to save time.
Use a plexiglass plate and apply some sealant
on it. Use a soft rubber roller 50 mm - 75 mm
(2 in - 3 in), available in arts products suppliers for
printing, and roll the sealant to get a thin uniform
coat on the plate (spread as necessary). When
ready, apply the sealant on bearing cover sur- rmr2014-014-012_b

faces. LUBRICATE
1. Plain bearing

rmr2014-014 7
Subsection 07 (ALTERNATOR)

rmr2014-014-015_a

LUBRICATE
1. Alternator shaft journal
rmr2014-014-003_a

Install alternator on engine and tighten retaining 1. Retaining screws

2. Alternator support
screws to specification. 3. Alternator
ALTERNATOR RETAINING SCREWS
Install a NEW lock nut and tighten to specification.
11 N•m ± 1 N•m
Tightening torque LOCK NUT
(97 lbf•in ± 9 lbf•in)
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

rmr2014-009-011_a

rmr2014-014-004_a 1. Lock nut

2. Screw
1. Retaining screws
3. Intake manifold support
2. Alternator flange
3. Alternator

Tighten alternator support retaining screws to ALTERNATOR SHAFT

specification. Alternator Shaft Removal
ALTERNATOR SUPPORT RETAINING SCREWS Remove alternator. Refer to ALTERNATOR in this
11 N•m ± 1 N•m subsection.
Tightening torque
(97 lbf•in ± 9 lbf•in) Use a soft hammer to push alternator shaft out of
alternator flange.

8 rmr2014-014
 Subsection 07 (ALTERNATOR)

Replace gearbox housing if measurement is out of

specification. Refer to GEARBOX subsection.

rmr2014-014-012_a

1. Plain bearing
2. Gearbox housing
A. Measure plain bearing inner diameter

ALTERNATOR SHAFT PLAIN BEARING

DIAMETER
SERVICE LIMIT 30.070 mm (1.1839 in)

Measure alternator shaft journal diameter.

rmr2014-014-011_a
Replace alternator shaft if out of specification.
1. Alternator shaft
2. Alternator flange
3. Soft hammer

Alternator Shaft Inspection

Check retaining ring if bent or otherwise dam-
aged. Replace if necessary.

rmr2014-014-013_a

1. Alternator shaft journal

2. Alternator shaft
A. Measure alternator shaft journal diameter

ALTERNATOR SHAFT JOURNAL DIAMETER

29.987 mm to 30.000 mm
NEW
(1.1806 in to 1.1811 in)
SERVICE LIMIT 29.977 mm (1.1802 in)

Alternator Shaft Clutch Slipping Moment

Check clutch slipping moment.
Hold alternator shaft.
rmr2014-014-008_a

1. Retaining ring
2. Alternator shaft

Measure alternator shaft plain bearing inner diam-

eter inside gearbox housing.

rmr2014-014 9
Subsection 07 (ALTERNATOR)

REQUIRED TOOL

GENERATOR SHAFT HOLDER

(P/N 529 036 298)

Check clutch slipping moment clockwise.

REQUIRED TOOL

ALTERNATOR SHAFT
ADAPTER (P/N 529 036 299)
rmr2014-014-010_a

FOR CLARITY ONLY THE SHAFT IS SHOWN

1. Splines
Torque wrench with actual torque viewer 2. Backfill room behind splines
3. Alternator shaft

Apply specified grease on splines and O-ring of

alternator output shaft.
ALTERNATOR OUTPUT SHAFT SPLINE
AND O-RING
COPASLIP (P/N 420
Service product
297 430)

rmr2014-014-014_a

1. Torque wrench
2. ALTERNATOR SHAFT ADAPTER (P/N 529 036 299)
3. Alternator shaft
4. GENERATOR SHAFT HOLDER (P/N 529 036 298)
5. Vice

Alternator shaft should start to turn at a torque

within the specified values.
CLUTCH SLIPPING MOMENT
11 N•m to 15 N•m
NEW
(97 lbf•in to 133 lbf•in)
SERVICE LIMIT 10 N•m (89 lbf•in)

If the torque is not within specification, replace al-

ternator shaft assembly. rmr2014-014-007_b

1. Splines
Alternator Shaft Installation 2. Alternator output shaft
3. O-ring
The installation is the reverse of removal proce-
dure. Pay attention to the following details. For alternator shaft installation refer to ALTERNA-
TOR INSTALLATION in this subsection.
Inspect grease filling inside alternator shaft bore.
Backfill the whole cavity behind the alternator
shaft splines with 6 g (.2 oz) of specified grease. ALTERNATOR FLANGE
ALTERNATOR SHAFT BORE Alternator Flange Removal
COPASLIP (P/N 420 Remove alternator. Refer to ALTERNATOR in this
Service product subsection.
297 430)

10 rmr2014-014
 Subsection 07 (ALTERNATOR)

Use a soft hammer to push alternator shaft out of

alternator flange.

rmr2014-014-017_a

1. Ball bearing
2. Alternator flange

Oil Seal and Ball Bearing Replacement

NOTE: Always replace oil seal and ball bearing at
the same time.
Heat alternator flange up to 100°C (212°F) before
removing the ball bearing and oil seal.
NOTICE Clean alternator flange from oil be-
fore heating.
Press out oil seal with ball bearing.
NOTE: Support alternator flange properly.
REQUIRED TOOL
rmr2014-014-011_a
Suitable tube, outer diameter 31 mm (1.22 in)
1. Alternator shaft
2. Alternator flange Press
3. Soft hammer

Alternator Flange Inspection

Check if alternator flange oil seal and/or O-ring are
brittle, hard or damaged. Replace if necessary.

rmr2014-014-018_a

1. Suitable tube, 31 mm (1.22 in)

2. Alternator flange
3. Ball bearing
4. Oil seal

rmr2014-014-016_a Press NEW oil seal in alternator flange.

1. O-ring
2. Oil seal NOTE: Oil seal must be installed with sealing lip
3. Alternator flange facing to the engine.
Check ball bearing for smooth operation, exces-
sive play and/or pitting. Replace if necessary.

rmr2014-014 11
Subsection 07 (ALTERNATOR)

REQUIRED TOOL OIL SEAL SEALING LIP

Service product Engine oil
OIL SEAL INSTALLER (P/N 529
036 297) For alternator flange installation refer to ALTER-
NATOR INSTALLATION in this subsection.

rmr2014-014-019_a

1. OIL SEAL INSTALLER (P/N 529 036 297)

2. Oil seal
3. Alternator flange

Press NEW ball bearing in alternator flange.

NOTICE Unless otherwise instructed, never
use a hammer to install ball bearings. Use a
press only.
REQUIRED TOOL
Suitable tube, outer diameter 41 mm (1.61 in)
Press

rmr2014-014-020_a

1. Suitable tube, 41 mm (1.61 in)

2. Ball bearing
3. Alternator flange

Alternator Flange Installation

The installation is the reverse of removal proce-
dure. Pay attention to the following details.
Lubricate sealing lip of oil seal before installation
of bearing flange.

12 rmr2014-014
 Subsection 08 (TIMING CHAIN)

TIMING CHAIN
SERVICE TOOLS
Description Part Number Page
CAMSHAFT LOCKING TOOL........................................................ 529 036 288 ............................................. 6
CAMSHAFT TURNING TOOL........................................................ 529 036 289 ............................................. 6

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 4
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ....................................... 7, 12

rmr2014-015 1
Subsection 08 (TIMING CHAIN)

Loctite 648

30 ± 3 N•m
(22 ± 2 lbf•ft)
Loctite 648

Engine oil

NEW
Loctite 243 11 ± 1 N•m
(97 ± 9 lbf•in)
NEW
20 ± 2 N•m Engine oil
(15 ± 1 lbf•ft)

Engine oil

Loctite 648
11 ± 1 N•m
(97 ± 9 lbf•in)

11 ± 1 N•m
(97 ± 9 lbf•in)

NEW = Component must be replaced when removed.

rmr2014-015-001_a

2 rmr2014-015
 Subsection 08 (TIMING CHAIN)

GENERAL PROCEDURES
Always disconnect BLACK (-) cable from the bat-
tery, then RED (+) cable before working on the en- TIMING CHAIN TENSIONER
gine. Timing Chain Tensioner Location
WARNING The timing chain tensioner is located in the cylin-
der head beside the exhaust port of the PTO cylin-
Always disconnect BLACK (-) cable first and der.
reconnect last.

When disassembling parts that are duplicated

in the engine, (e.g.: valves, springs, etc.), it is
strongly recommended to note their position
and to keep the parts of the same assembly as
a “group”. If you find a defective component,
it will be much easier to find the cause of the
failure. Since parts were broken-in together dur-
ing engine operation, they will maintain their
matched fit when reassembled together within
their “group”.

TROUBLESHOOTING
The following is provided to help in diagnosing the rmr2014-015-002_a

probable source of troubles. It is a guideline and 1. Screw plug location, timing chain tensioner
should not be assumed to provide solutions to ev-
ery cause of all problems. Timing Chain Tensioner Removal
1. Lock crankshaft, refer to CRANKSHAFT LOCK-
UNUSUAL ENGINE NOISE OR ING PROCEDURE in the CYLINDER BLOCK
VIBRATIONS subsection.
1. Faulty chain tensioner. 2. Remove plug screw and discard the gasket
- Replace chain tensioner. ring.
2. Chain guide(s) worn out. 3. Pull out spring and chain tensioner.
- Replace chain guide(s).
3. Stretched timing chain or worn sprockets.
- Replace timing chain and sprockets.
4. Camshaft timing gear screws loose.
- Retighten screws to recommended torque.
5. Incorrect camshaft timing adjustment.
- Replace damaged components and readjust
camshaft timing.

ENGINE LACKS ACCELERATION OR

POWER
1. Incorrect camshaft timing adjustment.
rmr2014-015-003_a
- Replace damaged components and readjust
camshaft timing. 1. Screw plug
2. Sealing washer
3. Spring
4. Chain tensioner

Timing Chain Tensioner Inspection

1. Check chain tensioner for scoring and freedom
of movement in bore.

rmr2014-015 3
Subsection 08 (TIMING CHAIN)

2. Compress chain tensioner and check for proper NOTE: When crankshaft is locked, the marks "IN"
operation. and "EX" on the camshaft timing gears must be
NOTE: The chain tensioner is difficult to com- aligned.
press when properly charged with oil, and easily
compressed when it is not.
3. Check spring for straightness, corrosion and
other visible damage.

Timing Chain Tensioner Installation

1. Apply engine oil on chain tensioner.
2. Insert chain tensioner in its bore with the
plunger pointing outwards.

rmr2014-017-022_a

1. Marks on camshaft timing gears aligned

3. Inspect timing chain for radial play while still in-

stalled on camshaft timing gears. See TIMING
CHAIN INSPECTION in this subsection.
4. Loosen camshaft timing gear screws.

rmr2014-015-004_a

TIMING CHAIN TENSIONER INSTALLATION

1. Plunger
2. Chain tensioner
3. Tensioner bore in cylinder head

3. Install spring on chain tensioner.

4. Install plug screw with a NEW gasket ring.
5. Tighten screw plug to specified torque.
PLUG SCREW
Gasket ring New
LOCTITE 243 (BLUE) rmr2014-017-022_b
Service product
(P/N 293 800 060) 1. Camshaft timing gear screws

20 N•m ± 2 N•m 5. Remove TIMING CHAIN TENSIONER, see pro-

Tightening torque
(15 lbf•ft ± 1 lbf•ft) cedure in this subsection.
6. Install all other removed parts. 6. Remove timing chain guide (intake side).

CAMSHAFT TIMING GEARS

Camshaft Timing Gear Removal
1. Remove VALVE COVER, refer to procedure in
CYLINDER HEAD subsection.
2. Lock crankshaft at TDC ignition, refer to the
CRANKSHAFT LOCKING PROCEDURE in the
in CYLINDER BLOCK subsection.

4 rmr2014-015
 Subsection 08 (TIMING CHAIN)

CHAIN GUIDE GROOVE DEPTH

SERVICE LIMIT 0.5 mm (.02 in)

rmr2014-015-010_a

1. Timing chain guide

Camshaft Timing Gear Installation

Installation is the reverse of the removal proce-
rmr2014-015-006_a
dure. However, pay attention to the following de-
1. Timing chain guide (intake side) tails.

7. Remove camshaft timing gear screws.
8. Remove camshaft timing gears and secure tim-
ing chain to the upper chain guide using a lock-
ing tie.
NOTICE Improper camshaft timing will dam-
age engine components.
1. Ensure that crankshaft is locked at TDC.
2. Check position of intake and exhaust
camshafts:
2.1 Intake cam lobe of cylinder no. "2" (center)
must show upwards.
2.2 Exhaust cam lobe of cylinder no. "3" (PTO
side) must show upwards.

rmr2014-015-007_a

1. Camshaft timing gear screws

2. Camshaft timing gears
3. Timing chain secured to camshaft holder

Camshaft Timing Gear Inspection

1. Check camshaft timing gears for wear or dete-
rmr2014-015-011_a
rioration. If a gear is worn or damaged, replace 1. Cam lobe of cylinder no. "2" (center)
camshaft timing gears and timing chain as a set. 2. Intake camshaft
3. Cam lobe of cylinder no. "3" (PTO side)
NOTE: For intermediate timing gear inspection, 4. Exhaust camshaft
refer to TIMING CHAIN in this subsection.
3. Turn both adjustment screws of the camshaft
2. Check timing chain guide for wear, cracks or locking tool counterclockwise to the stop to
deformation. Replace as required. bring the slide plates in top position.
3. Replace timing chain guide if any groove
caused by timing chain exceeds service limit.

rmr2014-015 5
Subsection 08 (TIMING CHAIN)

REQUIRED TOOL REQUIRED TOOL

CAMSHAFT LOCKING TOOL

(P/N 529 036 288) CAMSHAFT TURNING TOOL
(P/N 529 036 289)

rmr2014-015-014_a
rmr2014-015-012_a
1. Intake adjustment screw
1. Adjustment screws 2. Slide plate
2. Slide plates 3. Camshaft contact surface
3. Camshaft locking tool

4. Attach camshaft locking tool on camshaft

holder and tighten the 4 retaining screws to
specification.
CAMSHAFT LOCKING TOOL RETAINING
SCREWS
2.5 N•m ± 0.5 N•m
Tightening torque
(22 lbf•in ± 4 lbf•in)

rmr2014-015-015_a

1. Camshaft flange
2. Camshaft turning tool

6. Screw exhaust adjustment screw clockwise in

and proceed with the same adjustment proce-
dure as for the intake camshaft.

rmr2014-015-013_a

1. Camshaft locking tool properly installed

2. Retaining screws

5. Screw intake adjustment screw clockwise in to

align the slide plate with the camshaft contact
surface.
During the adjustment turn the camshaft back and
forth to achieve proper alignment of slide plate
with the camshaft contact surface.
rmr2014-015-016_a

NOTICE In final position the camshaft must 1. Exhaust adjustment screw

2. Slide plate
not move back and forth anymore 3. Camshaft contact surface

6 rmr2014-015
 Subsection 08 (TIMING CHAIN)

7. Install timing chain with camshaft timing gears.
10. Ensure marks on camshaft timing gears are
still aligned. If not, repeat procedure.
NOTICE After installation of timing chain ten-
sioner, the marks "IN" on intake and "EX" on ex-
haust camshafts must be aligned.

rmr2014-015-017_a

1. Timing chain
2. Camshaft timing gears

NOTICE Marks "IN" on intake and "EX" on ex-

haust camshafts must be aligned.

rmr2014-017-022_a

CAMSHAFT TIMING GEARS

1. Marks must be aligned

11. Install camshaft timing gear screws and

tighten as specified.
CAMSHAFT TIMING GEAR SCREWS
LOCTITE 648 (GREEN)
Service product
(P/N 413 711 400)
30 N•m ± 3 N•m
Tightening torque
(22 lbf•ft ± 2 lbf•ft)

rmr2014-017-022_a

CAMSHAFT TIMING GEARS

1. Marks must be aligned

8. Install timing chain guide.

rmr2014-015-019_a

1. Apply LOCTITE 648 (GREEN) (P/N 413 711 400) here

2. Timing gear screws

12. Ensure marks on camshaft timing gears are

still aligned. If not, repeat procedure.
rmr2014-015-018_a NOTICE After installation of timing chain ten-
1. Timing chain guide sioner, the marks "IN" on intake and "EX" on ex-
haust camshafts must be aligned.
9. Install TIMING CHAIN TENSIONER, see proce-
dure in this subsection.

rmr2014-015 7
Subsection 08 (TIMING CHAIN)

rmr2014-017-022_a rmr2014-017-022_c

CAMSHAFT TIMING GEARS 1. Radial play

1. Marks must be aligned
3. Remove the CAMSHAFT TIMING GEARS, see
13. Screw both adjustment screws of the procedure in this subsection.
camshaft locking tool counterclockwise to
the stop. 4. Remove:
– Valve train cover
14. Remove camshaft locking tool.
– Gasket (discard it).

rmr2014-015-021_a
rmr2014-015-025_a
1. Camshaft locking tool removal
1. Retaining screws
2. Valve train cover
15. Remove crankshaft locking tool. 3. Gasket (discard it)
16. Install remaining parts.
5. Remove:
– Screw retaining the intermediate timing gear
TIMING CHAIN shaft
Timing Chain Removal – Retaining screws of bearing bracket.
1. Remove valve cover, refer to CYLINDER HEAD
subsection.
2. Check timing chain for excessive radial play
while still installed on timing gears. Refer to
TIMING CHAIN INSPECTION in this subsec-
tion.

8 rmr2014-015
 Subsection 08 (TIMING CHAIN)

rmr2014-015-026_a rmr2014-015-029_a

1. Intermediate timing gear shaft screw 1. Timing chain

2. Retaining screws
3. Bearing bracket
NOTE: Make a mark on the timing chain to indi-
6. Withdraw: cate the operating direction of the chain before re-
moval.
– Bearing bracket
– Intermediate timing gear shaft. 9. Remove intermediate timing gear.
Move intermediate timing gear first upwards,
then tilt lower part out of the cylinder block.

rmr2014-015-027_a

1. Bearing bracket
2. Intermediate timing gear shaft
rmr2014-015-030_a

1. Intermediate timing gear

7. Remove chain guide (tensioner side).
Timing Chain Inspection
Check timing chain for wear and teeth condition.

mmr2009-114-015_a

1. Check teeth condition

NOTICE If timing chain is excessively

rmr2014-015-028_a
1. Chain guide (tensioner side)
8. Remove timing chain from intermediate timing
gear and take it out of the engine.
worn or damaged, replace timing chain and
camshaft timing gears as a set.
Intermediate Timing Gear Inspection
Check if gears are pitted, scored, rounded,
cracked, chipped or otherwise damaged.
Replace intermediate timing gear if necessary.

rmr2014-015 9
Subsection 08 (TIMING CHAIN)

rmr2014-015-031_a rmr2014-015-033_a

INTERMEDIATE TIMING GEAR INTERMEDIATE TIMING GEAR SHAFT

1. Crankshaft gear 1. Needle bearing running surface
2. Timing chain gear
3. Needle bearing Needle Bearing Replacement
Replace needle bearings and intermediate timing
gear shaft if necessary.
For needle bearing replacement use a suitable
punch and a press.
Position the needle bearings 0.5 mm (.02 in) be-
low the reference surface.

rmr2014-015-032_a

INTERMEDIATE TIMING GEAR

1. Needle bearing

Check needle bearing and intermediate timing

gear shaft for cracks, pitting, wear or other dam-
ages.
Check intermediate timing gear shaft needle bear-
ing running surface diameter.
INTERMEDIATE TIMING GEAR SHAFT - NEEDLE
BEARING RUNNING SURFACE
14.992 mm to 15.000 mm
NEW
(.5902 in to .5906 in)
SERVICE LIMIT 14.985 mm (.59 in) rmr2014-015-034_a

A. 0.5 mm (.02 in)

1. Needle bearings
2. Intermediate timing gear

Chain Guide Inspection (Tensioner Side)

Check chain guide for wear, cracks or deforming.
Replace as required.
Replace chain guide if groove depth caused by
timing chain exceeds service limit.
CHAIN GUIDE (TENSIONER SIDE)
GROOVE DEPTH
SERVICE LIMIT 0.5 mm (.02 in)

10 rmr2014-015
 Subsection 08 (TIMING CHAIN)

rmr2014-015-036_a

CORRECT ALIGNMENT
1. Small mark on intermediate timing gear
rmr2014-015-035_a 2. Tooth space
1. Chain guide 3. Intermediate timing gear
4. Mark on cylinder block

Timing Chain Installation

Installation is the reverse of the removal proce-
dure. However, pay attention to the following de-
tails.
NOTICE Improper camshaft timing will dam-
age engine components, strictly follow this
procedure.
1. Ensure that crankshaft is locked at TDC.
2. Place intermediate timing gear in timing chain
compartment.
3. Install timing chain through top of timing chain
rmr2014-015-037_a
compartment on intermediate timing gear.
WRONG ALIGNMENT
NOTE: If the same timing chain is reinstalled, be 1. Bore in on intermediate timing gear
2. Tooth
sure to reinstall it in the same operating direction 3. Intermediate timing gear
as marked during removal procedure. 4. Mark on cylinder block

4. Align mark on intermediate timing gear with 5. Install intermediate timing gear shaft.
mark on cylinder block.
NOTE: Flat spot of the intermediate timing gear
NOTICE To achieve proper valve timing use shaft must be parallel to upper rim of the gasket
the small mark on the intermediate timing gear surface.
for alignment. Do not use the bore for align-
ment.

rmr2014-015-038_a

1. Flat spot
2. Intermediate timing gear shaft
3. Upper rim of the gasket surface

rmr2014-015 11
Subsection 08 (TIMING CHAIN)

6. Install chain guide (tensioner side).

7. Align bearing bracket with intermediate timing
gear shaft and chain guide (tensioner side) and
install it.

rmr2014-015-041_a

VALVE TRAIN COVER TIGHTENING SEQUENCE

VALVE TRAIN COVER SCREWS

11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)
rmr2014-015-039_a

1. Intermediate timing gear shaft

2. Chain guide (tensioner side)
3. Bearing bracket
8. Tighten screws to specification.
10. Lock camshafts and install camshaft timing
gears as per CAMSHAFT TIMING GEAR IN-
STALLATION in this subsection.
11. Install all other removed parts.
NOTE: Be sure to remove camshaft and crank-
shaft locking tools when timing chain is com-
pletely installed.

rmr2014-015-040_a

1. Intermediate timing gear shaft screw

2. Retaining screws
3. Bearing bracket

BEARING BRACKET RETAINING SCREWS

11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

INTERMEDIATE TIMING GEAR SHAFT SCREW

LOCTITE 648 (GREEN)
Service product
(P/N 413 711 400)
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

9. Install valve train cover with NEW gasket.

Tighten screws to specification.

12 rmr2014-015
 Subsection 09 (CYLINDER HEAD)

CYLINDER HEAD
SERVICE TOOLS
Description Part Number Page
ENGINE LEAK DOWN TEST KIT ................................................... 529 035 661 ............................................. 5
VALVE SPRING COMPRESSOR CUP............................................ 529 036 209 ........................................... 16
VALVE SPRING COMPRESSOR .................................................... 529 035 724 ........................................... 16

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
SNAP-ON VALVE HOLDER............................................................ VL2 ........................................... 18
SNAP-ON VALVE STEM SEAL PLIERS ......................................... YA 8230 ........................................... 17

rmr2014-016 1
Subsection 09 (CYLINDER HEAD)

VALVE COVER

See tightening procedure

Loctite 243

See tightening See IGNITION SYSTEM

procedure

10 ± 1 N•m
(89 ± 9 lbf•in)
Loctite 243

Engine oil

NEW

14 ± 1 N•m
(124 ± 9 lbf•in)

See IGNITION SYSTEM NEW

Silicon heat compound Wacker P12

NEW = Component must be replaced when removed.

rmr2014-016-001_a

2 rmr2014-016
 Subsection 09 (CYLINDER HEAD)

CAMSHAFTS

See tightening procedure

NEW
Engine oil

NEW

Engine oil

Engine oil

See COOLING SYSTEM

Engine oil

Engine oil

NEW

NEW = Component must be replaced when removed.

rmr2014-016-002_a

rmr2014-016 3
Subsection 09 (CYLINDER HEAD)

CYLINDER HEAD

Engine oil

Engine oil
See ELECTRONIC FUEL See tightening procedure
NEW INJECTION (EFI)
NEW
Engine oil

Engine oil
NEW

NEW
11 ± 1 N•m
(97 ± 9 lbf•in) 11 ± 1 N•m
(97 ± 9 lbf•in)

Loctite 243

11 ± 1 N•m
(97 ± 9 lbf•in)

Engine oil

NEW

Engine oil

NEW = Component must be replaced when removed.

rmr2014-016-003_a

4 rmr2014-016
 Subsection 09 (CYLINDER HEAD)

GENERAL 3. Set gauge needle to zero.

NOTE: For a better understanding, some illustra- NOTE: All testers have specific instructions on
tions are taken with engine out of the vehicle. gauge operation and required pressure. Refer to
manufacturer's instructions.
When disassembling parts that are duplicated
in the engine, (e.g.: valves, springs, etc.), it is 4. Supply combustion chamber with air pressure.
strongly recommended to note their position
and to keep the parts of the same assembly as a
“group”. If you find a defective component, it will
be much easier to find the cause of the failure.
Since parts were broke-in together during engine
operation, they will maintain their matched fit
when reassembled together within their “group”.

INSPECTION
CYLINDER LEAK TEST
General
Before performing the cylinder leak test, verify the
following: rmr2014-016-201_a

– Clamp tightness TYPICAL

1. Gauge adaptor
– Hoses condition. 2. Leak tester
3. Air supply hose
NOTE: For best accuracy, the leak test should be
done with the engine at normal operating temper- 5. Note the amount or percentage of leakage (de-
ature. pending on tester).
LEAKAGE ENGINE
CAUTION Engine parts could be hot. PERCENTAGE CONDITION
NOTE: The following steps are the same for each
0% to 15% Excellent condition
cylinder.
16% to 25% Good condition
Preparation Fair condition; reduced
26% to 40%
1. Remove the VALVE COVER, see procedure in engine performance
this subsection.
Poor condition, diagnose
2. Remove spark plug. 41% and higher
and repair engine
3. Turn the engine counterclockwise to bring pis-
ton to TDC of compression stoke. Use a dial Diagnosis
gauge or a suitable tool to position the piston Listen for air leaks.
to TDC.
– Air escaping on intake port or throttle body
NOTE: The piston must be set precisely to TDC means leaking intake valve(s).
of compression stroke. If not, the engine will con- – Air escaping on exhaust port means leaking ex-
tinue to rotate when pressure builds up. haust valve(s).
Leak Test – Air bubbles out of coolant tank means leaking
cylinder head gasket.
1. Install a gauge adaptor into spark plug hole.
– Air or coolant escaping from cylinder head
REQUIRED TOOL means damaged gasket or loosened screws.
– Air escaping into crankcase area means exces-
ENGINE LEAK DOWN TEST sively worn cylinder or broken piston rings.
KIT (P/N 529 035 661) – Air or oil escaping from crankcase means dam-
aged gasket or loosened screws.
2. Connect the leak down tester to an adequate
air supply.

rmr2014-016 5
Subsection 09 (CYLINDER HEAD)
Repair Tips
Blue exhaust gas means damaged or worn piston
rings or valve stem seals.
White exhaust gas means damaged cylinder head
gasket.
Coolant tank cap opening without overheat means
damaged cylinder head gasket.
Leaking valves can be caused by carbon deposits
or burnt valve face.
Assembly
Reverse the preparation procedure.
TROUBLESHOOTING
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to DIAG-
NOSTIC AND FAULT CODES subsection.
NOTE: When diagnosing an engine problem, al-
ways perform the cylinder leak test. This will help
pinpoint a problem. Refer to CYLINDER LEAK
TEST in this subsection.
UNUSUAL ENGINE NOISE OR
VIBRATIONS
1. Discharged or defective valve lifters.
- Check engine oil pressure, refer to LUBRICATION
SYSTEM subsection.
- Check and replace hydraulic valve lifters, refer to
HYDRAULIC VALVE LIFTERS in this subsection.
2. Camshaft(s) or camshaft housing worn out.
- Check and replace damaged parts.
3. Faulty chain tensioner.
- Replace chain tensioner. Refer to TIMING CHAIN
subsection.
4. Chain guide(s) worn out.
- Replace chain guide(s). Refer to TIMING CHAIN
subsection.
5. Stretched timing chain or worn out sprockets.
- Replace timing chain and sprockets. Refer to
TIMING CHAIN subsection.
6. Loose timing chain gear screws.
- Retighten screws with recommended torque.
7. Incorrect camshaft timing.
- Replace damaged components and readjust
camshaft timing.
6 rmr2014-016
OIL LEAKAGE FROM CYLINDER HEAD
1. Leaking valve cover gasket.
- Replace valve cover gaskets and retighten valve
cover with recommended torque.
- Check valve cover for cracks or other damage.
2. Leaking spark plug tube gaskets.
- Replace spark plug tube gaskets.
- Clean spark plug area from oil spillage.
3. Blow-by connector is leaking.
- Replace blow by connector O-ring.
4. Leaking cylinder head gasket.
- Check cylinder head for damage.
- Replace cylinder head gasket and retighten
screws with recommended torquing procedure.
ENGINE SUDDENLY TURNS OFF OR
LACKS ACCELERATION OR POWER
1. Incorrect camshaft timing.
- Replace damaged components and readjust
camshaft timing.
2. Leaking intake or exhaust valves.
- Perform a CYLINDER LEAK TEST. Repair or re-
place damaged components.
3. Broken valve spring(s).
- Replace defective parts.
PROCEDURES
VALVE COVER
Valve Cover Access
Refer to to the appropriate section and remove
the following:
– Front storage compartment
– Console module
– Primary air intake silencer
– Secondary air intake silencer.
Valve Cover Removal
1. Unplug ignitions coils.
2. Remove ignition coils with gaskets.
NOTE: The ignition coil gasket may remain in the
valve cover.
 Subsection 09 (CYLINDER HEAD)

rmr2014-016-004_a rmr2014-016-005_a

1. Retaining screws 1. Valve cover screws

2. Ignition coils 2. Valve cover
3. Gaskets 3. Gasket

3. Disconnect vent tube from the blow-by-connec- 7. Remove valve cover small gaskets (spark plug
tor. tubes) and discard them.

rmr2014-016-202_a rmr2014-016-006_a

1. Clamp 1. Small gaskets

2. Vent tube
8. If necessary remove blow-by connector with
4. Remove valve cover screws. O-ring from valve cover.
5. Move valve cover to the clutch side.
6. Remove:
– Valve cover
– Gasket (discard it).

rmr2014-016 7
Subsection 09 (CYLINDER HEAD)

NOTICE Adhere to the following proce-

dure, otherwise damage to the V-ring will
occur causing crankcase venting malfunc-
tion.
4.1 Move the valve cover towards the clutch
side.

rmr2014-016-010_a

1. Retaining screws
2. Blow-by connector
3. O-ring
4. Valve cover

Valve Cover Inspection

Check the valve cover for cracks or other damage.
Check if the valve cover gaskets are brittle, hard rmr2014-016-008_a
or otherwise damaged. Step 1: Move valve cover towards clutch side
Check V-ring contact surface for wear or damage.
4.2 Put valve cover onto cylinder head.
Replace defective parts.
4.3 Push valve cover towards the PTO side to
Valve Cover Installation ensure that the V-ring properly seals on
sealing surface inside the cover.
For installation reverse the removal procedure.
However, pay attention to the following details.
1. Properly fit NEW small gaskets into the
camshaft housing grooves.
2. Properly fit NEW large gasket into the valve
cover groove.
3. Apply engine oil to the V-ring and its sealing sur-
face in the valve cover.

rmr2014-016-009_a

Step 1: Push valve cover towards PTO side

5. Install valve cover screws and tighten as per fol-

lowing procedure:

rmr2014-016-007_a

INSIDE VALVE COVER

1. Apply engine oil here

4. Install valve cover.

8 rmr2014-016
 Subsection 09 (CYLINDER HEAD)

VALVE COVER SCREWS TIGHTENING

PROCEDURE
5 N•m ± 0.6 N•m
STEP A
(44 lbf•in ± 5 lbf•in)

rmr2014-016-012_a

1. Camshaft housing retaining screws

3. Remove the camshaft housing upper half with

gaskets.

rmr2014-016-011_b

TIGHTENING SEQUENCE

VALVE COVER SCREWS TIGHTENING

PROCEDURE
10 N•m ± 1 N•m
STEP B
(89 lbf•in ± 9 lbf•in)

rmr2014-016-013_a

1. Upper half of camshaft housing

4. Remove camshafts.
Remove and discard V-ring

rmr2014-016-011_a

TIGHTENING SEQUENCE

CAMSHAFTS
Camshaft Removal
1. Remove VALVE COVER, see procedure in this
subsection.
Refer to TIMING CHAIN subsection and remove:
– Timing chain tensioner
– Timing chain gears. rmr2014-016-014_a

1. Intake camshaft
2. Remove camshaft housing retaining 2. Exhaust camshaft
screws (16). 3. V-ring (discard it)

rmr2014-016 9
Subsection 09 (CYLINDER HEAD)

5. Remove the camshaft housing lower half with CAMSHAFT JOURNAL DIAMETER
gaskets from cylinder head.
PTO JOURNAL
31.959 mm to 31.975 mm
NEW
(1.2582 in to 1.2589 in)
SERVICE LIMIT 31.950 mm (1.2579 in)
CENTER AND CLUTCH JOURNAL
22.967 mm to 22.980 mm
NEW
(.9042 in to .9047 in)
SERVICE LIMIT 22.960 mm (.9039 in)

CAMSHAFT LOBE HEIGHT

INTAKE CAMSHAFT
38.350 mm to 38.550 mm
NEW
rmr2014-016-015_a (1.5098 in to 1.5177 in)
1. Camshaft housing lower half
SERVICE LIMIT 38.300 mm (1.5079 in)
6. Remove gaskets from camshaft housing halves EXHAUST CAMSHAFT
and discard gaskets.
38.800 mm to 39.000 mm
7. If necessary remove water pump drive gear NEW
(1.5276 in to 1.5354 in)
from exhaust camshaft. Refer to COOLING
SYSTEM subsection. SERVICE LIMIT 38.750 mm (1.5256 in)

Camshaft Inspection Replace parts if necessary.

1. Check each lobe and bearing journal for scoring,
scuffing, cracks, or other signs of wear.
2. Measure camshaft bearing journal diameter
and lobe height, using a micrometer.
Camshaft Housing Inspection
Check camshaft housing for scoring, scuffing,
cracks, or other signs of wear.
Make sure oil channels of camshaft housing lower
part are not clogged. Blow them out with pressur-
ized air.

rmr2014-016-016_a

A. Camshaft journal (PTO side)

B. Camshaft journal (center and clutch side)
C. Camshaft lobes rmr2014-016-017_a

1. Camshaft housing lower half - view from beneath

2. Camshaft housing lower half - view from above
3. Oil orifices

Replace parts if necessary.

10 rmr2014-016
 Subsection 09 (CYLINDER HEAD)

Camshaft Journal Radial Clearance

Measure clearance between camshaft journals
and camshaft housing, using the plastic feeler
gauge.
NOTE: The plastic feeler gauge is available at au-
tomotive parts retailer.
Install camshaft housing lower half on cylinder
head.
Place the camshafts in the camshaft housing
lower half and apply a plastic-gauge on the
camshaft bearing journal.

vmr2008-016-066_b

TYPICAL
1. Pressed plastic gauge
2. Graduated scale

CAMSHAFT JOURNAL RADIAL CLEARANCE

PTO SIDE BEARING
0.025 mm to 0.066 mm
NEW
(.001 in to .0026 in)
SERVICE LIMIT 0.075 mm (.003 in)
CENTER AND CLUTCH SIDE BEARING
0.020 mm to 0.054 mm
NEW
(.001 in to .002 in)
vmr2008-016-066_a

TYPICAL SERVICE LIMIT 0.065 mm (.0026 in)

1. Plastic gauge
2. Camshaft journal
Install camshaft housing upper half in the proper
position and tighten screws to specification, refer
to CAMSHAFT INSTALLATION in this subsection.
Unfasten camshaft housing.
Measure the maximum width of the pressed plas-
tic gauge with the corresponding graduated scale.
Replace parts if necessary.
Camshaft Installation
The assembly is the reverse of the removal proce-
dure. However pay attention to the following de-
tails.
1. Install camshaft housing lower half.
2. Before assembly of the camshafts apply engine
oil on camshaft bearings.

rmr2014-016 11
Subsection 09 (CYLINDER HEAD)

rmr2014-016-020_a

CAMSHAFT HOUSING TIGHTENING SEQUENCE

rmr2014-016-019_a

1. Areas where to apply engine oil NOTE: After the reassembly of the camshafts is
3. Apply engine oil on camshaft journal diameter. completed, check if camshafts can be turned eas-
ily.
4. Place camshafts in lower camshaft housing:
For proper camshaft timing refer to TIMING
– Intake: Cams of cylinder no. 2 (center) must CHAIN subsection.
face upwards
– Exhaust: Cams of cylinder no. 3 (PTO) must Install all other removed parts.
face upwards.
. HYDRAULIC VALVE LIFTERS
Hydraulic Valve Lifter Functional Test
NOTE: If engine noise seems to come from the
valve lifter with engine at normal operating tem-
perature perform following test.
1. Start and run engine until it reaches normal op-
erating temperature.
2. Rev engine 2 minutes up to 2500 rpm.
3. Check if engine noise is still detected and stop
engine.
4. If engine is still noisy follow the next steps.
5. Remove valve cover, refer to VALVE COVER in
this subsection.
rmr2014-016-023_a
6. Remove spark plugs of all cylinders, refer to IG-
1. Intake camshaft
2. Cams of cylinder no. 2 (center) NITION SYSTEM subsection.
3. Exhaust camshaft
4. Cams of cylinder no. 3 (PTO) 7. Turn crankshaft until cylinder no. 1 is in TDC
ignition.
5. Install the camshaft housing upper half, then
tighten screws as per following sequence: NOTICE In TDC ignition position the both
cams of the cylinder show upwards.
NOTE: Always perform step A on all camshaft
housing screws before going to step B. 8. Press all 4 lifters of cylinder no. 1 with a suit-
able aluminium bolt.
CAMSHAFT HOUSING TIGHTENING TORQUE
NOTE: Do not scratch or damage valve liter sur-
5 N•m ± 0.5 N•m face or cams.
STEP A
(44 lbf•in ± 4 lbf•in)
11 N•m ± 1 N•m NOTICE If a hydraulic valve lifter can be com-
STEP B pressed by hand it must be replaced.
(97 lbf•in ± 9 lbf•in)

12 rmr2014-016
 Subsection 09 (CYLINDER HEAD)

2. Measure valve lifter diameter. Replace if out of

specification.
HYDRAULIC VALVE LIFTER
28.354 mm to 28.370 mm
NEW
(1.1163 in to 1.1169 in)
SERVICE LIMIT 28.340 mm (1.1157 in)
HYDRAULIC VALVE LIFTER RADIAL CLEARANCE
SERVICE LIMIT 0.100 mm (.0039 in)

Hydraulic Valve Lifter Installation

For installation reverse the removal procedure.
rmr2014-016-025_a
However pay attention to the following details.
PRESS IN
1. Valve lifter Apply engine oil on the outside diameter of the
2. Aluminium bolt
hydraulic valve lifter.
9. Repeat procedure for cylinder no. 2 and no. 3.

Hydraulic Valve Lifter Removal

NOTE: Hydraulic valve lifter are maintenance
free.
1. Remove valve cover, see procedure in this sub-
section.
2. Remove timing chain gears, refer to TIMING
CHAIN subsection.
3. Remove camshafts and camshaft housing, see
procedure in this subsection.
4. Pull hydraulic valve lifter off the cylinder head.
NOTE: When disassembling the hydraulic valve
lifter, it is strongly recommended to note their rmr2014-016-026_b

original position. 1. Apply engine oil on outer diameter

For proper camshaft timing refer to TIMING

CHAIN subsection.
Install all other removed parts.

CYLINDER HEAD
Cylinder Head Removal
1. Remove engine from the vehicle. Refer to EN-
GINE REMOVAL AND INSTALLATION subsec-
tion.
2. Remove intake manifold. Refer to AIR INTAKE
SYSTEM subsection.
3. Remove valve cover. See procedure in this sub-
rmr2014-016-026_a section.
1. Hydraulic valve lifter 4. Remove chain tensioner. Refer to TIMING
CHAIN REMOVAL subsection.
Hydraulic Valve Lifter Inspection
5. Remove the camshaft timing gears. Refer to
1. Check surface of hydraulic valve lifter for scor- TIMING CHAIN subsection.
ing or other damage.

rmr2014-016 13
Subsection 09 (CYLINDER HEAD)

6. Remove camshafts and camshaft housing. See

procedure in this subsection.
7. Remove hydraulic valve lifters. See procedure
in this subsection.
8. Remove M6 cylinder head screws.

rmr2014-016-029_a

UPPER SIDE
1. Oil orifices

rmr2014-016-027_a

1. Remove M6 cylinder head screws

9. Remove and discard M10 cylinder head

screws.

rmr2014-016-024_a

BOTTOM SIDE
1. Oil orifices
2. Timing chain tensioner bore

Cylinder Head Inspection

rmr2014-016-028_a Check for cracks between valve seats or other
1. Remove M10 cylinder head screws damage, if so, replace cylinder head.
10. Pull cylinder head off the cylinder block. Check cylinder head mating surface for flatness
using a straight edge.
11. Remove and discard cylinder head gasket.
Check hydraulic valve lifter bores for scoring or
Cylinder Head Cleaning other damage, if so, replace cylinder head.
1. Remove carbon deposits from combustion
chambers, exhaust ports and piston tops.
2. Clean cylinder head, especially cylinder head
screw surface from oil spillage.
3. Blow out the oil orifices with pressurized air and
make sure they are not clogged.

14 rmr2014-016
 Subsection 09 (CYLINDER HEAD)

CYLINDER HEAD M10 SCREWS TIGHTENING

PROCEDURE
30 N•m ± 2 N•m
STEP A
(22 lbf•ft ± 1 lbf•ft)
STEP B Additional 90° ± 5°
STEP C Additional 90° ± 5°

rmr2014-016-030_a

1. Cylinder head
2. Straight edge
3. Feeler gauge

Check cylinder head warpage.

CYLINDER HEAD WARPAGE rmr2014-016-028_b

M10 SCREWS TIGHTENING SEQUENCE

NEW MAXIMUM 0.03 mm (.0012 in)
SERVICE LIMIT 0.05 mm (.002 in) NOTE: Use a torque angle gauge to carry out the
step B and step C.
If warpage exceeds specification, resurface the
cylinder head as follows.
Use a 400 - 600 grit wet sandpaper on a surface
plate and gently grind off the mating surface.
NOTE: To ensure an even surface, rotate cylinder
head several times during resurfacing.
Replace cylinder head, if resurfacing fails.

Cylinder Head Installation

For installation, reverse the removal procedure.
However, pay attention to the following details.
1. Install a NEW cylinder head gasket. rmr2014-016-031_a

1. Torque angle gauge

NOTICE Each installation of the cylinder
head requires a NEW cylinder head gasket. 5. Install M6 screws. Tighten as follows.
Using a gasket twice would cause engine M6 CYLINDER HEAD SCREWS
damage.
11 N•m ± 1 N•m
Tightening torque
2. Install cylinder head on the cylinder block. (97 lbf•in ± 9 lbf•in)
3. Install NEW M10 cylinder head screws.
NOTICE This assembly uses stretch screws.
Always use NEW screws and strictly adhere to
the tightening procedure.
4. Tighten cylinder head screws as follows:
NOTE: Always perform one step on all M10 cylin-
der head screws before going to the next step.

rmr2014-016 15
Subsection 09 (CYLINDER HEAD)

rmr2014-016-027_b rmr2014-016-033_a

M6 SCREWS TIGHTENING SEQUENCE 1. Valve cotters

2. Valve spring retainer
3. Valve spring
VALVE SPRINGS
NOTE: Identify the position of each part very care-
Valve Spring Removal fully, so it can be reinstalled in its original place.
1. Remove CYLINDER HEAD, see procedure in
this subsection. Valve Spring Inspection
2. Compress valve spring. 1. Check valve spring for rust, corrosion or other
visible damage.
REQUIRED TOOLS
2. Check valve spring free length and straight-
VALVE SPRING COMPRESSOR ness.
(P/N 529 035 724)

VALVE SPRING COMPRESSOR

CUP (P/N 529 036 209)

R400motr80A A
A. Spring free length

VALVE SPRING FREE LENGTH

rmr2014-016-032_a
1. Valve spring compressor clamp
2. Valve spring compressor cup
3. Remove valve cotters.
4. Withdraw valve spring compressor tools.
5. Remove valve spring retainer and valve spring.
16
NEW 31.35 mm (1.2343 in)
SERVICE LIMIT 29.50 mm (1.1614 in)
Replace valve spring, if out of specification.
Valve Spring Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTE: Ensure to reinstall all parts in their original
position as marked during removal.
1. Apply some grease on valve cotters, so that
they remain in place while releasing the valve
spring.
rmr2014-016
 Subsection 09 (CYLINDER HEAD)

2. Make sure valve cotters are properly engaged 3. Remove and discard valve stem seal with spe-
into valve stem groove. cial pliers.
REQUIRED TOOL
SNAP-ON VALVE STEM SEAL
PLIERS (P/N YA 8230)

rmr2014-016-034_a

1. Valve cotters

3. After spring is installed, ensure it is properly

locked by lightly tapping on valve stem end with
rmr2014-016-036_a
a soft hammer so that valve opens and closes
1. Valve stem seal
a few times.
NOTICE Improperly locked valve spring will Valve Inspection
cause severe engine damage and hitting the Inspect valve surface, check for abnormal stem
valve stem end with excessive force could wear and bending.
damage the valve.

VALVES
Valve Removal
NOTE: Identify the position of each part very care-
fully, so it can be reinstalled in its original place.
1. Remove VALVE SPRING, see procedure in this
subsection.
2. Push on the valve stem, then pull valves out of
cylinder head.

mmr2009-115-072_a

VALVE OUT OF ROUND

INTAKE AND EXHAUST VALVE
NEW 0.005 mm (.0002 in)
SERVICE LIMIT 0.010 mm (.0004 in)

Replace valve if out of specification.

Valve Stem and Valve Guide Clearance
1. Measure valve stem at three places, using a mi-
crometer.

rmr2014-016-035_a

1. Intake valves 32 mm (1.26 in)

2. Exhaust valves 28.5 mm (1.12 in)

rmr2014-016 17
Subsection 09 (CYLINDER HEAD)

VALVE GUIDE INNER DIAMETER

5.000 mm to 5.012 mm
NEW
(.1969 in to .1973 in)
SERVICE LIMIT 5.050 mm (.1988 in)

Replace cylinder head, if valve guide is out of

specification.
A Valve Face and Seat

2 3

R400motr83A

A. Valves stem diameter

VALVE STEM DIAMETER

INTAKE VALVE
4.966 mm to 4.980 mm
NEW
(.1955 in to .1961 in)
SERVICE LIMIT 4.940 mm (.1945 in)
EXHAUST VALVE
4.956 mm to 4.970 mm
NEW
(.1951 in to .1957 in)
SERVICE LIMIT 4.940 mm (.1945 in) R1503motr107A 1
TYPICAL
Replace valve if stem is out of specification or if 1. Valve seat
2. Exhaust valve contaminated area
its surface is damaged or worn. 3. Valve face (contact surface to valve seat)
2. Measure valve guide inner diameter, using a
small bore gauge. 1. Check valve face and seat for burning, pitting
and other signs of damage.
NOTE: Clean valve guide from carbon deposits
before measuring. 2. Check if valve seats properly in cylinder head.
Proceed as follows.
2.1 Apply some lapping compound on valve
face and work valve on its seat with a lap-
ping tool.
REQUIRED TOOL
SNAP-ON VALVE HOLDER (P/N VL2)

NOTE: The location of contact area should

be in center of valve face.
2.2 Repeat procedure until valve seat and
valve face fit together.
3. Measure valve seat contact width, using a
caliper.
rmr2014-016-037_a

1. Valve guide, intake side

2. Valve guide, exhaust side
A. Valve guide inner diameter

18 rmr2014-016
 Subsection 09 (CYLINDER HEAD)

A B

rmr2014-016-038_a

1. Sealing lips of valve stem seal

V01C1HA

A. Valve face contact width 3. Install VALVE SPRING. See procedure in this
B. Valve seat contact width subsection.
VALVE SEAT CONTACT WIDTH 4. Install all other removed parts.
INTAKE VALVE
1.05 mm to 1.35 mm
NEW
(.041 in to .053 in)
SERVICE LIMIT 1.70 mm (.067 in)
EXHAUST VALVE
1.30 mm to 1.50 mm
NEW
(.051 in to .059 in)
SERVICE LIMIT 1.80 mm (.071 in)

Replace cylinder head if out of specification.

Valve Installation
For installation reverse the removal procedure.
Pay attention to the following details.
NOTE: Ensure to reinstall all parts in their original
position as marked during removal.
1. Install a NEW valve stem seal whenever valve
is removed.
2. Apply engine oil on valve stem and carefully
slide through cylinder head and valve stem seal.
NOTICE Be careful when passing the valve
stem through the sealing lip of the seal.

rmr2014-016 19
 Subsection 10 (CYLINDER BLOCK)

CYLINDER BLOCK
SERVICE TOOLS
Description Part Number Page
CRANKSHAFT LOCKING BOLT..................................................... 529 036 285 ..................................... 11, 14
HEXAGON SOCKET WRENCH ..................................................... 529 036 287 ..................................... 11, 14
PISTON CIRCLIP INSTALLER........................................................ 529 036 295 ........................................... 20

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
SNAP-ON PISTON RING COMPRESSOR TOOL .......................... rc-980 ........................................... 21

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 5910 ............................................................................... 293 800 081 ............................................. 9
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ............................................. 7

rmr2014-017 1
Subsection 10 (CYLINDER BLOCK)

28 ± 2 N•m
(21 ± 1 lbf•ft) Loctite 648

11 ± 1 N•m
(97 ± 9 lbf•in)
NEW
19 ± 1 N•m
(168 ± 9 lbf•in)

Loctite 243

Loctite 243
12 ± 1 N•m
(106 ± 9 lbf•in)

19 ± 1 N•m
20 ± 2 N•m (168 ± 9 lbf•in)
(15 ± 1 lbf•ft) Loctite 648
28 ± 2 N•m
(21 ± 1 lbf•ft) Loctite 243
Engine oil
Loctite 243
Engine oil
Engine oil

Engine oil
Engine oil
11 ± 1 N•m
(97 ± 9 lbf•in)

Engine oil
Loctite 5910

11 ± 1 N•m
(97 ± 9 lbf•in)

24 ± 2 N•m
(18 ± 1 lbf•ft)
See tightening procedure

NEW = Component must be replaced when removed.

rmr2014-017-001_a

2 rmr2014-017
 Subsection 10 (CYLINDER BLOCK)

NEW

NEW

Engine oil

Engine oil Engine oil

Engine oil
See tightening procedure

Engine oil

Engine oil

Engine oil
Engine oil

Loctite 243

11 ± 1 N•m
Engine oil (97 ± 9 lbf•in)

NEW = Component must be replaced when removed.

rmr2014-017-002_a

rmr2014-017 3
Subsection 10 (CYLINDER BLOCK)
GENERAL
When disassembling parts that are duplicated in
the engine, (e.g.: pistons, connecting rods etc.),
it is strongly recommended to note their position
(cylinder 1, 2 or 3) and to keep them as a “group”.
If you find a defective component, it would be
much easier to find the cause of the failure within
the group of parts. Besides, since used parts
have matched together during the engine oper-
ation, they will keep their matched fit when you
reassemble them together within their “group”.
Even though many parts do not need to be re-
moved to reach other parts, it is recommended
to remove these parts anyway in order to check
them.
During assembly/installation, use torque values
and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, cotter pins, etc.) must be replaced.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory stan-
dards.
TROUBLESHOOTING
The following is provided to help in diagnosing the
probable source of troubles. It is a guideline and
should not be assumed to show all causes for all
problems.
Always check for fault codes. If a fault code is de-
tected, service the fault code first. Refer to MON-
ITORING SYSTEM AND FAULT CODES subsec-
tion.
UNUSUAL ENGINE NOISE OR
VIBRATIONS
1. Heavy wear on plain bearings.
- Check radial play of plain bearings. Replace if out
of specification.
2. Crankshaft and balancer shaft are not properly
aligned.
- Disassemble cylinder block and check if marks
are properly aligned.
4 rmr2014-017
3. Crankshaft axial play out of specification.
- Measure crankshaft axial play. If crankshaft axial
play is out of specification, replace ring halves.
4. Balancer shaft axial play out of specification.
- Measure balancer shaft axial play. If balancer
shaft axial play is out of specification, replace
balancer shaft or cylinder block.
5. Connecting rod axial play out of specification.
- Measure connecting rod axial play on crankshaft.
Replace connecting rod or crankshaft if out of
specification.
6. Connecting rod screws got loose.
- Replace damaged components and retighten
screws with the recommended torque.
BLUE SMOKE IN THE EXHAUST
1. Oil scrapper rings worn out.
- Replace piston rings.
ENGINE SUDDENLY TURNS OFF (POOR
IDLING)
1. Piston rings worn out.
- Replace piston rings.
2. Piston/cylinder clearance out of specification.
- Check piston/cylinder clearance. Replace if out of
specification.
3. Melted or broken piston.
- Check if oil spray nozzle is not clogged. Refer to
LUBRICATION SYSTEM subsection. Replace pis-
ton and cylinder block if necessary.
PROCEDURES
CYLINDER BLOCK
Cylinder Block Disassembly
1. Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION subsection.
2. Drain engine oil. Refer to LUBRICATION SYS-
TEM subsection.
3. Lock crankshaft, refer to CRANKSHAFT LOCK-
ING PROCEDURE in this subsection.
4. Remove valve cover, refer to CYLINDER HEAD
in this subsection.
5. Remove air intake manifold together with
wiring harness. Refer to AIR INTAKE SYSTEM
subsection.
6. Refer to TIMING CHAIN subsection to remove
the following parts:
– Camshaft timing gears
 Subsection 10 (CYLINDER BLOCK)

– Timing chain
– Timing chain guides
– Intermediate timing gear.
7. Remove cylinder head. Refer to CYLINDER
HEAD subsection.
8. Remove alternator, refer to ALTERNATOR sub-
section.
9. Refer to ELECTRIC STARTER AND STARTER
DRIVE subsection to remove the following
parts:
– Valve train cover
– Starter drive gears
– Sprag clutch gear rmr2014-017-004_a

1. Screws M6 x 35 (qty 11)

– Sprag clutch 2. Screws M8 x 70 (qty 2)
– Electric starter. 3. Screws M8 x 40 (qty 2)
4. Screws M9 x 113 (qty 8)
10. Refer to LUBRICATION SYSTEM subsection
to remove the following parts: 16. Carefully remove cylinder block lower half by
– Oil tank cover using a soft hammer.
– Oil cooler NOTE: Ensure not to damage the sealing surface
– Venting tubes. of the cylinder block halves.
– Oil duct cover
– Oil pump drive gears
– Engine oil pressure regulator and oil pres-
sure pump
– Oil scavenge pump module (PTO side)
11. Remove clutch cover, refer to CLUTCH (SE6)
or CLUTCH (SM6).
12. Remove gearbox housing assembly. Refer to
GEARBOX subsection.
13. Remove oil sump cover and oil strainers. Re-
fer to LUBRICATION SYSTEM subsection.
14. Remove crankshaft locking tool.
NOTE: Before splitting the cylinder block, mea- rmr2014-017-005
sure crankshaft and balancer shaft axial play. Re-
fer to CRANKSHAFT and BALANCER SHAFT in 17. See procedures in this subsection to remove:
this subsection. – Balancer shaft
15. Remove cylinder block screws: – Crankshaft
15.1 Start removing the M6 screws. – Crankshaft ring halves
15.2 Then remove the M8 screws. – Pistons and connecting rods.
15.3 Finally remove and discard the M9 If necessary remove:
screws. – Knock sensor, refer to ELECTRONIC FUEL IN-
JECTION (EFI) subsection
– Oil nozzles, refer to LUBRICATION SYSTEM
subsection.

rmr2014-017 5
Subsection 10 (CYLINDER BLOCK)

Plain Bearing Removal

NOTE: If the engine has to be dismantled within
the scope of repair work, take this opportunity to
clean the oil nozzles. Refer to LUBRICATION SYS-
TEM subsection.
When the plain bearings need to be removed from
the cylinder block, mark them to identify the cor-
rect position at installation. See the following il-
lustration for an example.

rmr2014-017-008_a

CYLINDER BLOCK UPPER HALF

1. Check oil passages

rmr2014-017-006_a

1. Mark on balancer shaft plain bearings

2. Mark on crankshaft plain bearings

Cylinder Block Cleaning

Clean cylinder block using a part cleaner, then use
compressed air to dry it.
rmr2014-017-009_a
Blow out oil orifices and oil bores and check if they CYLINDER BLOCK UPPER HALF
are not clogged. 1. Check oil orifices

rmr2014-017-007_a rmr2014-017-010_a

CYLINDER BLOCK UPPER HALF CYLINDER BLOCK UPPER HALF

1. Check oil orifices 1. Check oil orifice
2. Oil bores of oil nozzles

6 rmr2014-017
 Subsection 10 (CYLINDER BLOCK)

rmr2014-017-011_a rmr2014-017-014_a

CYLINDER BLOCK UPPER HALF CYLINDER BLOCK LOWER HALF

1. Check oil orifice 1. Check oil orifices

rmr2014-017-012_a rmr2014-017-015_a

CYLINDER BLOCK LOWER HALF CYLINDER BLOCK LOWER HALF

1. Check oil passages 1. Check oil passages

Clean all metal components in a solvent.

Clean cylinder block mating surfaces with LOCTITE
CHISEL (GASKET REMOVER) (P/N 413 708 500) and
a brass brush. Brush a first pass in one direction
then make the final brushing perpendicularly (90°)
to the first pass (cross hatch).
NOTE: Do not wipe with rags. Use a new clean
hand towel only.

Cylinder Block Inspection

Check cylinder block for cracks or other damages.
Check cylinder block mating surfaces for flatness
using a straight edge.
rmr2014-017-013_a
Replace cylinder block if necessary.
CYLINDER BLOCK LOWER HALF
1. Check oil passages Check cylinder bore for cracks, scoring and wear
ridges on the top and bottom of the cylinder.
Cylinder Taper
Measure cylinder bore diameter at 3 recom-
mended positions. See the following illustration.
rmr2014-017 7
Subsection 10 (CYLINDER BLOCK)

CYLINDER OUT OF ROUND

NEW MAXIMUM 0.008 mm (.0003 in)
SERVICE LIMIT 0.020 mm (.0008 in)

Plain Bearings
Check the plain bearings for scoring or other dam-
ages.
Measure plain bearing inside diameter and com-
pare with crankshaft and balancer shaft bearing
journal diameter (refer to CRANKSHAFT and BAL-
ANCER SHAFT in this subsection). Proceed as fol-
lows.
rmr2014-017-016_a
– Use the OLD plain bearings and put together
TYPICAL both cylinder block halves.
1. First measuring diameter
2. Second measuring diameter – Perform the torquing procedure as described in
3. Third measuring diameter
A. 10 mm (.394 in)
CYLINDER BLOCK ASSEMBLY.
B. 65 mm (2.559 in) – Measure the inside diameter of the crankshaft
C. 120 mm (4.724 in)
and balancer shaft plain bearings, using a bore
The difference between measurements should gauge.
not exceed the service limit mentioned in next
table.
CYLINDER TAPER
NEW MAXIMUM 0.036 mm (.0014 in)
SERVICE LIMIT 0.050 mm (.002 in)

Cylinder Out of Round

Measure cylinder bore diameter in piston axis di-
rection from top of cylinder. Take another mea-
surement 90° from first one and compare.
NOTE: Take the same measuring points as de-
scribed in CYLINDER TAPER.
rmr2014-017-017_a

1. Bore gauge
2. Crankshaft plain bearing

CRANKSHAFT PLAIN BEARING INSIDE

DIAMETER
SERVICE LIMIT 50.085 mm (1.9719 in)

mmr2009-116-052_a

TYPICAL
A. Perpendicular to piston axis
B. Parallel to piston axis

8 rmr2014-017
 Subsection 10 (CYLINDER BLOCK)

2. Install pistons, refer to PISTONS AND CON-

NECTING RODS in this subsection.
3. Apply engine oil on all plain bearings.
4. Install the following components:
– Oil nozzles (refer to LUBRICATION SYSTEM
subsection)
– Crankshaft and ring halves (refer to CRANK-
SHAFT)
– Connecting rod caps (refer to PISTONS AND
CONNECTING RODS)
– Balancer shaft (refer to BALANCER SHAFT).
5. Apply sealant on mating surface of cylinder
rmr2014-017-018_a block lower half as shown on next illustration.
1. Bore gauge
2. Balancer shaft plain bearing CYLINDER BLOCK SEALANT

BALANCER SHAFT PLAIN BEARING LOCTITE 5910 (P/N 293

Service product
INSIDE DIAMETER 800 081)

SERVICE LIMIT 36.080 mm (1.4205 in) IMPORTANT: When beginning the application of
the cylinder block sealant, the assembly and the
Replace bearings if they are out of specifications. first torquing should be done within 10 minutes.
Oil Spray Nozzles It is suggested to have all you need on hand to
save time.
Clean the oil spray nozzles. Refer to LUBRICA-
TION SYSTEM subsection.
Cylinder Block Assembly
For assembly, reverse the disassembly proce-
dure. Pay attention to the following details.
1. Correctly reinstall plain bearings as follows.
1.1 Use NEW bearings if diameters are out of
specification. Refer to PLAIN BEARING
INSPECTION in this subsection.
1.2 Bearings must to be flush with the cylinder
block split surface and their protrusions
have to fit in the notched areas in the
cylinder block seat.
rmr2014-017-020_a

1. Apply Loctite 5910 here

NOTICE Ensure not to apply too much

sealant, as it will spread out inside cylinder
block.
6. Attach cylinder block lower half onto cylinder
block upper half.
7. Install NEW M9 cylinder block screws and
tighten as per following procedure.
NOTE: Always perform step A on all M9 cylinder
block screws before going to step B.
Use a torque angle gauge to carry out step B.
rmr2014-017-019_a

1. Bearing protrusion in cylinder block notch

rmr2014-017 9
Subsection 10 (CYLINDER BLOCK)

CYLINDER BLOCK M9 SCREWS TIGHTENING

PROCEDURE
30 N•m ± 3 N•m
STEP A
(22 lbf•ft ± 2 lbf•ft)
STEP B Additional 120° ± 5°

rmr2014-017-004_d

M6 SCREWS TIGHTENING SEQUENCE

NOTE: Before continuing the assembly process,

the free movement and axial clearance of balancer
shaft and crankshaft has to be checked. Refer to
CRANKSHAFT and BALANCER SHAFT in this sub-
section for the procedure.
rmr2014-017-004_b
10. Reassemble engine in accordance with the
M9 SCREWS TIGHTENING SEQUENCE
proper assembly procedures.
8. Install M8 cylinder block screws and tighten as
per following the sequence. CRANKSHAFT
M8 CYLINDER BLOCK SCREWS Crankshaft Locking Procedure
24 N•m ± 2 N•m NOTICE The crankshaft must be locked at
Tightening torque
(18 lbf•ft ± 1 lbf•ft)
TDC for removal and installation work on
crankshaft, balancer shaft and camshaft.
NOTE: When the crankshaft is locked, the piston
of cylinder no. 1 (clutch side) is at TDC. Crankshaft
can be not locked at cylinder no. 2 and no. 3 TDC.
1. Remove the valve cover. Refer to CYLINDER
HEAD subsection.
2. Remove spark plugs.
3. Remove plug screw with O-ring from valve train
cover.

rmr2014-017-004_c

M8 SCREWS TIGHTENING SEQUENCE

9. Install M6 cylinder block screws and tighten as

per following the sequence.
M6 CYLINDER BLOCK SCREWS
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

10 rmr2014-017
 Subsection 10 (CYLINDER BLOCK)

rmr2014-019-030_a
rmr2014-017-023_a
1. Plug screw
2. O-ring 1. Crankshaft access plug screw
3. Valve train cover 2. Gasket ring

4. Turn crankshaft to bring piston of cylinder no. 1 6. Lock crankshaft.

(clutch side) to TDC ignition.
NOTE: TDC ignition of cylinder no. 1 (clutch side)
is reached when the marks "IN" and "EX" on the
camshaft timing gears are aligned.
REQUIRED TOOL
HEXAGON SOCKET WRENCH
(P/N 529 036 287)
NOTE: When installing the crankshaft locking bolt
turn crankshaft slightly back and forth to ensure
alignment with the hole in the crankshaft.
REQUIRED TOOL
CRANKSHAFT LOCKING BOLT
(P/N 529 036 285)

rmr2014-017-024_a

rmr2014-017-022_a 1. Crankshaft locking bolt

CAMSHAFT TIMING GEARS
1. Marks must be aligned Crankshaft Removal
5. Remove crankshaft access plug screw and gas- 1. Disassemble CYLINDER BLOCK, see proce-
ket ring. dure in this subsection.
NOTE: Prior to disassembling the cylinder block
it is recommended to check the crankshaft axial
play. Refer to CRANKSHAFT INSPECTION in this
subsection.
2. Remove balancer shaft.

rmr2014-017 11
Subsection 10 (CYLINDER BLOCK)

Crankshaft Inspection
Check each bearing journal of crankshaft for scor-
ing, scuffing, cracks or other signs of wear.
Check if crankshaft gears are worn or otherwise
damaged.
Blow out the oil orifices and check if they are not
clogged.

rmr2014-017-025_a

1. Balancer shaft

3. Unscrew connecting rod cap screws and re-

move connecting rod caps. Refer to PISTONS
AND CONNECTING RODS in this subsection.
4. Remove crankshaft ring halves.

rmr2014-017-028_a

1. Balancer gear
2. Primary drive gear
3. Check oil orifices

Replace crankshaft if damaged.

Crankshaft Radial Play
Measure crankshaft bearing journal diameter, us-
ing a micrometer. Compare to inside diameter of
crankshaft plain bearings in cylinder block (refer to
CYLINDER BLOCK in this subsection).
rmr2014-017-026_a

1. Ring halves

5. Remove crankshaft locking bolt.

6. Remove crankshaft from cylinder block.

rmr2014-017-029_a

1. Micrometer
2. Crankshaft area for plain bearing

rmr2014-017-027_a

1. Crankshaft

12 rmr2014-017
 Subsection 10 (CYLINDER BLOCK)

CRANKSHAFT BEARING JOURNAL DIAMETER

49.984 mm to 50.000 mm
NEW
(1.9679 in to 1.9685 in)
SERVICE LIMIT 49.980 mm (1.9677 in)

CRANKSHAFT RADIAL PLAY

SERVICE LIMIT 0.090 mm (.0035 in)

Crankshaft Pin Diameter

Measure crankshaft pin diameter, using a microm-
eter. Compare to inside diameter of connecting
rod plain bearings (refer to CONNECTING ROD IN-
SPECTION in this subsection). rmr2014-017-031_a

1. Dial indicator
2. Crankshaft

CRANKSHAFT AXIAL PLAY

0.080 mm to 0.313 mm
NEW
(.0031 in to .0123 in)
SERVICE LIMIT 0.350 mm (.0138 in)

If play is out of specification, replace the crank-

shaft ring halves and repeat measurement.

rmr2014-017-030_a

1. Micrometer
2. Crankshaft pin area for plain bearing

CRANKSHAFT PIN DIAMETER

47.984 mm to 48.000 mm
NEW
(1.8891 in to 1.8898 in)
SERVICE LIMIT 47.980 mm (1.889 in)

CONNECTING ROD BIG END RADIAL PLAY

rmr2014-017-032_a
SERVICE LIMIT 0.080 mm (.0031 in)
1. Crankshaft ring halves

Crankshaft Axial Play

Crankshaft Installation
With the crankshaft in cylinder-block, measure the
For installation, reverse the removal procedure.
crankshaft axial play, using a dial indicator.
Pay attention to following details.
1. Install pistons and connecting rods in the cylin-
der block. Refer to PISTONS AND CONNECT-
ING RODS in this subsection.
2. Turn cylinder block upside down.
NOTICE Be careful that connecting rods do
not hit the cylinder block.
3. Apply engine oil on all plain bearings.
4. Install crankshaft.

rmr2014-017 13
Subsection 10 (CYLINDER BLOCK)

NOTICE If the oil spray nozzle is damaged or

bent, it must be replaced. Refer to LUBRICA-
TION SYSTEM subsection.

rmr2014-017-035_a

1. Mark on balancer shaft

2. Mark on crankshaft

rmr2014-017-033_a

1. Oil spray nozzles

5. Properly reinstall crankshaft ring halves with the

slots facing against crankshaft counterweights.
NOTE: Ring halves have to be flush with the cylin-
der block sealing surface.

rmr2014-017-036_a

1. Mark on balancer shaft

2. Cylinder block mating surface

8. Install cylinder block lower half. Refer to CYLIN-

rmr2014-017-034_a
1. Ring halve
2. Sealing surface
6. Install connecting rod caps. Refer to PISTONS
AND CONNECTING RODS in this subsection.
NOTICE It is absolutely necessary to follow
this procedure. Otherwise severe engine dam-
age can occur.
7. Install balancer shaft. Refer to BALANCER
SHAFT in this subsection.
NOTICE Crankshaft and balancer shaft marks
must be aligned.
DER BLOCK in this subsection.
9. Lock crankshaft at TDC, before further assem-
bly of the engine. See CRANKSHAFT LOCKING
PROCEDURE in this subsection.
NOTE: When installing the crankshaft locking bolt
turn crankshaft slightly back and forth to ensure
alignment with the hole in the crankshaft.
REQUIRED TOOL
HEXAGON SOCKET WRENCH
(P/N 529 036 287)
CRANKSHAFT LOCKING BOLT
(P/N 529 036 285)

14 rmr2014-017
 Subsection 10 (CYLINDER BLOCK)

BALANCER SHAFT Balancer Shaft Radial Play

Balancer Shaft Removal Measure balancer shaft bearing journal diameter,
using a micrometer. Compare to inside diameter
1. Disassemble CYLINDER BLOCK, see proce- of balancer shaft plain bearings in cylinder block
dure in this subsection. (refer to CYLINDER BLOCK in this subsection).
NOTE: Prior to disassembling the cylinder block it
is recommended to check the balancer shaft axial
play. Refer to BALANCER SHAFT INSPECTION in
this subsection.
2. Remove balancer shaft.

rmr2014-017-039_a

1. Micrometer
2. Balancer shaft area for plain bearing

BALANCER SHAFT BEARING JOURNAL

rmr2014-017-025_a
DIAMETER
36.019 mm to 39.3035 mm
1. Balancer shaft NEW
(1.4181 in to 1.5474 in)
Balancer Shaft Inspection SERVICE LIMIT 36.015 mm (1.4179 in)
Check each bearing journal of balancer shaft for BALANCER SHAFT RADIAL PLAY
scoring, scuffing, cracks or other signs of wear.
SERVICE LIMIT 0.080 mm (.0031 in)
Check if balancer shaft gear is worn or otherwise
damaged.
Balancer Shaft Axial Play
With the balancer shaft in cylinder-block, measure
the balance shaft axial play, using a dial indicator.

rmr2014-017-038_a

1. Balancer gear
2. Bearing journals

Replace balancer shaft if damaged. rmr2014-017-040_a

1. Dial indicator
Check balancer gear on the crankshaft at the 2. Balancer shaft
same time and replace crankshaft if necessary
(refer to CRANKSHAFT in this subsection).

rmr2014-017 15
Subsection 10 (CYLINDER BLOCK)

BALANCER SHAFT AXIAL PLAY 2. To ensure correct reinstallation mark:

– the connecting rod cap with corresponding
0.10 mm to 0.23 mm
NEW rod
(.0039 in to .0091 in)
– the assembly direction of the connecting rod.
SERVICE LIMIT 0.30 mm (.012 in)

Balancer Shaft Installation

For installation, reverse the removal procedure.
Pay attention to following detail.
NOTICE Balancer shaft and crankshaft marks
have to be aligned.

rmr2014-017-047_a

1. Marks
2. Cap
3. Connecting rod

3. Unscrew connecting rod screws and remove

connecting rod cap.
NOTE: It is recommended to measure connecting
rod big end axial play prior to remove connecting
rmr2014-017-035_a
rod. Refer to CONNECTING ROD INSPECTION.
1. Mark on balancer shaft
2. Mark on crankshaft

rmr2014-017-025_b

1. Connecting rod screws

2. Connecting rod cap
rmr2014-017-036_a

1. Mark on balancer shaft 4. Remove CRANKSHAFT and BALANCER

2. Cylinder block mating surface
SHAFT as per procedure in this subsection.
PISTONS AND CONNECTING 5. Turn cylinder block and push piston with con-
necting rod out of the cylinder.
RODS
Piston and Connecting Rod Removal Piston and Connecting Rod
Disassembly
1. Disassemble CYLINDER BLOCK as per proce-
dure in this subsection. 1. Remove one piston pin circlip and discard it.

16 rmr2014-017
 Subsection 10 (CYLINDER BLOCK)

mmr2009-116-075_a

TYPICAL
1. Piston pin circlip
rmr2014-017-042_a
NOTE: The removal of both piston pin circlips is 1. Crankshaft
not necessary to remove piston pin. 2. Feeler gauge

2. Push piston pin out of piston.
1 2
CONNECTING ROD BIG END AXIAL PLAY
0.100 mm to 0.352 mm
3 NEW
(.004 in to .014 in)
SERVICE LIMIT 0.400 mm (.016 in)

Connecting Rod Small End Radial Play

Measure inside diameter as shown using a bore
gauge.

R1503motr27A

TYPICAL
1. Piston
2. Piston pin
3. Circlip
vmr2006-044-039_d
3. Detach piston from connecting rod. TYPICAL
1. Longitudinal measure
Connecting Rod Inspection 2. Measure at 90° from longitudinal axis

Connecting Rod Big End Axial Play

Using a feeler gauge, measure distance between
butting face of connecting rod and crankshaft
counterweight. If the distance exceeds specified
tolerance, replace the worn part.

2 1

R1004motr11A

TYPICAL
1. Bore gauge
2. Connecting rod

rmr2014-017 17
Subsection 10 (CYLINDER BLOCK)

CONNECTING ROD SMALL END DIAMETER

20.010 mm to 20.020 mm
NEW
(.7878 in to .7882 in)
SERVICE LIMIT 20.025 mm (.7884 in)

If the connecting rod small end diameter is out of

specification, replace the connecting rod.
Measure piston pin diameter (refer to PISTON PIN vmr2006-044-039_a
INSPECTION) and compare to inside diameter of TYPICAL
connecting rod to obtain connecting rod small end 1. Longitudinal measure
2. Measures at 60° from longitudinal axis
radial play.
CONNECTING ROD SMALL END RADIAL PLAY CONNECTING ROD BIG END DIAMETER
SERVICE LIMIT 0.045 mm (.0018 in) SERVICE LIMIT 48.060 mm (1.8921 in)

Connecting Rod Big End Radial Play
1. Measure inside diameter of connecting rod big
end and compare to crankshaft pin diameter.
1.1 Install the OLD plain bearings as they were
mounted initially.
1.2 Perform the tightening procedure as de-
scribed in PISTON AND CONNECTING
ROD INSTALLATION in this subsection.
NOTE: Match the marks on the cap and con-
necting rod. ALWAYS use the OLD connect-
ing rod screws.
CONNECTING ROD BIG END RADIAL PLAY
SERVICE LIMIT 0.080 mm (.0031 in)
If connecting rod big end diameter is out of spec-
ification, install NEW plain bearings.
Piston Pin Inspection
Using synthetic abrasive woven, clean piston pin
from deposits.
Inspect piston pin for scoring, cracking or other
damages.
Measure piston pin diameter, using a micrometer.
See the following illustration for the proper mea-
surement position.

R400motr30A A
A. Measure piston pin diameter here

rmr2014-017-043_a PISTON PIN DIAMETER

1. Marks
2. Cap 19.995 mm to 20.000 mm
NEW
3. Connecting rod (.7872 in to .7874 in)
1.3 Measure inside diameter as shown. SERVICE LIMIT 19.990 mm (.787 in)

Replace the piston pin, if it is out of specification.

Piston Inspection
Inspect piston for scoring, scuffing, cracking or
other damages. Replace piston and piston rings
if necessary.

18 rmr2014-017
 Subsection 10 (CYLINDER BLOCK)

Using a micrometer, measure piston at 10 mm

(.394 in) perpendicularly (90°) to piston pin axis.

2 1
1

A
R400motr96A

F00B09A
TYPICAL
1. Measuring perpendicularly (90°) to piston pin axis
1. Use the micrometer to set the cylinder bore gauge
A. 10 mm (.394 in) 2. Cylinder bore gauge

PISTON MEASUREMENT
83.950 mm to 83.966 mm
NEW
(3.3051 in to 3.3057 in)
SERVICE LIMIT 83.940 mm (3.3047 in)

Replace the piston, if it is out of specification.

Piston/Cylinder Clearance
1. Adjust and lock a micrometer to the piston di-
mension.

1 1

F00B0AA

TYPICAL
1. Indicator set to 0 (zero)

NOTE: Make sure the cylinder bore gauge indica-

tor is set exactly at the same position as with the
micrometer, otherwise the reading will be false.
3. Position the cylinder bore gauge 32 mm
F00B08A
(1.26 in) below the cylinder head mating sur-
face, measuring perpendicularly (90°) to piston
1. Micrometer set to the piston dimension pin axis.
NOTE: Make sure used piston is not worn. 4. Read the measurement on the cylinder bore
gauge. The result is the exact piston/cylinder
2. With the micrometer set to the dimension, ad-
clearance.
just a cylinder bore gauge to the micrometer di-
mension and set the indicator to 0 (zero). PISTON/CYLINDER CLEARANCE
0.027 mm to 0.057 mm
NEW
(.0011 in to .0022 in)
SERVICE LIMIT 0.070 mm (.0028 in)

If clearance exceeds the specified tolerance, re-

place the piston and repeat the measurement pro-
cedure.

rmr2014-017 19
Subsection 10 (CYLINDER BLOCK)

Piston and Connecting Rod Assembly

For assembly, reverse the disassembly proce-
dure. Pay attention to the following details.
1. Apply engine oil on the piston pin.
2. Insert piston pin into piston and connecting rod.
NOTE: Ensure to reinstall all parts in their original
position as marked during removal.
3. Install NEW piston pin circlip(s).
mmr2011-075-029_a

REQUIRED TOOL 1. Circlip

2. Sleeve
3. Installer handle
PISTON CIRCLIP 4. Distance sleeve
INSTALLER (P/N 529
036 295) 3.4 Remove distance sleeve and insert in-
staller handle into the sleeve.
3.5 Insert the end of the handle into the piston
NOTICE Always replace disassembled pin, then push to engage the circlip into
piston pin circlips by NEW ones. the piston groove.
3.1 Place the circlip in the sleeve and push
piston circlip installer handle until circlip 1
reaches the mid position in the sleeve.

R1503motr28A

TYPICAL
1. Sleeve with piston circlip inside
mmr2011-075-041_a
2. Piston clip installer handle
TYPICAL
1. Circlip NOTE: Take care that the hook of the piston
2. Sleeve
3. Installer handle pin circlip is positioned properly.
3.2 Put the distance sleeve on the installer
handle.
3.3 Push piston circlip installer handle until
distance sleeve makes contact with the
sleeve.

R400motr102A

CORRECT POSITION OF THE PISTON PIN CIRCLIP

20 rmr2014-017
 Subsection 10 (CYLINDER BLOCK)

NOTICE If piston pin circlip installation fails,

repeat step 3 by using a NEW circlip.
4. Correctly install plain bearings and carefully
clean split surface on both sides (cracked area)
with compressed air.

3
2 rmr2014-017-045

NOTICE Piston installed with the arrow in

the wrong direction will cause serious engine
damage.

R1004motr20A

TYPICAL
1. Half bearing of connecting rod big end
2. Split surface of the connecting rod
3. Protrusion of bearing in line with connecting rod groove

Piston and Connecting Rod Installation

1. Use engine oil and lubricate:
– Piston
– Piston rings
– Cylinder bore rmr2014-017-046_a

– Connecting rod bearings. 1. Arrow toward exhaust side

2. Compress piston rings and slide piston into 3. Turn cylinder block upside down.
cylinder bore. Pay attention to the following.
4. Install CRANKSHAFT as per procedure in this
REQUIRED TOOL subsection.
SNAP-ON PISTON RING COMPRESSOR 5. Oil the crankshaft crank pin.
TOOL (P/N RC-980)
6. Match the marks on the caps and connecting
rods and install caps.
NOTE: Reinstall piston in the same cylinder
and assembly direction as marked during re- NOTE: Reinstall the caps in the same assembly
moval. direction as marked during removal.
2.1 Lubricate piston ring compressor tool with NOTE: Connecting rods are symmetrical. NEW
engine oil. ones can be installed in any direction.
2.2 If reused, install piston in its original bore.
2.3 Piston rings are properly installed (spac-
ing). See procedure in this subsection.
2.4 The arrow on top of the piston must be
installed towards exhaust.

rmr2014-017 21
Subsection 10 (CYLINDER BLOCK)

NOTICE Failure to strictly follow this proce-

dure may cause screws to loosen and lead to
severe engine damage.
8. Install BALANCER SHAFT as per procedure in
this subsection.
9. Install all other removed parts.

PISTON RINGS
Piston Ring Removal
1. Remove piston, see procedure in this subsec-
tion.
rmr2014-017-047_a
2. Remove rings from piston.
1. Marks
2. Cap
3. Connecting rod Piston Ring Inspection
NOTICE Always use NEW connecting rod Ring/Piston Groove Clearance
screws for the final assembly of the connect- Using a feeler gauge measure each ring/piston
ing rod. As the screws have been stretched groove clearance.
from the previous assembly, it is very impor-
tant to use NEW screws at assembly.
7. Tighten connecting rod screws as per following
procedure:
7.1 Torque both screws of a connecting rod.
CONNECTING ROD SCREWS 2
TIGHTENING PROCEDURE
STEP A 40 N•m (30 lbf•ft)

7.2 Use a torque angle gauge to carry out step

B.
CONNECTING ROD SCREWS
TIGHTENING PROCEDURE R1503motr32A 1
STEP B Additional 70° TYPICAL
1. Piston
2. Feeler gauge

RING/PISTON GROOVE CLEARANCE

UPPER COMPRESSION RING
0.025 mm to 0.070 mm
NEW
(.001 in to .0028 in)
SERVICE LIMIT 0.100 mm (.0039 in)
LOWER COMPRESSION RING
0.020 mm to 0.060 mm
NEW
(.0008 in to .0024 in)
SERVICE LIMIT 0.100 mm (.0039 in)
OIL SCRAPER RING
rmr2014-017-048_a
0.010 mm to 0.045 mm
1. Torque angle gauge NEW
(.0004 in to .0018 in)
SERVICE LIMIT 0.080 mm (.0031 in)

22 rmr2014-017
 Subsection 10 (CYLINDER BLOCK)

If the clearance is out of specification, the piston

and rings should be replaced.
Ring End Gap 1
1. Place piston ring in the cylinder bore between
2
8 mm to 16 mm (.315 in to .63 in) from top of
cylinder.
NOTE: In order to correctly position the ring in the 3
cylinder bore, use piston as a pusher.
2. Using a feeler gauge, check ring end gap. vmr2007-036-009_a

1. Upper compression ring

RING END GAP 2. Lower compression ring
3. Oil scraper ring
UPPER COMPRESSION RING
2. Check that rings rotate smoothly after installa-
0.10 mm to 0.30 mm tion.
NEW
(.0039 in to .0118 in)
3. Space the piston ring end gaps 120° apart and
SERVICE LIMIT 0.40 mm (.0157 in) do not align the gaps with the piston pin bore
LOWER COMPRESSION RING or the thrust side axis.
0.35 mm to 0.55 mm
NEW A
(.0138 in to .0217 in)
SERVICE LIMIT 0.60 mm (.0236 in) A A
OIL SCRAPER RING
0.20 mm to 0.70 mm
NEW
(.0079 in to .0276 in)
SERVICE LIMIT 0.80 mm (.0315 in)
1
If the ring end gap is out of specification, replace
piston rings.
2
Piston Ring Installation
1. Install the piston rings in the following assem-
bly order.
NOTE: Use a ring expander to prevent break- A31C2OA

age during installation. The oil ring must be TYPICAL

installed by hand. 1. DO NOT align ring gap with piston thrust side axis
2. DO NOT align ring gap with piston pin bore axis
1.1 Install oil scraper ring. A. 120°
1.2 Install the lower compression ring with the
word “K-TOP” facing up.
1.3 Install upper compression ring with the
word “K-TOP” facing up.

rmr2014-017 23
 Subsection 11 (CLUTCH (SM6))

CLUTCH (SM6)
SERVICE TOOLS
Description Part Number Page
CENTER BOLT............................................................................... 529 036 290 ..................................... 20, 22
CLUTCH ASSEMBLY HOLDER ..................................................... 529 036 292 ..................................... 34–35
CLUTCH HUB TURNING TOOL .................................................... 529 036 291 ........................................... 41
CRANKSHAFT LOCKING BOLT..................................................... 529 036 286 ........................................... 34
ECM ADAPTER TOOL................................................................... 529 036 166 ........................................... 15
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ..................................... 14–15
HEXAGON SOCKET WRENCH ..................................................... 529 036 287 ..................................... 22, 34
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ............................. 8–9, 11, 16

SERVICE PRODUCTS
Description Part Number Page
BRAKE FLUID................................................................................ 293 600 131 ............................................. 6
KLÜEBER PASTE 46 MR 401........................................................ 420 297 616 ........................................... 27
LOCTITE 243 (BLUE)..................................................................... 293 800 060 .........................17, 19, 28, 30
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ..................................... 36, 40
PETAMO GREASE GHY 133N ...................................................... 420 899 271 ........................................... 35
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ..................................... 21, 31

rmr2014-018 1
Subsection 11 (CLUTCH (SM6))

1.35 ± 0.15 N•m

(12 ± 1 lbf•in)

8 ± 2 N•m
(71 ± 18 lbf•in)

NEW 24.5 ± 1.5 N•m

15 ± 1 N•m (18 ± 1 lbf•ft)
(133 ± 9 lbf•in)

5.5 ± 0.5 N•m

(49 ± 4 lbf•in)

NEW
13 ± 1 N•m
(115 ± 9 lbf•in)

NEW = Component must be replaced when removed.

rmr2014-018-100_a

2 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

NEW

NEW NEW

Loctite 648 3 ± 0,3 N•m

7,5 ± 0,5 N•m (27 ± 3 lbf•in)
NEW
(66 ± 4 lbf•in)
19 ± 1 N•m 11 ± 1 N•m
(168 ± 9 lbf•in) (97 ± 9 lbf•in)
Loctite 243

NEW

11 ± 1 N•m
(97 ± 9 lbf•in)

NEW

11 ± 1 N•m
(97 ± 9 lbf•in)

NEW
20 ± 2 N•m
(15 ± 1 lbf•ft)

NEW = Component must be replaced when removed.

rmr2014-018-001_a

rmr2014-018 3
Subsection 11 (CLUTCH (SM6))

19 ± 1 N•m
(168 ± 9 lbf•in)

Loctite 243
11 ± 1 N•m
(97 ± 9 lbf•in)
Loctite 243
19 ± 1 N•m
(168 ± 9 lbf•in)
Loctite 243
NEW

Loctite 5910
11 ± 1 N•m
(97 ± 9 lbf•in)

Loctite 648

170 ± 10 N•m
(125 ± 7 lbf•ft)

Engine oil

Loctite 648
Engine oil

See tightening
procedure

Engine oil
NEW

Klueber paste 46MR401

11 ± 1 N•m
(97 ± 9 lbf•in)

NEW = Component must be replaced when removed.

rmr2014-018-002_a

4 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

GENERAL
NOTE: For a better understanding, many of the
following illustrations are produced with the en-
gine out of vehicle. To carry out the instructions,
it is not necessary to remove the engine from ve-
hicle.
Always disconnect the battery negative cable be-
fore working the engine.
NOTICE Always disconnect BLACK (-) cable
first and reconnect last.
During assembly/installation, use torque values rmr2014-018-137_a

and service products as specified in the exploded HYDRAULIC OPERATION

1. Hydraulic cylinder
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced with new ones.

NOTICE Hoses, cables or locking ties re- rmr2014-018-003_a

moved during a procedure must be reinstalled PNEUMATIC ASSIST

1. Diaphragm
as per factory standards.
A diaphragm assists the hydraulic system in dis-
NOTICE Avoid spilling brake fluid on plastic,
placing the pressure plate to disengage the clutch.
rubber or painted parts. Protect these parts
with a rag when servicing the hydraulic clutch The diaphragm is activated by vacuum applied
system. through an electronically controlled solenoid valve
(controlled by the ECM).
NOTICE Sealing washers must be discarded
and replaced with new ones every time a Banjo
fitting is unscrewed.
Periodically check the clutch hoses for damages
or leaks. Repair any damages or leaks.

SYSTEM DESCRIPTION
The engine on the SM6 model features a hydrauli-
cally operated pneumatically assisted type clutch
system.

rmr2014-018-004_a

1. Solenoid
2. Vent to secondary air intake silencer
3. Check valve
4. Vacuum to clutch release servo

rmr2014-018 5
Subsection 11 (CLUTCH (SM6))

When the clutch lever is depressed and the en- Clutch Fluid Level Verification
gine is running, the ECM modulates the clutch Ensure vehicle is on a level surface.
solenoid valve to provide a variable assist to the
clutch. Set the handlebar in order to position the top of
clutch fluid reservoir horizontally.
The pneumatic assist will vary according to throt-
tle position and to the engine RPM Wipe clean the reservoir cap area.
The level of assistance provided will vary accord- Remove retaining screws of reservoir cap using a
ing to the available vacuum in the intake manifold, Phillips screwdriver.
which will decrease as the throttle is opened.
A check valve is used to help the modulation of
vacuum on the diaphragm during take off. There-
fore, its orientation is important for proper opera-
tion. A wrong installed check valve leads to mal-
function of the pneumatic assist of the clutch.

rmr2014-018-109_a

RETAINING SCREWS TO REMOVE

Carefully remove reservoir cap. Pay attention not

to drop the seal.
Check clutch fluid level inside the reservoir:
– The fluid must be on the fill level line.
rmr2014-018-005_a

1. Check valve

When the clutch solenoid is not activated, the di-

aphragm vacuum hose is opened to atmospheric
pressure which allows the diaphragm to return to
its free position.
NOTE: A damaged diaphragm will cause engine
oil to be drawn into the air intake from the clutch
area. The burning engine oil will produce blue
smoke out of the exhaust system.

MAINTENANCE
CLUTCH FLUID rmr2014-018-110_a

FLUID REMOVED FOR CLARITY PURPOSE

1. Fill level line
Recommended Clutch Fluid
Use only DOT 4 BRAKE FLUID (P/N 293 600 131) or If the fluid level is lower than specified, add fluid to
equivalent. the reservoir up to the fill level line. Do not over-
fill.
NOTICE To avoid serious damage to the
hydraulic clutch system, use only brake fluid
of the recommended type from a sealed con-
tainer. Do not use fluid from an old or already
opened container, nor mix different fluids for
topping up the system.

6 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

WARNING
Avoid getting brake fluid on skin or in eyes,
it may cause severe burns. In case of con-
tact with the skin, wash thoroughly. In case
of contact with the eyes, immediately rinse
with plenty of water for at least 10 minutes
and then consult a doctor immediately.

NOTE: A low level may indicate leaks or worn

clutch discs.
Reinstall the reservoir cover.
Ensure seal is located inside reservoir cap and the
seal is completely collapsed. rmr2014-018-114_a

LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY

Clutch Fluid Replacement 1. Clutch bleeder cap

Clutch Fluid Draining Connect a clear hose to the clutch bleeder on the
Remove the following LH body panels, refer to LH side of vehicle.
BODY subsection: Insert the other end of the hose in an appropriate
– Top side panel container (such as an empty break fluid bottle).
– Rear side panel. Loosen the clutch bleeder.
Remove clutch reservoir cover screws. Do not re-
move cover at this time.

rmr2014-018-115_a

LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY

1. Hose installation location
2. Clutch bleeder

rmr2014-018-109_a Depress and release the clutch lever several times

RETAINING SCREWS TO REMOVE until no more fluid flows out of bleeder.
NOTICE Leave cover on reservoir to avoid
spillage during the following procedure.
Remove cap on clutch bleeder

rmr2014-018 7
Subsection 11 (CLUTCH (SM6))

Clutch Bleeding Procedures

Clutch Fluid Bleeding using a Pump (System
Completely Empty)
NOTE: If the system is completely empty, it is
easier to bleed the system by pushing the fluid
from the bleeder to the reservoir. Use the follow-
ing procedure.
Remove cap on clutch bleeder

rmr2014-018-116_a

TYPICAL

Tighten clutch bleeder.

rmr2014-018-114_a

LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY

1. Clutch bleeder cap

Install the vacuum/pressure pump and the re-

mote reservoir onto the clutch bleeder with a
rmr2014-018-115_a
clear hose.
LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY
1. Hose installation location REQUIRED TOOL
2. Clutch bleeder

Clutch Fluid Filling VACUUM/PRESSURE PUMP

Remove reservoir cover. (P/N 529 021 800)
Turn handlebar fully on right side.
NOTE: Turning the handlebar will help the bleed- Add recommended fluid in the pump remote
ing process. reservoir.
Fill reservoir with the RECOMMENDED CLUTCH Set pump to the PRESSURE position.
FLUID. Loosen clutch bleeder.
Ensure that clutch fluid reaches the fill level line.
Bleed system using the CLUTCH FLUID BLEED-
ING USING A PUMP (SYSTEM COMPLETELY
EMPTY) procedure.
NOTE: If a pump is not available, use the CLUTCH
FLUID BLEEDING WITHOUT A PUMP procedure.

rmr2014-018-115_a

LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY

1. Pump installation location
2. Clutch bleeder

8 rmr2014-018

Activate the pump lever several times until
fluid reaches the clutch reservoir. Then, tighten
bleeder.
NOTICE Do not overfill reservoir.
rmr2014-018-115_a
LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY
1. Pump installation location
2. Clutch bleeder
Depress clutch lever several times. If it feels
spongy, bleed system again using the CLUTCH
FLUID BLEEDING USING A PUMP (SYSTEM
NOT COMPLETELY EMPTY) procedure.
Top up fluid reservoir.
Install cover on reservoir.
Clutch Fluid Bleeding using a Pump
(System not Completely Empty)
Remove cap on clutch bleeder
rmr2014-018-114_a
LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY
1. Clutch bleeder cap
Install the vacuum/pressure pump and the re-
mote reservoir onto the clutch bleeder with a
clear hose.
rmr2014-018
Subsection 11 (CLUTCH (SM6))
REQUIRED TOOL
VACUUM/PRESSURE PUMP
(P/N 529 021 800)
Set pump to the VACUUM position.
Loosen clutch bleeder.
rmr2014-018-115_a
LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY
1. Pump installation location
2. Clutch bleeder
Depress and release the pump lever several
times until no more air bubbles flow out of
bleeder. Then, tighten bleeder.
NOTE: Check the clutch fluid level in reservoir of-
ten to prevent air from being drawn into the sys-
tem.
Pump until no more air comes out.
Tighten clutch bleeder.
rmr2014-018-115_a
LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY
1. Hose installation location
2. Clutch bleeder
Depress clutch lever several times. If it feels
spongy, repeat procedure until system is entirely
bled of trapped air.
Top up fluid reservoir.
Install cover on reservoir.
9
Subsection 11 (CLUTCH (SM6))

Clutch Fluid Bleeding without a Pump

NOTE: If a pump is not available, use the follow-
ing procedure.
Remove cap on clutch bleeder

rmr2014-018-116_a

TYPICAL

Tighten the clutch bleeder.

rmr2014-018-114_a

LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY

1. Clutch bleeder cap

Connect a clear hose to the clutch bleeder.

Insert the other end of the hose into a clean con-
tainer containing enough new brake fluid for the
end of the hose to be submerged.
Loosen the clutch bleeder.
rmr2014-018-115_a

LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY

1. Hose installation location
2. Clutch bleeder

Release the clutch lever.

rmr2014-018-115_a

LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY

1. Pump installation location
2. Clutch bleeder

Depress the clutch lever until it reaches the end

of its stroke.

rmr2014-018-117

TYPICAL

IMPORTANT: Do not release clutch lever until

bleeder has been tightened.
Repeat this sequence of depressing lever and
loosening/tightening bleeder screw until no more
air bubbles appear in hose.

10 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

NOTE: Check fluid level often to prevent air from

being pumped into the system.
Depress clutch lever several times. If it feels
spongy, repeat the procedure until system is
entirely bled of trapped air.
Top up reservoir.
Install cover on reservoir.

INSPECTION
CLUTCH OPERATION TEST
Pneumatic Assist Quick Test rmr2014-018-006_a

1. Vacuum hose
With the engine not running, depress the clutch 2. Diaphragm cover
lever a few times.
Install the vacuum/pressure pump onto the clutch
Note clutch lever resistance. cover vacuum hose fitting.
REQUIRED TOOL

VACUUM/PRESSURE PUMP
(P/N 529 021 800)

rmr2014-018-118_a

TYPICAL

Start engine and let run at idle.

Depress clutch lever a few times.
Compare lever resistance with and without en-
gine running. rmr2014-018-111_a

CLUTCH COVER VACUUM HOSE FITTING

Lever must be easier to depress when the engine
is running. Otherwise, carry out a VACUUM LEAK Set the pump to vacuum and activate its lever sev-
TEST. eral times until vacuum specified in the following
table is obtained.
Vacuum Leak Test
VACUUM LEAK TEST
Disconnect vacuum hose from diaphragm cover
fitting. VACUUM TIME WITHOUT LEAK
25 in Hg 30 seconds

If vacuum leaks, check the following:

– Clutch cover screws for tightness
– Tightness of diaphragm nut
– Diaphragm.
If the vacuum leak test was good, check the
vacuum-assist components.

rmr2014-018 11
Subsection 11 (CLUTCH (SM6))

NOTE: If there is no clutch assist or only partial as-

sist, the check valve or the solenoid valve should
be suspected. To identify where the problem is,
verify if vacuum is present after the check-valve.
If so, perform the clutch solenoid valve test de-
scribed in this subsection.
Remove the vacuum/pressure test pump and
hose.
Install the system vacuum hose on the clutch
cover and secure it as specified in the exploded
view.

Hydraulic Operation Test rmr2014-018-103_a

Lift and safely block RH front of vehicle to pre- 1. Clutch lever position set to 1
vent engine oil leakage when removing diaphragm
cover and diaphragm. Again, observe the adjustment screw position.
Remove diaphragm cover and move it aside. Re-
fer to DIAPHRAGM COVER in this subsection.

rmr2014-018-008_b

MOVEMENT OF ADJUSTMENT SCREW

1. Adjustment screw
rmr2014-018-007_a

1. Diaphragm cover screws It should move outwards approximately 2 mm

2. Diaphragm cover (.079 in) with clutch lever position set to step 1.
Observe the adjustment screw position. NOTE: Adjustment screw must maintain its posi-
tion as long as clutch lever is held depressed.
If adjustment screw does not maintain its po-
sition while clutch lever is depressed, check
hydraulic components for leakage. Replace hy-
draulic components if necessary, refer to MAS-
TER-CYLINDER and HYDRAULIC CYLINDER in
this subsection.

rmr2014-018-008_a

1. Adjustment screw

Set clutch lever position to 1.

Fully depress clutch lever and hold.
12 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

TROUBLESHOOTING
RATTLE AT IDLE OR DURING CLUTCH
ENGAGEMENT
1. Check clutch drum and clutch dampener parts
(spring disc(s) and thrust washer) for any wear.
- Replace defective parts in accordance with clutch
layout.
rmr2008-028-029_a

OVERHEATED/WORN CLUTCH PLATES TYPICAL

1. Screws
AND/OR OVERHEATED DIAPHRAGM
1. Faulty pneumatic clutch assist.
Place master-cylinder reservoir over a drain pan.
- Check CLUTCH SOLENOID VALVE (CSV). Remove the retaining screw and clutch fluid hose
- Check clutch adjustment.
from the master cylinder.
- Check cooling oil nozzle.
- Check indexation of the oil guiding ring, the open-
ing must align with the cooling oil nozzle.

PROCEDURES
CLUTCH LEVER
Clutch Lever Inspection
Check clutch lever for cracks or other damages.
rmr2008-028-030_a
Replace as required. TYPICAL
1. Remove screw
Clutch Lever Replacement
Empty reservoir into drain pan.
Remove screw and nut retaining the clutch lever.
Tie off clutch hose to handlebar to avoid spillage.
Remove clutch lever.
Installation is the reverse of the removal. NOTICE Be sure to protect all parts from the
brake fluid as it will strip the finish off parts.
Clean off any spillage immediately.
MASTER-CYLINDER
Discard sealing washers.
Master-Cylinder Removal
Remove clutch switch. Refer to STARTING SYS-
Drain fluid from clutch system. Refer to CLUTCH
TEM subsection.
FLUID REPLACEMENT procedure in this subsec-
tion. Remove master-cylinder.
Loosen screw retaining clutch fluid hose to reser- Master-Cylinder Installation
voir.
Installation is the reverse of the removal proce-
NOTE: Do not remove screw at this time to avoid dure, however pay attention to the following.
spillage.
If clutch fluid hose was disconnected:
Remove screws retaining master-cylinder to han-
dlebar. – Replace both sealing washers on clutch hose
fitting.
– Bleed clutch system. Refer to CLUTCH FLUID
in MAINTENANCE in this subsection.

CLUTCH SOLENOID VALVE (CSV)

CSV Test with B.U.D.S.
Connect to the latest B.U.D.S. software, refer to
COMMUNICATION TOOLS AND B.U.D.S.
rmr2014-018 13
Subsection 11 (CLUTCH (SM6))

Select the Read Data button. REQUIRED TOOL

Select the Faults page tab.
FLUKE 115 MULTIMETER
Check for fault codes. (P/N 529 035 868)
To test the solenoid valve operation, select the
Activation page tab and confirm you are on the
CSV INPUT VOLTAGE TEST
ECM page.
Activate the clutch solenoid valve by selecting the TEST PROBES VOLTAGE
solenoid symbol. Clutch solenoid
Battery
valve connector Battery ground
voltage
Pin 2

rmr2008-016-081_a

1. Activate here

This will validate the clutch solenoid mechanical

and electrical operation. rmr2008-054-003_b

CSV INPUT VOLTAGE TEST

If the solenoid valve works, check clutch compo-
nents. If voltage is out of specification:
If the solenoid valve does not work, proceed with – Check fuse F8.
a voltage test. – Carry out a CSV CIRCUIT CONTINUITY TEST.
If voltage is correct:
CSV Input Voltage Test
– Carry out a CSV RESISTANCE TEST.
Remove the RH upper side panel, refer to the
BODY subsection. CSV Resistance Test
Disconnect the clutch solenoid valve connector. Disconnect clutch solenoid valve connector.
Turn ignition switch to ON. Set the multimeter to .
REQUIRED TOOL

FLUKE 115 MULTIMETER

(P/N 529 035 868)

Measure the clutch solenoid valve resistance as

follows.
CSV RESISTANCE TEST
RESISTANCE @
TEST PROBES
20°C (68°F)
Solenoid pins 1 and 2 23 ± 1.2
rmr2014-018-108_a

PARTS REMOVED FOR CLARITY

1. Clutch solenoid valve connector
2. Clutch solenoid valve

Set the multimeter to Vdc setting.

14 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

– A clogged solenoid valve

– A malfunctioning clutch solenoid check valve.
Repair or replace as applicable.

Clutch Solenoid Valve Removal

Remove the RH top side panel. Refer to the
BODY subsection.
Remove the air intake manifold. Refer to AIR IN-
TAKE SYSTEM subsection.
Disconnect clutch solenoid valve connector.
Remove screws securing clutch solenoid valve to
rmr2008-054-002_a support bracket.
If resistance is out of specification:
– Replace the clutch solenoid valve.
If resistance is good:
– Carry out a CSV CIRCUIT CONTINUITY TEST.

CSV Circuit Continuity Test

Connect ECM connector A on the ECM adapter
tool.
REQUIRED TOOL

ECM ADAPTER TOOL

(P/N 529 036 166)
rmr2008-054-001_b
Set the multimeter to . TYPICAL - PARTS REMOVED FOR CLARITY
1. Solenoid valve
REQUIRED TOOL 2. Solenoid connector
3. Vacuum hose from intake manifold
4. Vacuum hose to diaphragm cover
FLUKE 115 MULTIMETER 5. Hose to airbox
(P/N 529 035 868)
Cut Oetiker clamps and remove hoses from clutch
valve solenoid.
Measure the circuit continuity resistance as fol-
lows. NOTE: Mark hoses location for reinstallation.

CSV CIRCUIT CONTINUITY TEST Clutch Solenoid Valve Installation

RESISTANCE For installation, reverse the removal procedure.
TEST PROBES
@ 20°C (68°F)
Clutch solenoid Fuse F8 CHECK VALVE
connector Front fuse box (CLUTCH SOLENOID VALVE)
pin 2 contact A-9
Close to 0 Check Valve Access
Clutch solenoid
ECM-A Refer to BODY and remove the following parts on
connector
Contact A-3
pin 1 the LH side:
– Top side panel
If resistance is out of specification: – Rear side panel
– Repair or replace wiring/connectors. – Middle side panel
If resistance is correct, check for the following:
– An obstructed vacuum hose Check Valve Removal
– A stuck solenoid valve plunger Cut Oetiker clamps retaining the check valve.

rmr2014-018 15
Subsection 11 (CLUTCH (SM6))

DIAPHRAGM COVER
Diaphragm Cover Access
Refer to BODY subsection and remove the follow-
ing parts on the RH side:
– Bottom rear side panel
– Rear side panel.

Diaphragm Cover Removal

Lift and safely block RH front of vehicle to pre-
vent engine oil leakage when removing diaphragm
cover and/or diaphragm.
rmr2014-018-005_b Install a drain pan under clutch hose.
1. Oetiker clamps
2. Check valve Cut Oetiker clamp and remove vacuum hose from
diaphragm cover.
Remove the check valve. NOTE: Disconnect vacuum hose ONLY if di-
aphragm cover must be removed from the vehi-
Check Valve Inspection cle. Otherwise, omit this step.
Using the vacuum/pressure pump, test the check
valve operation.
REQUIRED TOOL

VACUUM/PRESSURE PUMP
(P/N 529 021 800)

Check Valve Installation

Install the check valve with the flow arrow point-
ing towards the air intake manifold.
Install NEW Oetiker clamps.

rmr2014-018-013_a

1. Vacuum hose
2. Oetiker clamp

Remove:
– Diaphragm cover retaining screws
– Diaphragm cover.
NOTICE Do not let the diaphragm cover hang
from the hose and do not stretch or twist the
vacuum hose.

rmr2014-018-005_c

1. Flow arrow towards air intake manifold

Install all other removed parts.

16 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

rmr2014-018-014_a rmr2014-018-016_a

1. Retaining screws 1. Mounting lug

2. Diaphragm cover 2. Diaphragm slot inserted on lug
3. Arrow on disc plate
4. Banjo bolt
Diaphragm Cover Inspection
Clean diaphragm cover and check for cracks or Position diaphragm cover so that vacuum hose im-
other damage. pulse nipple is to the left of the banjo bolt.
Check with compressed air if vacuum hole is
clogged.

rmr2014-018-006_b

1. Diaphragm cover
2. Impulse nipple
3. Banjo bolt
4. Retaining screws
rmr2014-018-015_a

1. Vacuum hole Tighten diaphragm cover retaining screws in a

2. Vacuum hose impulse nipple criss-cross pattern to specification.
3. Diaphragm cover
DIAPHRAGM COVER RETAINING SCREWS
Diaphragm Cover Installation
LOCTITE 243 (BLUE)
Ensure: Service product
(P/N 293 800 060)
– Slots in diaphragm are properly positioned on
7.5 N•m ± 0.5 N•m
mounting lugs Tightening torque
(66 lbf•in ± 4 lbf•in)
– Arrow of the disc plate shows to the banjo bolt.
NOTICE Wrong position of the disc plate CLUTCH DIAPHRAGM
causes insufficient clutch plate lubrication.
Diaphragm Removal
Remove the DIAPHRAGM COVER. See proce-
dure in this subsection.

rmr2014-018 17
Subsection 11 (CLUTCH (SM6))

Pull diaphragm out of its mounting lugs, then ro-

tate it away from the lugs to avoid damaging the
diaphragm when removing retaining nut.

rmr2014-018-022_a

1. Thrust washer
2. Disc plate
3. Diaphragm

rmr2014-018-020_a
Remove:
1. Mounting lugs – Support disc
2. Diaphragm rotated out of lugs – Oil guiding ring.
Unscrew retaining nut while holding adjustment
screw with a 6 mm Allen wrench.

rmr2014-018-023_a

1. Support disc
2. Oil guiding ring
rmr2014-018-021_a

1. Retaining nut
2. Adjustment screw Diaphragm Inspection
Inspect rubber diaphragm for wear, tears, or other
Remove: damages. Replace if necessary.
– Thrust washer
– Disc plate Diaphragm Installation
– Diaphragm. Installation is the reverse of the removal proce-
dure. However, pay attention to following.
Install support disc so that its mark "OUTSIDE"
faces towards the diaphragm cover.
NOTICE Incorrect mounting position of sup-
port disc will damage diaphragm causing en-
gine oil to be drawn into the air intake from the
clutch area.

18 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

rmr2014-018-024_a rmr2014-018-026_a

1. Oil guiding ring 1. Disc plate

2. Support disc 2. Stamped arrow
3. Mark "OUTSIDE"
Install thrust washer.
Install diaphragm.
Tighten nut while holding adjustment screw with
NOTICE Do not install diaphragm into its a 6 mm Allen wrench.
mounting lugs yet. RETAINING NUT
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
19 N•m ± 1 N•m
Tightening torque
(168 lbf•in ± 9 lbf•in)

rmr2014-018-025_a

1. Mounting lug
2. Diaphragm out of lug

Install disc plate so that stamped arrow faces to-

wards the diaphragm cover.
NOTICE Incorrect mounting position of disc
plate will damage diaphragm causing engine
oil to be drawn into the air intake from the
clutch area.
rmr2014-018-021_b
1. Retaining nut
2. Adjustment screw
Turn adjustment screw so that the arrow of the
disc plate shows towards next to the banjo bolt.
NOTE: Lubrication oil comes from an oil orifice on
the top at the clutch cover into the open side of
the oil guiding ring and from there into the clutch.
Wrong assembly position of the disc plate gives
also wrong assembly position of the oil guiding
plate and will cause insufficient clutch plate lubri-
cation.
Position the slots in diaphragm onto the mounting
lugs.

rmr2014-018 19
Subsection 11 (CLUTCH (SM6))

rmr2014-018-016_b rmr2014-018-027_a

1. Mounting lug 1. Screws

2. Diaphragm slot inserted on lugs 2. Oil duct cover
3. Banjo bolt 3. Gasket
4. Arrow shows next to banjo bolt 4. Oil sieve

Install diaphragm cover. Refer to DIAPHRAGM Remove all clutch cover screws starting with up-
COVER in this subsection. per clutch cover screws. Install center bolts into
upper clutch cover screw bores as you remove
CLUTCH COVER screws.
REQUIRED TOOL
Clutch Cover Access
Refer to BODY and remove the following panels CENTER BOLT (P/N 529
036 290)
on the RH side:
– Middle side panel
– Top side panel
– Bottom rear side panel
– Bottom front side panel
– Rear side panel
– Middle side panel support.
Remove lateral frame support.
Drain engine oil, refer to LUBRICATION SYSTEM.

Clutch Cover Removal

Place a drain pan under the clutch cover to catch
oil spillage.
Remove diaphragm cover and diaphragm. Refer rmr2014-018-028_a

to procedures in this subsection. 1. M6x45 retaining screws (16)

2. M6x20 retaining screws (1)
Remove:
Remove:
– Oil duct cover screws
– Clutch cover
– Oil duct cover
– Gasket (discard it).
– Gasket
– Oil sieve. NOTE: Gently tap on clutch cover using a soft rub-
ber mallet to separate it from the cylinder block.

20 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

rmr2014-018-029

Remove banjo bolt and discard sealing ring. rmr2014-018-031_a

1. Clutch housing
2. Clean oil bores
3. Clean oil orifice

rmr2014-018-030_a

1. Banjo bolt
2. Sealing ring (discard it)
rmr2014-018-032_a
3. Clutch cover
1. Clutch housing
Remove following parts only if necessary: 2. Clean oil orifice

– Oil pump housing and scavenge pump, refer to Check if ball inside Banjo bolt moves freely. Re-
LUBRICATION SYSTEM subsection place if necessary.
– Oil guiding plate, refer to LUBRICATION SYS-
TEM subsection.
Clutch Cover Inspection
Inspect the clutch cover for cracks or other dam-
ages. Replace if necessary.
Check sealing surface for flatness.
Clean oil bores and oil orifice in clutch hous-
ing from contaminants using PULLEY FLANGE
CLEANER (P/N 413 711 809), then use an air gun to
dry it.
Check if the oil bores and oil orifice are not
clogged.
rmr2014-018-033_a

1. Ball
2. Spring
3. Banjo bolt

rmr2014-018 21
Subsection 11 (CLUTCH (SM6))

Clutch Cover Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
Install Banjo bolt with NEW sealing ring and
tighten to specification.
BANJO BOLT
Sealing ring NEW
19 N•m ± 1 N•m
Tightening torque
(168 lbf•in ± 9 lbf•in)

Remove plug screw with O-ring from valve train

cover.
rmr2014-019-028_a

1. Mark on balance shaft

2. Cylinder block mating surface

Install 4 center bolts into clutch cover screw

bores.
REQUIRED TOOL
CENTER BOLT (P/N 529
036 290)

Fit NEW small gasket on NEW clutch cover gas-

ket.

rmr2014-019-030_a

1. Plug screw
2. O-ring
3. Valve train cover

Using the HEXAGON SOCKET WRENCH (P/N 529

036 287) turn crankshaft counter clockwise until
mark on balance shaft is align with cylinder block
mating surface.
NOTE: In this position piston no.1 is in TDC posi-
tion.
REQUIRED TOOL
HEXAGON SOCKET WRENCH
(P/N 529 036 287)

rmr2014-019-070_a

1. Small gasket
2. Clutch cover gasket

Install NEW clutch cover gaskets.

22 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

rmr2014-019-045_a
rmr2014-019-028_b
1. Center bolts 1. Slot
2. Gaskets 2. Balance shaft

Turn oil pump shaft until dot align with one of the Remove the 4 center bolts.
marks on the oil pump housing.
Install oil duct cover on clutch cover.
Install clutch cover and oil duct cover screws and
tighten as per following as per the following se-
quence.
CLUTCH COVER AND OIL DUCT COVER
SCREWS TIGHTENING PROCEDURE
Gaskets NEW
5 N•m ± 0.6 N•m
STEP A
(44 lbf•in ± 5 lbf•in)

rmr2014-018-034_a

1. Dot
2. Oil pump shaft
3. Marks
4. Oil pump housing

Attach the clutch cover taking care that the 2 flat rmr2014-018-035_a

surfaces of the oil pump shaft insert into the slot TIGHTENING SEQUENCE
of the balance shaft.
CLUTCH COVER AND OIL DUCT COVER
SCREWS TIGHTENING PROCEDURE
11 N•m ± 1 N•m
STEP B
(97 lbf•in ± 9 lbf•in)

rmr2014-018 23
Subsection 11 (CLUTCH (SM6))

rmr2014-018-037_a

1. Retaining screw
rmr2014-018-035_b 2. Step washer
TIGHTENING SEQUENCE 3. Clutch spring

Reinstall remaining parts, refer to the appropriate Remove retaining ring located behind the clutch
instructions in this subsection. release pin and slide pressure plate over push rod
assembly.
PRESSURE PLATE, CLUTCH
SPRINGS AND CLUTCH RELEASE
ROD
Pressure Plate, Clutch Spring and
Clutch Release Rod Removal
Refer to DIAPHRAGM in this subsection and re-
move:
– Diaphragm
– Support disc
– Oil guiding ring.
Unscrew oil guiding plate retaining screws and re-
move oil guiding plate.

rmr2014-018-104_a

1. Retaining ring
2. Pressure plate

NOTICE For replacing the clutch springs and/

or clutch plates, the following steps must not
be performed.
Pull clutch release rod assembly out of engine.

rmr2014-018-036_a

1. Retaining screws
2. Oil guiding plate

Loosen the retaining screws in a crisscross pat-

tern, then remove them with the step washers
and clutch springs.

24 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

rmr2014-018-132_a

1. Clutch release pin

rmr2014-018-038_a

1. Clutch release rod assembly Remove and discard sealing ring of clutch release
2. Clutch release pin rod.
3. Adjustment screw

Using a 6 mm Allen wrench, unscrew the adjust-

ment screw while holding the clutch release pin
with a 17 mm wrench.

rmr2014-018-043_a

1. Sealing ring
2. Clutch release rod

Pressure Plate, Clutch Spring and

Clutch Release Rod Inspection
Pressure Plate
rmr2014-018-130_a
Inspect pressure plate for cracks or other dam-
1. Adjustment screw
ages. Replace if necessary.
2. Clutch release pin Inspect thrust surface for wear or other damages.
Using a 4 mm Allen wrench, unscrew the clutch Check if bearing in pressure plate turns smoothly
release rod counter clockwise while holding the and freely. Replace if necessary.
clutch release pin with a 17 mm wrench.
NOTICE The clutch release rod has a left
hand thread.

rmr2014-018 25
Subsection 11 (CLUTCH (SM6))

REQUIRED TOOL
Suitable tube, outer diameter 41 mm (1.61 in)
Press

5. Install NEW retaining ring.

rmr2014-018-044_a

1. Bearing
2. Thrust surface

Ball Bearing Replacement

1. Remove and discard retaining ring.

rmr2014-018-044_b

1. Retaining ring
2. Bearing
3. Pressure plate

Clutch Spring
Measure each clutch spring free length. Replace
all clutch springs as a set if one is out of specifi-
cations.
CLUTCH SPRING FREE LENGTH
NEW 59.95 mm (2.36 in)
SERVICE LIMIT 58.50 mm (2.303 in)
rmr2014-018-044_b

1. Retaining ring
2. Bearing
3. Pressure plate

2. Heat pressure plate up to 100°C (212°F)before

removing the ball bearing.
NOTICE Clean pressure plate from oil before
heating.
3. Press out ball bearing.
NOTE: Support pressure plate properly.
REQUIRED TOOL
Suitable tube, outer diameter 35 mm (1.38 in) vmr2008-017-016

Press Clutch Release Rod, Clutch Release Pin and

Adjustment Screw
4. Press NEW ball bearing in pressure plate. Visually inspect clutch release rod, clutch release
NOTE: Unless otherwise instructed, never use a pin and adjustment screw for wear or other dam-
hammer to install ball bearing. Use a press only. age. Replace if necessary.

26 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

Pressure Plate, Clutch Spring and

Clutch Release Rod Installation
For installation, reverse the removal procedure.
However, pay attention to the following.
Install NEW sealing ring onto clutch release rod.
Lubricate circumferential at the end of the clutch
release rod in the area of the sealing ring.
CLUTCH RELEASE ROD LUBRICATION

Service product KLÜEBER PASTE 46 MR

401 (P/N 420 297 616)

rmr2014-018-056_a

1. Clutch release rod assembly

2. Clutch release pin
3. Clutch shaft

Tighten pressure plate retaining screws in a criss-

cross pattern to specification.
PRESSURE PLATE RETAINING SCREWS
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)
rmr2014-018-046_a

1. Clutch release rod

2. Sealing ring
3. Lubricate here

Screw in clutch release rod counter clockwise

completely into clutch release pin by hand.
NOTE: Clutch release rod has a left hand thread.

rmr2014-018-037_b

1. Clutch spring
2. Step washer
rmr2014-018-058_a 3. Retaining screw
1. Clutch release pin
2. Clutch release rod Install pressure plate and a NEW retaining ring.
Insert clutch release rod assembly into clutch
shaft.

rmr2014-018 27
Subsection 11 (CLUTCH (SM6))

Clutch Release Rod Adjustment

NOTICE The axial clearance of the clutch re-
lease rod must be adjusted if the adjustment
screw was disassembled or if following parts
were renewed:
– Pressure plate
– Clutch release rod
– Clutch release pin
– Adjustment screw
– Clutch hub.
NOTICE For clutch release rod adjustment
the hydraulic cylinder must be fitted on the
engine PTO side.
rmr2014-018-104_a

1. Retaining ring Remove cap on clutch bleeder

2. Pressure plate

Install oil guiding plate and tighten screws criss-

cross wise to specification.
OIL GUIDING PLATE RETAINING SCREWS
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

rmr2014-018-114_a

LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY

1. Clutch bleeder cap

Connect a clear hose on the clutch bleeder to

catch up clutch fluid in a drain pan.
Loosen clutch bleeder.
NOTICE Clutch bleeder must be loosened to
ensure that clutch cylinder is venting to atmos-
rmr2014-018-036_b
phere.
1. Oil guiding plate
2. Retaining screws

Proceed with CLUTCH RELEASE ROD ADJUST-

MENT if the adjustment screw was disassembled
before.

28 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

rmr2014-018-115_a

LH SIDE OF VEHICLE - PARTS REMOVED FOR CLARITY

1. Hose installation location
2. Clutch bleeder

Using a 4 mm Allen wrench, screw in the clutch

release rod while holding the clutch release pin rmr2014-018-049_a
with a 17 mm wrench. 1. Clutch release pin
2. Hydraulic piston
Stop when the pressure plate starts moving or 3. Hydraulic clutch housing
when you the release rod becomes harder to
screw in. To adjust the axial play screw out the clutch re-
NOTE: Clutch release rod has a left hand thread. lease rod counter clockwise by exactly 4 turns
while holding the clutch release pin with a 17 mm
wrench.
CLUTCH RELEASE ROD AXIAL PLAY
4 turns = 4 mm (.16 in)

rmr2014-018-048_c

1. Clutch release pin

2. Pressure plate
3. Turn Allen wrench
4. Hold 17 mm wrench

NOTICE The pressure plate starts moving rmr2014-018-048_d

when the hydraulic piston touches the hy-
draulic cylinder housing on the PTO engine
side.
1. Clutch release pin
2. Turn Allen wrench
Apply thread locker on the adjustment screw
thread and tighten adjustment screw to spec-
ification. Turn adjustment screw with an Allen
wrench 6 mm while holding the clutch release
pin with a 17 mm wrench.

rmr2014-018 29
Subsection 11 (CLUTCH (SM6))

ADJUSTMENT SCREW
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
19 N•m ± 1 N•m
Tightening torque
(168 lbf•in ± 9 lbf•in)

rmr2014-019-032_a

1. Clutch plates, 1.9 mm - 2.1 mm (.075 in - .083 in) (8x)

2. Friction plates, 2.4 mm (.094 in) (8x)

Remove:
– Hardened clutch plate 2.1 mm (.083 in), mark
with a color dot
– Friction plate with larger inner diameter
rmr2014-018-055_a
– Spring disc
1. Adjustment screw – Thrust washer
2. Clutch release pin – Clutch plate 1.9 mm (.075 in)
Reinstall the remaining parts, refer to the appro- NOTICE The clutch plate in position second
priate instructions in this subsection. to last is hardened and is marked with a color
dot. If the color dot is not visible anymore due
CLUTCH PLATES to disappearance during engine operation,
mark the hardened clutch plate at disassem-
Clutch Plates Removal bly.
Refer to procedures in this subsection and re-
move: NOTICE The bottom clutch plate 1.9 mm
– Diaphragm cover (.075 in) must be reinstalled in the same posi-
tion.
– Diaphragm
– Clutch cover
– Clutch springs
– Pressure plate with clutch release rod.
Remove clutch plates 1.9 mm - 2.1 mm
(.075 in - .083 in) (8x) and friction plates 2.4 mm
(.094 in) (8x).

30 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

SPRING DISC WARPAGE

SERVICE LIMIT 0.2 mm (.008 in)

Measure height of the spring disc in a crosswise

direction, in reference to the flat surface

rmr2014-019-036_a

1. Hardened clutch plate, 2.1 mm (.083 in)

2. Marked with a color dot
3. Spring disc
4. Thrust washer
5. Friction plate with larger inner diameter
6. Clutch plate, 1.9 mm (.075 in) rmr2014-018-120_a
7. Clutch hub
TYPICAL - MEASURING SPRING DISC FREE LENGTH

Spring Disc Inspection SPRING DISC FREE LENGTH

Inspect spring disc for cracks, wear or other dam- 2.3 mm to 2.5 mm
ages. Replace if necessary. NEW
(.091 in to .098 in)
Clean spring disc. SERVICE LIMIT 2.1 mm (.083 in)
SPRING DISC CLEANING
PULLEY FLANGE Clutch Plates Inspection
Service product CLEANER (P/N 413 Inspect each plate for cracks, bent or broken
711 809) teeth, missing or excessively worn friction mate-
rial and any other damage.
Place spring disc on a flat surface so that the outer
circumference of the disc is flat on the surface. Check clutch plates for warpage.
Use a feeler gauge to measure warpage between Clutch plates must be free of scores and blueing
spring disc and flat surface. (overheating).
Inspect hardened clutch plate for wear on spring
disc side.
Place plates on a flat surface. Use a feeler gauge
to measure warpage between plates and flat sur-
face.
CLUTCH PLATE WARPAGE
SERVICE LIMIT 0.15 mm (.006 in)

rmr2014-018-121_a

MEASURING WARPAGE OF SPRING DISC

rmr2014-018 31
Subsection 11 (CLUTCH (SM6))

Clutch Plates Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
First, install the clutch plate 1.9 mm (.075 in) onto
clutch hub.
Install friction plate with larger inner diameter.
NOTICE Ensure the closed side of the friction
plate tabs is facing towards the gearbox.

rmr2014-018-121_a

MEASURING WARPAGE OF SPRING DISC

Plate warpage must not exceed service limit.

Measure the thickness of the clutch plate assem-
bly (friction and clutch plates).
NOTE: Thickness of the clutch plate assembly is
measured without the spring disc and thrust
washer.
NOTICE Manually compress clutch plates
to achieve proper measurement of the clutch rmr2014-019-042_a

plate assembly thickness. 1. Closed side of the friction plate tab

2. Towards gearbox
CLUTCH PLATES ASSEMBLY THICKNESS
(FRICTION PLATES (9X) AND CLUTCH
Install thrust washer.
PLATES (10X)) Install spring disc with convex side towards gear-
41.48 mm to 41.72 mm
box.
NEW
(1.633 in to 1.643 in)
SERVICE LIMIT 38.50 mm (1.516 in)

rmr2014-019-043_a

TYPICAL - CORRECT SPRING DISC INSTALLATION

1. Clutch hub
2. Clutch plate, 1.9 mm (.075 in)
rmr2014-019-037_a
3. Friction plate with larger inner diameter
4. Thrust washer
1. Clutch plates (10x) 5. Spring disc
2. Friction plates (9x) 6. Hardened clutch plate, 2.1 mm (.083 in)
A. Service limit
Install hardened clutch plate.
If plates are warped, damaged, or worn out of tol-
erance, replace all clutch plates as a set. NOTICE Hardened clutch plate is color
marked.

32 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

rmr2014-019-042_a

1. Closed side of the friction plate tab

2. Towards gearbox

rmr2014-019-036_b
Place the tabs of the last friction plate into the
1. Clutch hub shorter slots of clutch drum.
2. Clutch plate, 1.9 mm (.075 in)
3. Friction plate with larger inner diameter
4. Thrust washer
5. Spring disc
6. Hardened clutch plate, 2.1 mm (.083 in)
7. Marked with a color dot

Beginning with a friction plate, install friction

plates (8x) and clutch plates (8x) in alternate or-
der.
NOTICE Ensure the closed side of the friction
plate tabs is facing towards the gearbox.

rmr2014-019-051_a

1. Shorter slot
2. Last friction plate

Reinstall remaining parts, refer to the appropriate

instructions in this subsection.

CLUTCH HUB
Clutch Hub Removal
Remove the following items, see procedures in
rmr2014-019-050_a
this subsection:
1. Friction plate (8x)
2. Clutch plate (8x) – Diaphragm cover and diaphragm
– Clutch Cover
– Clutch springs
– Pressure plate
– Clutch release rod assembly
– Clutch disc assembly.
Remove plug screw with O-ring from valve train
cover.

rmr2014-018 33
Subsection 11 (CLUTCH (SM6))

rmr2014-019-030_a rmr2014-019-031_a

1. Plug screw 1. Mark on balance shaft

2. O-ring 2. Cylinder block mating surface
3. Valve train cover 3. Crankshaft locking bolt

Using the HEXAGON SOCKET WRENCH (P/N 529 Lock clutch hub.
036 287) turn crankshaft counter clockwise until
mark on balance shaft is align with cylinder block REQUIRED TOOL
mating surface. CLUTCH ASSEMBLY HOLDER
NOTE: In this position piston no.1 is in TDC posi- (P/N 529 036 292)
tion.
REQUIRED TOOL NOTE: Insert service tool completely to the bot-
tom of the clutch drum.
HEXAGON SOCKET WRENCH
(P/N 529 036 287)

Lock crankshaft.
NOTICE Ensure that service tool engages in
cylinder block bore properly.
NOTICE This locking procedure must not be
used for camshaft timing since locking position
is inadequate.
NOTE: Crankshaft also can be locked as de-
scribed in CRANKSHAFT LOCKING PROCEDURE
in the CYLINDER BLOCK subsection.
rmr2014-019-033_a
REQUIRED TOOL
1. Clutch assembly holder
CRANKSHAFT LOCKING BOLT 2. Clutch hub
3. Clutch drum
(P/N 529 036 286)
Remove:
– Clutch hub retaining nut
– Spring washer
– Clutch hub with remaining clutch plates.

34 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

rmr2014-019-047_a

1. Clutch drum thrust washer

rmr2014-019-034_a

1. Clutch hub retaining nut

Lubricate clutch hub teeth.
2. Spring washer
3. Clutch hub CLUTCH HUB TEETH
PETAMO GREASE GHY
Clutch Hub Inspection Service product
133N (P/N 420 899 271)
Clean oil orifices with compressed air and check
if they are not clogged. Insert the clutch hub.

rmr2014-018-122_a

INSPECT
1. Oil orifices

Clutch Hub Installation rmr2014-019-048_a

For installation, reverse the removal procedure. 1. Lubricate clutch hub teeth
2. Clutch hub
However, pay attention to following. 3. Clutch shaft
4. Clutch drum
Ensure clutch drum thrust washer is installed on
clutch shaft ahead of clutch drum assembly be- Lock clutch hub.
fore installing the clutch hub.
REQUIRED TOOL

CLUTCH ASSEMBLY HOLDER

(P/N 529 036 292)

NOTE: Insert service tool completely to the bot-

tom of the clutch drum.
Reinstall spring washer and hub retaining nut.

rmr2014-018 35
Subsection 11 (CLUTCH (SM6))

rmr2014-019-049_a rmr2014-019-047_a

1. Clutch assembly holder 1. Clutch drum thrust washer

2. Clutch hub
3. Clutch drum
4. Spring washer
Remove:
5. Clutch hub retaining nut – Clutch drum
Tighten nut to specification. – Thrust washer.
NOTE: Before removing the clutch drum it is rec-
CLUTCH HUB RETAINING NUT
ommended to check the sliding friction torque of
Service product
LOCTITE 648 (GREEN) the clutch gear, refer to CLUTCH DRUM INSTAL-
(P/N 413 711 400) LATION in this subsection.
170 N•m ± 10 N•m
Tightening torque
(125 lbf•ft ± 7 lbf•ft)

Remove crankshaft locking bolt.

Reinstall remaining parts, refer to the appropriate
instructions in this subsection.

CLUTCH DRUM
Clutch Drum Removal
Remove the following items, see procedures in
this subsection:
– Diaphragm cover and diaphragm
– Clutch Cover rmr2014-019-052_a

1. Clutch drum
– Clutch springs 2. Thrust washer
– Pressure plate
– Clutch release rod assembly Clutch Drum Disassembly
– Clutch disc assembly Remove:
– Clutch hub. – Retaining nuts with flat head screws
Remove the clutch drum thrust washer. – Outer support plate
– Distance sleeves.

36 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

rmr2014-019-053_a rmr2014-019-055_a

1. Retaining nuts 1. Clutch gear

2. Flat head screws 2. Springs discs
3. Outer support plate 3. Thrust washer
4. Distance sleeves 4. Inner support plate

Remove: Clutch Drum Inspection

– Anti backlash gear together with anti backlash
springs Compression Springs and Retainers
– Compression springs with their retainers. Measure free length of each compression spring,
refer to the following table.
COMPRESSION SPRINGS FREE LENGTH
NEW 29.46 mm (1.16 in)
SERVICE LIMIT 29.00 mm (1.142 in)
ANTI BACKLASH SPRING FREE LENGTH
NEW 10.99 mm (.433 in)
SERVICE LIMIT 10.50 mm (.413 in)

If a spring is out of specification, replace all

springs as well as all spring retainers.
Inspect spring retainers for wear, cracks or scor-
rmr2014-019-054_a
ing. Replace all springs and all spring retainers as
1. Anti backlash gear an assembly.
2. Anti backlash springs
3. Compression springs Support Plates
4. Spring retainers
Inspect support plates for cracks or abnormal
Remove: wear. Replace if necessary.
– Clutch gear Inspect the thrust surface of inner support plate
– Spring discs for abnormal wear or grooves. If necessary,
– Thrust washer replace inner support plate, thrust washer and
– Inner support plate. spring disc as an assembly.

rmr2014-018 37
Subsection 11 (CLUTCH (SM6))

rmr2014-019-056_a rmr2014-019-058_a

1. Inspect thrust surface of inner support plate INSPECT SLOTS IN CLUTCH DRUM FOR WEAR

Clutch Gear Inspect spring cavities for deep grooves, caused

Inspect bearing sleeve surface for scoring and by springs. Replace clutch drum if necessary.
wear. NOTE: Slight markings caused by the springs are
Measure inner diameter of bearing sleeve. normal. Do not replace clutch drum needlessly.

rmr2014-019-059_a
rmr2014-019-057_a

A. Inner diameter 1. Inspect spring cavities

1. Bearing sleeve surface
Clutch Drum Assembly
BEARING SLEEVE INNER DIAMETER
NOTICE Assembly of the clutch drum must
30.015 mm to 30.035 mm be carried out with utmost care. Failure to
NEW
(1.1817 in to 1.1825 in) strictly follow the procedures may cause parts
SERVICE LIMIT 30.040 mm (1.1827 in) to loosen and/or malfunction of the clutch
drum and may lead to serious engine damage.
Inspect teeth condition for pitting or other dam-
age. Assemble the clutch drum in the reverse order of
disassembly. However, pay attention to the fol-
Replace clutch drum drive gear if necessary. lowing details.
Clutch Drum NOTICE The position of the clutch drum,
Inspect slots in clutch drum for damages or wear support plates and clutch gear for assembly
caused by friction plates. Replace if necessary. is clearly indicated with location holes in each
part. During assembly ensure that all location
holes are aligned with each other.

38 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

rmr2014-019-061_a

1. Inner support plate

rmr2014-019-060_a
2. Thrust washer
ALIGNMENT OF LOCATION HOLES FOR CLUTCH DRUM 3. Flat head screws
ASSEMBLY
1. Hole in clutch drum Apply engine oil on the spring discs.
2. Hole in inner support plate
3. Hole in clutch gear
4. Hole in anti backlash gear
Install spring discs with the concave side facing to
5. Hole in outer support plate the thrust washer.
Insert the three M8 x 28 flat head screws from the
inside of the drum. Hold the screws in position as
you install the remaining parts.
For installation align slots of thrust washer with
clutch drum ribs.

rmr2010-015-013_a

1. Concave side of spring discs

rmr2014-019-062_a

1. Clutch drum ribs

2. Slots of thrust washer

Install inner support plate on clutch drum, ensure

the location holes are aligned with each other.

rmr2014-019-063_a

1. Inner support plate

2. Spring discs

rmr2014-018 39
Subsection 11 (CLUTCH (SM6))

Install the clutch gear, ensure the location holes

are aligned with each other.
Install clutch drum springs with spring retainers
into the corresponding spring cavities.
Apply engine oil on contact surface between
clutch gear and anti backlash gear.

rmr2014-019-065_a

1. Distance sleeves
2. Outer support plate
3. Location holes

Tighten nuts to specification.

CLUTCH DRUM NUTS TIGHTENING PROCEDURE
LOCTITE 648 (GREEN)
Service product
rmr2014-019-069_a (P/N 413 711 400)
1. Clutch gear 11 N•m ± 1 N•m
2. Lubricate contact surface STEP A
3. Location hole (97 lbf•in ± 9 lbf•in)
4. Clutch drum springs
5. Spring retainers 29 N•m ± 1 N•m
STEP B
(21 lbf•ft ± 1 lbf•ft)
Install anti backlash gear.
NOTICE Ensure that location holes are Finally check the friction damper torque, refer to
CLUTCH DRUM INSTALLATION for proper proce-
aligned and mark "THIS SIDE VISIBLE" is
dure.
visible.
Install anti backlash springs into corresponding Clutch Drum Installation
spring cavities. For installation, reverse the removal procedure.
However, pay attention to the following.
Insert the first thrust washer on the clutch shaft
before installing clutch drum.

rmr2014-019-064_a

1. Anti backlash gear

2. Anti backlash springs

Apply engine oil on distance sleeves and install rmr2014-019-066_a

them on clutch drum screws, then outer support 1. Thrust washer

plate. Ensure that the location holes are aligned
with each other. Install clutch drum on the clutch shaft:
1. Engage anti backlash gear in primary drive gear.

40 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

2. Turn clutch hub counter clockwise to align

clutch gear with primary drive gear.
REQUIRED TOOL
CLUTCH HUB TURNING TOOL
(P/N 529 036 291)

3. Push clutch hub completely down.

rmr2014-018-059_a

CHECK FOR SLIDING FRICTION TORQUE

1. Clutch hub turning tool
2. Torque wrench with actual torque viewer

rmr2014-018-057_a

1. Clutch hub turning tool

2. Clutch drum
3. Primary drive gear

After installation of the clutch drum check for slid-

ing friction torque of the clutch drum to the clutch
gear:
1. Ensure crankshaft is still locked.
rmr2014-019-068_a
2. Check if friction damper torque is within speci-
1. Spring retainers
fication. 2. Clutch drum side surface
Turn clutch drum in both directions until spring re-
Install the clutch drum thrust washer on clutch
tainers contact the clutch drum side surface and
shaft.
measure torque required for movement.
There must be sliding friction torque between the
contacts.
If free-play has been detected, inspect all clutch
drum components (e.g. spring disc, thrust
washer, inner support plate). Refer to CLUTCH
DRUM INSPECTION in this subsection.
FRICTION DAMPER TORQUE
75 N•m to 90 N•m (55 lbf•ft to 66 lbf•ft)

REQUIRED TOOL
Torque wrench with actual torque viewer
CLUTCH HUB TURNING TOOL rmr2014-019-047_a

(P/N 529 036 291) 1. Clutch drum thrust washer

Install clutch hub and all remaining parts. See pro-

cedures in this subsection.

rmr2014-018 41
Subsection 11 (CLUTCH (SM6))

HYDRAULIC CYLINDER Leaking engine oil indicates:

– Worn sealing ring of the clutch release rod. Re-
Hydraulic Cylinder Access place sealing ring, refer to PRESSURE PLATE,
Refer to BODY and remove the following parts on CLUTCH SPRINGS AND CLUTCH RELEASE
the LH side: ROD in this subsection.
– Rear side panel – Worn O-ring of the support cover behind the hy-
– Bottom rear side panel draulic cylinder. Replace O-ring, refer to SUP-
Remove front sprocket. PORT COVER in this subsection.
Remove:
Hydraulic Cylinder Removal – Retaining screws
Check area below venting slot of the gearbox – Hydraulic cylinder with clutch hose.
housing for signs of brake fluid or engine oil.

rmr2014-018-133 _a

1. Retaining screws
2. Hydraulic cylinder
3. Gearbox housing
rmr2014-018-105_a

1. Hydraulic cylinder Place cylinder over drain pan.

2. Bottom hydraulic cylinder screw
3. Check this area for leaking brake fluid Remove:
4. Gearbox housing
– Clutch bleeder
– Clutch hose.

rmr2014-018-051_a
rmr2014-018-134_a
HYDRAULIC CYLINDER REMOVED FOR CLARITY
1. Venting slot TYPICAL
2. Gearbox housing 1. Clutch bleeder cap
2. Clutch bleeder
3. Washers
Leaking brake fluid indicates a damaged hydraulic 4. Clutch hose
piston gasket ring. Replace hydraulic cylinder. 5. Hydraulic cylinder

42 rmr2014-018
 Subsection 11 (CLUTCH (SM6))

Hydraulic Cylinder Installation From clutch side insert a suitable punch into the
For installation, reverse the removal procedure. clutch shaft and press out hydraulic cylinder cover.
However. Pay attention to the following. REQUIRED TOOL
Install hydraulic cylinder and tighten to specifica- Suitable punch, length 300 mm (11.81 in),
tion. diameter 11 mm (.43 in)
HYDRAULIC CYLINDER RETAINING SCREWS
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

Install clutch hose and clutch bleeder on hydraulic

cylinder.

rmr2014-018-053_a

1. Suitable punch
2. Support cover
3. Gearbox housing

Remove and discard O-ring of support cover.

rmr2014-018-140_a

1. Clutch bleeder
2. Clutch hose
3. Hydraulic cylinder

Refill clutch fluid and bleed clutch system. Refer

to CLUTCH FLUID in this subsection.

SUPPORT COVER
Support Cover Location
The support cover is located behind the hydraulic
cylinder.
rmr2014-018-054_a

Support Cover Removal 1. O-ring

2. Support cover
Remove the hydraulic cylinder cover only if nec-
essary, for instance if engine oil leakage is pre- Support Cover Inspection
sumed. Visually inspect support cover bore for scoring,
Refer to procedures in this subsection and re- scratches or abnormal wear. Replace if neces-
move: sary.
– Diaphragm cover
– Diaphragm
– Clutch springs
– Pressure plate with clutch release rod
– Hydraulic cylinder.

rmr2014-018 43
Subsection 11 (CLUTCH (SM6))

rmr2014-018-054_b

1. Bore
2. Support cover

Support Cover Installation

For installation, reverse the removal procedure.
However. Pay attention to the following.
Install a NEW O-ring for the hydraulic cylinder
cover.

44 rmr2014-018
 Subsection 12 (CLUTCH (SE6))

CLUTCH (SE6)
SERVICE TOOLS
Description Part Number Page
CENTER BOLT............................................................................... 529 036 290 ......................................... 5, 8
CLUTCH ASSEMBLY HOLDER ..................................................... 529 036 292 ..................................... 18, 20
CLUTCH COVER HOLDING DEVICE ............................................ 529 036 294 ......................................... 6, 9
CLUTCH HUB TURNING TOOL .................................................... 529 036 291 ........................................... 25
CRANKSHAFT LOCKING BOLT..................................................... 529 036 286 ........................................... 18
HEXAGON SOCKET WRENCH ..................................................... 529 036 287 ....................................... 7, 18

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ..................................... 20, 24
PETAMO GREASE GHY 133N ...................................................... 420 899 271 ........................................... 19
PULLEY FLANGE CLEANER ......................................................... 413 711 809 ....................................... 6, 15

rmr2014-019 1
Subsection 12 (CLUTCH (SE6))

11 ± 1 N•m
(97 ± 9 lbf•in)

28 ± 2 N•m
11 ± 1 N•m (21 ± 1 lbf•ft)
(97 ± 9 lbf•in)

Loctite 243

28 ± 2 N•m
(21 ± 1 lbf•ft)

Loctite 243

NEW
Engine oil

NEW

11 ± 1 N•m
(97 ± 9 lbf•in)

Loctite 243

6 ± 0,7 N•m
(53 ± 6 lbf•in) Engine oil
NEW

11 ± 1 N•m
(97 ± 9 lbf•in)
20 ± 2 N•m
(15 ± 1 lbf•ft)

NEW = Component must be replaced when removed.

rmr2014-019-001_a

2 rmr2014-019
 Subsection 12 (CLUTCH (SE6))

11 ± 1 N•m Engine oil

(97 ± 9 lbf•in) NEW

Engine oil

Engine oil

Loctite 648

Loctite 648
170 ± 10 N•m
(125 ± 7 lbf•ft)

2 ± 0,3 N•m
(18 ± 3 lbf•in)
Engine oil
Loctite 243

Engine oil

See tightening
procedure

NEW = Component must be replaced when removed.

rmr2014-019-002_a

rmr2014-019 3
Subsection 12 (CLUTCH (SE6))
GENERAL
NOTE: For a better understanding, many of the
following illustrations are produced with the en-
gine out of vehicle. To carry out the instructions,
it is not necessary to remove the engine from ve-
hicle.
Always disconnect the battery negative cable be-
fore working the engine.
WARNING
Always disconnect BLACK (-) cable first and
reconnect last.
During assembly/installation, use torque values
and service products as specified in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.
NOTICE Hoses, cables or locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
NOTICE Sealing washers must be discarded
and replaced with new ones every time a Banjo
fitting is unscrewed.
Periodically check the oil hoses for damages or
leaks. Repair any leaks and replace damaged
hose.
SYSTEM DESCRIPTION
The engine on the SE6 model features a sequen-
tial electronically controlled mechanical 6-speed
transmission with a hydraulic type clutch system.
The transmission control module (TCM) controls
all commands of the shifting and clutch function-
ality.
The clutch cover assembly includes the hydraulic
control module (HCM), the shift linkage, valve
housing as well as engine oil temperature and
clutch oil pressure sensor.
4 rmr2014-019
Inside the HCM is a double rotor pressure pump
which generate pressurized engine oil coming
from the oil tank for the clutch and shifting ac-
tivities which are regulated by spool valves and
controlled by solenoids.
The valve housing distributes pressurized oil to
the clutch piston, which is clamping the clutch
plates, and also to the clutch hub for lubricating
the clutch.
The clutch is disengaged by 6 clutch springs.
For a smooth engagement and for more precise
torque at low torque levels the clutch package is
equipped with a spring disc.
rmr2014-019-003_a
HYDRAULIC CLUTCH SIDE
1. Clutch cover including HCM
TROUBLESHOOTING
TROUBLESHOOTING
GUIDELINES
SHIFTING PROBLEMS
1. For any shifting problems, refer to TROU-
BLESHOOTING in ELECTRONIC SHIFT SYSTEM
(SE6) subsection.
RATTLE AT IDLE OR DURING CLUTCH
ENGAGEMENT
1. Check clutch drum and clutch dampener parts
(discs springs and thrust washer) for any wear.
- Replace defective parts in accordance with clutch
layout.
SLIPPING CLUTCH
1. Check for errors in BUDS.
- Replace clutch pack If error: High kiss point —
Low coefficient of friction is displayed.
 Subsection 12 (CLUTCH (SE6))

2. Check engine oil specification and quantity.

- Replace to engine oil with correct specification,
refer to ENGINE OIL in the LUBRICATION SYS-
TEM subsection.
3. Check HCM oil pressure, refer to HYDRAULIC
CONTROL MODULE (SE6).
4. Check clutch plates for wear.
- Replace clutch plates.
5. Sealing ring of oil supply piston and/or clutch
piston is worn.
- Replace sealing ring. rmr2014-019-009_a

1. Locking ties
6. Clogged HCM oil filter. 2. HCM connector
3. Clutch pressure sensor connector
- Replace HCM oil filter, refer to HYDRAULIC CON-
TROL MODULE (SE6) subsection. Place a drain pan under the clutch cover to catch
oil spillage.
PROCEDURES Remove:
– Oil duct cover screws
CLUTCH COVER – Oil duct cover
Clutch Cover Access – Gasket
Refer to BODY and remove the following panels – Oil sieve.
on the RH side:
– Middle side panel
– Top side panel
– Bottom rear side panel
– Bottom front side panel
– Rear side panel
– Middle side panel support
– Lateral frame support.
Drain engine oil, refer to LUBRICATION SYSTEM.
Disconnect:
– HCM connector
– Oil pressure sensor.
rmr2014-019-004_a

Clutch Cover Removal 1.

2.
Screws
Oil duct cover
Remove locking ties and disconnect HCM con- 3. Gasket
4. Oil sieve
nector and clutch pressure sensor connector.
Remove all clutch cover screws starting with up-
NOTICE If clutch cover is removed to have
per clutch cover screws. Install center bolts into
access to the clutch it is recommended to dis- upper clutch cover screw bores as you remove
connect the TCM connector and remove clutch screws.
cover together with TCM wiring harness.
REQUIRED TOOL
CENTER BOLT (P/N 529
036 290)

rmr2014-019 5
Subsection 12 (CLUTCH (SE6))

529036294

rmr2014-019-005_a

1. M6x45 retaining screws (16)

2. M6x20 retaining screws (1)
3. Clutch cover

Remove:
– Clutch cover
– Gasket (discard it).
NOTE: Gently tap on clutch cover using a soft
rubber mallet to separate it the from the cylinder
block.
rmr2014-019-007_a

1. Clutch cover holder

2. Clutch cover
3. Clutch cover bolts (3x)

Remove following parts only if necessary:

– Valve housing, refer to VALVE HOUSING AND
OIL SUPPLY PISTON in this subsection
– Shift activating lever assembly, refer to GEAR-
BOX subsection
– HCM, refer to HYDRAULIC CONTROL MOD-
ULE (SE6) subsection
– Oil filter cover assembly, refer to HYDRAULIC
CONTROL MODULE (SE6) subsection
rmr2014-019-006_a
– Pressure sensor housing, refer to HYDRAULIC
1. Clutch cover
2. Gasket CONTROL MODULE (SE6) subsection
– Oil guiding plate, refer to LUBRICATION SYS-
Fix clutch cover holder in a vice and attach clutch TEM subsection.
cover using 3 clutch cover bolts.
REQUIRED TOOL
Clutch Cover Inspection
Inspect the clutch cover for cracks or other dam-
CLUTCH COVER HOLDING ages. Replace if necessary.
DEVICE (P/N 529 036 294)
Check sealing surface for flatness.
Clean oil passages in clutch cover from contami-
nants using PULLEY FLANGE CLEANER (P/N 413 711
809), then use compressed air to dry it.
Check if the oil bores are not clogged.

6 rmr2014-019
 Subsection 12 (CLUTCH (SE6))

Clutch Cover Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
Remove plug screw with O-ring from valve train
cover.

rmr2014-019-008_a

1. Clutch cover
2. Clean oil bores

rmr2014-019-030_a

1. Plug screw
2. O-ring
3. Valve train cover

Using the HEXAGON SOCKET WRENCH (P/N 529

036 287) turn crankshaft counterclockwise until
mark on balance shaft is align with cylinder block
mating surface.
NOTE: In this position piston no.1 is in TDC posi-
tion.
rmr2014-019-038_a
REQUIRED TOOL
1. Clutch cover
2. Clean oil bores
HEXAGON SOCKET WRENCH
Check HCM connector for leakage. Replace HCM (P/N 529 036 287)
wiring harness if necessary. Refer to HYDRAULIC
CONTOL MODULE (HCM) subsection.

rmr2014-019-028_a

rmr2014-019-027_a 1. Mark on balance shaft

1. HCM connector 2. Cylinder block mating surface
2. Clutch cover
Install 4 center bolts into clutch cover screw
bores.

rmr2014-019 7
Subsection 12 (CLUTCH (SE6))

REQUIRED TOOL
CENTER BOLT (P/N 529
036 290)

Fit NEW small HCM gasket on NEW clutch cover

gasket.

rmr2014-019-029_a

1. Dot
2. Oil pump shaft
3. Mark
4. HCM oil pump cover

Attach the clutch cover taking care that the 2 flat

rmr2014-019-070_a
surfaces of the oil pump shaft insert into the slot
1. HCM gasket
2. Clutch cover gasket of the balance shaft.
Install NEW clutch cover gaskets.

rmr2014-019-028_b

1. Slot
rmr2014-019-045_a 2. Balance shaft
1. Center bolts
2. Gaskets Install and tighten 3 clutch cover retaining screws.
Turn oil pump shaft of HCM until dot on oil pump Remove the 4 center bolts.
shaft is align with the mark on the oil pump cover. Install oil duct cover on clutch cover.
Install clutch cover and oil duct cover screws and
tighten as per following procedure.

8 rmr2014-019
 Subsection 12 (CLUTCH (SE6))

CLUTCH COVER AND OIL DUCT COVER VALVE HOUSING AND OIL
TIGHTENING PROCEDURE SUPPLY PISTON
Gaskets NEW
Valve Housing and Oil Supply Piston
STEP A
5 N•m ± 0.6 N•m Access
(44 lbf•in ± 5 lbf•in)
Refer to BODY and remove the following panels
on the RH side:
– Middle side panel
– Top side panel
– Bottom rear side panel
– Bottom front side panel
– Rear side panel
– Middle side panel support
– Lateral frame support.
Drain engine oil, refer to LUBRICATION SYSTEM.
Disconnect:
– HCM connector
– Oil pressure sensor.
rmr2014-019-026_b
Valve Housing and Oil Supply Piston
TIGHTENING SEQUENCE
Removal
CLUTCH COVER AND OIL DUCT COVER Remove clutch cover, refer to CLUTCH COVER in
TIGHTENING PROCEDURE this subsection.
11 N•m ± 1 N•m Fix clutch cover holder in a vice and attach clutch
STEP B
(97 lbf•in ± 9 lbf•in) cover using 3 clutch cover bolts.
REQUIRED TOOL

CLUTCH COVER HOLDING

DEVICE (P/N 529 036 294)

rmr2014-019-026_a

TIGHTENING SEQUENCE

Reinstall remaining parts, refer to the appropriate

instructions in this subsection. rmr2014-019-007_a

1. Clutch cover holder

2. Clutch cover
3. clutch cover bolts (3x)

Remove:
– Valve housing screws
– Valve housing
– Gasket (discard it).

rmr2014-019 9
Subsection 12 (CLUTCH (SE6))

rmr2014-019-010_a rmr2014-019-012_a

1. Screws 1. O-ring
2. Valve housing 2. Sealing ring
3. Gasket 3. Inner oil supply sleeve
4. Clutch cover 4. O-ring
5. Sealing ring
Remove: 6. Outer oil supply sleeve

– Inner oil supply sleeve
– Outer oil supply sleeve.
NOTE: Use a screw driver to remove outer oil
supply sleeve.
Valve Housing and Oil Supply Sleeve
Inspection
Clean valve housing and visually inspect sealing
surface.
Blow out oil orifice and check if it is not clogged.

rmr2014-019-013_a

1. Oil orifice
2. Valve housing

Check inner and outer oil supply sleeve for dam-

rmr2014-019-011_a
ages.
1. Inner oil supply sleeve
2. Outer oil supply sleeve
3. Screw driver Valve Housing and Oil Supply Sleeve
4. Valve housing Installation
Remove oil supply piston gaskets and discard Installation is the reverse of the removal proce-
them. dure. Pay attention to following details.
Install NEW oil supply sleeve gaskets and lubri-
cate them with engine oil.

10 rmr2014-019
 Subsection 12 (CLUTCH (SE6))

rmr2014-019-012_a rmr2014-019-010_a

1. O-ring 1. Screws
2. Sealing ring 2. Valve housing
3. Inner oil supply sleeve 3. Gasket
4. O-ring 4. Clutch cover
5. Sealing ring
6. Outer oil supply sleeve Install all other removed parts.
Carefully install outer oil supply sleeve.
HYDRAULIC CLUTCH PISTON
NOTICE Take care not damaging the gasket
during installation.
AND PRESSURE PLATE
NOTE: Outer oil supply sleeve pivot must be in-
Hydraulic Clutch Piston and Pressure
serted in the recess of the valve housing bore. Plate Removal
Remove clutch cover, refer to CLUTCH COVER in
this subsection.
Remove:
– Oil duct cover screws
– Oil duct cover
– Clutch cylinder with hydraulic clutch piston.

rmr2014-019-014_a

1. Pivot
2. Outer oil supply sleeve
3. Recess
4. Valve housing

Install NEW valve housing gasket.

Install valve housing and tighten screws to speci-
fication. rmr2014-019-015_a

1. Screws
VALVE HOUSING SCREWS 2. Oil duct cover
3. Clutch cylinder
Gasket NEW
Carefully push out hydraulic clutch piston from
11 N•m ± 1 N•m clutch cylinder.
Tightening torque
(97 lbf•in ± 9 lbf•in)

rmr2014-019 11
Subsection 12 (CLUTCH (SE6))

rmr2014-019-016_a rmr2014-019-018_a

1. Punch HYDRAULIC CLUTCH PISTON

2. Clutch cylinder 1. Inspect sealing ring
3. Hydraulic clutch piston 2. Inspect piston surface

Remove: Clutch Cylinder Oil Duct Cover Inspection

– Pressure plate Clean clutch cylinder and oil duct cover. Visually
– Clutch springs. inspect cylinder surface for scoring, scratches or
abnormal wear.
Inspect piston bores for wear, scoring and
scratches.
Inspect clutch cylinder and oil duct cover oil bores
if clogged.
Replace if necessary.

rmr2014-019-017_a

1. Pressure plate
2. Clutch springs

Hydraulic Clutch Piston and Pressure

Plate Inspection
Hydraulic Clutch Piston Inspection
rmr2014-019-019_a
Clean piston and visually inspect piston surface for 1. Piston bores
scoring, scratches or abnormal wear. Replace if 2. Oil bores
necessary. 3. Clutch cylinder

Remove and discard sealing ring.

12 rmr2014-019
 Subsection 12 (CLUTCH (SE6))

vmr2008-017-016

rmr2014-019-020_a
CLUTCH SPRING FREE LENGTH
1. Piston bore
2. Oil bores
3. Oil duct cover NEW 23.33 mm (.919 in)
SERVICE LIMIT 22.00 mm (.866 in)
Pressure Plate Inspection
Inspect pressure plate for cracks or other dam-
ages.
Hydraulic Clutch Piston and Pressure
Plate Installation
Inspect thrust surface for wear or other damages.
Installation is the reverse of the removal proce-
Replace if necessary. dure. However, pay attention to following details.
Install NEW hydraulic piston sealing ring.
NOTE: Do not twist sealing ring during assembly.

rmr2014-019-021_a

1. Trust surface
2. Pressure plate

Clutch Spring Inspection rmr2014-019-022_a

1. Piston
Measure each clutch spring free length. Replace 2. Sealing ring
all clutch springs as a set if one is out of specifi-
cations. Before installing lubricate with engine oil:
– Hydraulic clutch piston
– Sealing ring
– Clutch cylinder bore
– Oil duct cover bore.

rmr2014-019 13
Subsection 12 (CLUTCH (SE6))

rmr2014-019-023_a rmr2014-019-025_a

LUBRICATE TIGHTENING SEQUENCE

1. Hydraulic clutch piston
2. Sealing ring
3. Clutch cylinder bores
4. Oil duct cover bore
CLUTCH PLATES
Push in hydraulic clutch piston by hand. Clutch Plates Removal
Remove clutch cover, refer to CLUTCH COVER in
this subsection.
Refer to HYDRAULIC CLUTCH PISTON AND
PRESSURE PLATE in this subsection and re-
move:
– Oil duct cover
– Hydraulic clutch cylinder
– Pressure plate
– Clutch springs.
Remove clutch plates 1.9 mm - 2.1 mm
(.075 in - .083 in) (8x) and friction plates 2.4 mm
(.094 in) (8x).
rmr2014-019-024_a

1. Hydraulic clutch piston

2. Clutch cylinder

Install clutch cylinder together with oil duct cover.

Tighten oil duct cover screws as per following se-
quence.
OIL DUCT COVER SCREWS
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

rmr2014-019-032_a

1. Clutch plates, 1.9 mm - 2.1 mm (.075 in - .083 in) (8x)

2. Friction plates, 2.4 mm (.094 in) (8x)

Remove:
– Hardened clutch plate 2.1 mm (.083 in), mark
with a color dot
– Friction plate with larger inner diameter
– Disc spring

14 rmr2014-019
 Subsection 12 (CLUTCH (SE6))

– Thrust washer
– Clutch plate 1.9 mm (.075 in)
NOTICE The clutch plate in position second
to last is hardened and is marked with a color
dot. If the color dot is not visible anymore due
to disappearance during engine operation,
mark the hardened clutch plate at disassem-
bly.
NOTICE The bottom clutch plate 1.9 mm
(.075 in) must be reinstalled in the same posi-
tion.
rmr2014-018-121_a

MEASURING WARPAGE OF SPRING DISC

SPRING DISC WARPAGE

SERVICE LIMIT 0.2 mm (.008 in)

Measure height of the spring disc in a crosswise

direction, in reference to the flat surface

rmr2014-019-036_a

1. Hardened clutch plate, 2.1 mm (.083 in)

2. Marked with a color dot
3. Spring disc
4. Thrust washer
5. Friction plate with larger inner diameter
6. Clutch plate, 1.9 mm (.075 in)
7. Clutch hub

rmr2014-018-120_a
Spring Disc Inspection TYPICAL - MEASURING SPRING DISC FREE LENGTH
Inspect spring disc for cracks, wear or other dam-
ages. Replace if necessary. SPRING DISC FREE LENGTH
Clean spring disc. 2.3 mm to 2.5 mm
NEW
(.091 in to .098 in)
SPRING DISC CLEANING
SERVICE LIMIT 2.1 mm (.083 in)
PULLEY FLANGE
Service product CLEANER (P/N 413
711 809) Clutch Plates Inspection
Inspect each plate for cracks, bent or broken
Place spring disc on a flat surface so that the outer teeth, missing or excessively worn friction mate-
circumference of the disc is flat on the surface. rial and any other damage.
Use a feeler gauge to measure warpage between Check clutch plates for warpage.
spring disc and flat surface.
Clutch plates must be free of scores and blueing
(overheating).
Inspect hardened clutch plate for wear on spring
disc side.

rmr2014-019 15
Subsection 12 (CLUTCH (SE6))

Place plates on a flat surface. Use a feeler gauge If plates are warped, damaged, or worn out of tol-
to measure warpage between plates and flat sur- erance, replace all clutch plates as a set.
face.
Clutch Plates Installation
CLUTCH PLATE WARPAGE
For installation, reverse the removal procedure.
SERVICE LIMIT 0.15 mm (.006 in) However, pay attention to the following.
First, install the clutch plate 1.9 mm (.075 in) onto
clutch hub.
Install friction plate with larger inner diameter.
NOTICE Ensure the closed side of the friction
plate tabs is facing towards the gearbox.

V02D0KA

TYPICAL

Plate warpage must not exceed service limit.

Measure the thickness of the clutch plate assem-
bly (friction and clutch plates).
NOTE: Thickness of the clutch plate assembly is rmr2014-019-042_a
measured without the spring disc and thrust 1. Closed side of the friction plate tab
washer. 2. Towards gearbox

CLUTCH PLATES ASSEMBLY THICKNESS Install thrust washer.

(FRICTION PLATES (9X) AND CLUTCH Install spring disc with convex side towards gear-
PLATES (10X))
box.
41.48 mm to 41.72 mm
NEW
(1.633 in to 1.643 in)
SERVICE LIMIT 38.50 mm (1.516 in)

rmr2014-019-043_a

TYPICAL - CORRECT SPRING DISC INSTALLATION

1. Clutch hub
2. Clutch plate, 1.9 mm (.075 in)
3. Friction plate with larger inner diameter
rmr2014-019-037_a 4. Thrust washer
5. Spring disc
1. Clutch plates (10x) 6. Hardened clutch plate, 2.1 mm (.083 in)
2. Friction plates (9x)
A. Service limit
Install hardened clutch plate.

16 rmr2014-019
 Subsection 12 (CLUTCH (SE6))

NOTICE Hardened clutch plate is color

marked.

rmr2014-019-042_a

1. Closed side of the friction plate tab

2. Towards gearbox

Place the tabs of the last friction plate into the

shorter slots of clutch drum.

rmr2014-019-036_b

1. Clutch hub
2. Clutch plate, 1.9 mm (.075 in)
3. Friction plate with larger inner diameter
4. Thrust washer
5. Spring disc
6. Hardened clutch plate, 2.1 mm (.083 in)
7. Marked with a color dot

Beginning with a friction plate, install friction

plates (8x) and clutch plates (8x) in alternate or-
der.
NOTICE Ensure the closed side of the friction
plate tabs is facing towards the gearbox.
rmr2014-019-051_a

1. Shorter slot
2. Last friction plate

Reinstall remaining parts, refer to the appropriate

instructions in this subsection.

CLUTCH HUB
Clutch Hub Removal
Remove the following items, see procedures in
this subsection:
– Clutch Cover
– Oil duct cover with hydraulic clutch cylinder
rmr2014-019-050_a

1. Friction plate (8x)

– Pressure plate
2. Clutch plate (8x) – Clutch springs
– Clutch disc assembly.
Remove plug screw with O-ring from valve train
cover.

rmr2014-019 17
Subsection 12 (CLUTCH (SE6))

rmr2014-019-030_a rmr2014-019-031_a

1. Plug screw 1. Mark on balance shaft

2. O-ring 2. Cylinder block mating surface
3. Valve train cover 3. Crankshaft locking bolt

Using the HEXAGON SOCKET WRENCH (P/N 529 Lock clutch hub.
036 287) turn crankshaft counterclockwise until
mark on balance shaft is align with cylinder block REQUIRED TOOL
mating surface. CLUTCH ASSEMBLY HOLDER
NOTE: In this position piston no.1 is in TDC posi- (P/N 529 036 292)
tion.
REQUIRED TOOL NOTE: Insert service tool completely to the bot-
tom of the clutch drum.
HEXAGON SOCKET WRENCH
(P/N 529 036 287)

Lock crankshaft.
NOTICE Ensure that service tool engages in
cylinder block bore properly.
NOTICE This locking procedure must not be
used for camshaft timing since locking position
is inadequate.
NOTE: Crankshaft also can be locked as de-
scribed in CRANKSHAFT LOCKING PROCEDURE
in the CYLINDER BLOCK subsection.
rmr2014-019-033_a
REQUIRED TOOL
1. Clutch assembly holder
CRANKSHAFT LOCKING BOLT 2. Clutch hub
3. Clutch drum
(P/N 529 036 286)
Remove:
– Clutch hub retaining nut
– Spring washer
– Clutch hub with remaining clutch plates.

18 rmr2014-019
 Subsection 12 (CLUTCH (SE6))

Clutch Hub Installation

For installation, reverse the removal procedure.
However, pay attention to following.
Ensure clutch drum thrust washer is installed on
clutch shaft ahead of clutch drum assembly be-
fore installing the clutch hub.

rmr2014-019-034_a

1. Clutch hub retaining nut

2. Spring washer
3. Clutch hub

Clutch Hub Inspection

Clean oil orifices with compressed air and check
rmr2014-019-047_a
if they are not clogged. 1. Clutch drum thrust washer

Lubricate clutch hub teeth.

CLUTCH HUB TEETH
PETAMO GREASE GHY
Service product
133N (P/N 420 899 271)

Insert the clutch hub.

rmr2014-019-039_a

INSPECT
1. Oil orifices

rmr2014-019-048_a

1. Lubricate clutch hub teeth

2. Clutch hub
3. Clutch shaft
4. Clutch drum

rmr2014-018-122_a Lock clutch hub.

INSPECT
1. Oil orifices

rmr2014-019 19
Subsection 12 (CLUTCH (SE6))

REQUIRED TOOL

CLUTCH ASSEMBLY HOLDER

(P/N 529 036 292)

NOTE: Insert service tool completely to the bot-

tom of the clutch drum.
Reinstall spring washer and hub retaining nut.

rmr2014-019-047_a

1. Clutch drum thrust washer

Remove:
– Clutch drum
– Thrust washer.
NOTE: Before removing the clutch drum it is rec-
ommended to check the sliding friction torque of
the clutch gear, refer to CLUTCH DRUM INSTAL-
LATION in this subsection.
rmr2014-019-049_a

1. Clutch assembly holder

2. Clutch hub
3. Clutch drum
4. Spring washer
5. Clutch hub retaining nut

Tighten nut to specification.

CLUTCH HUB RETAINING NUT
LOCTITE 648 (GREEN)
Service Product
(P/N 413 711 400)
170 N•m ± 10 N•m
Tightening Torque
(125 lbf•ft ± 7 lbf•ft)

Remove crankshaft locking bolt.

rmr2014-019-052_a
Reinstall remaining parts, refer to the appropriate 1. Clutch drum
instructions in this subsection. 2. Thrust washer

CLUTCH DRUM Clutch Drum Disassembly

Remove:
Clutch Drum Removal
– Retaining nuts with flat head screws
Remove the following items, see procedures in – Outer support plate
this subsection:
– Distance sleeves.
– Clutch cover
– Oil duct cover with hydraulic clutch cylinder
– Pressure plate
– Clutch springs
– Clutch disc assembly.
– Clutch hub
Remove the clutch drum thrust washer.

20 rmr2014-019
 Subsection 12 (CLUTCH (SE6))

rmr2014-019-053_a rmr2014-019-055_a

1. Retaining nuts 1. Clutch gear

2. Flat head screws 2. Springs discs
3. Outer support plate 3. Thrust washer
4. Distance sleeves 4. Inner support plate

Remove: Clutch Drum Inspection

– Anti backlash gear together with anti backlash
springs Compression Springs and Retainers
– Compression springs with their retainers. Measure free length of each compression spring,
refer to the following table.
COMPRESSION SPRINGS FREE LENGTH
NEW 29.46 mm (1.16 in)
SERVICE LIMIT 29.00 mm (1.142 in)
ANTI BACKLASH SPRING FREE LENGTH
NEW 10.99 mm (.433 in)
SERVICE LIMIT 10.50 mm (.413 in)

If a spring is out of specification, replace all

springs as well as all spring retainers.
Inspect spring retainers for wear, cracks or scor-
rmr2014-019-054_a
ing. Replace all springs and all spring retainers as
1. Anti backlash gear an assembly.
2. Anti backlash springs
3. Compression springs Support Plates
4. Spring retainers
Inspect support plates for cracks or abnormal
Remove: wear. Replace if necessary.
– Clutch gear Inspect the thrust surface of inner support plate
– Spring discs for abnormal wear or grooves. If necessary,
– Thrust washer replace inner support plate, thrust washer and
– Inner support plate. spring disc as an assembly.

rmr2014-019 21
Subsection 12 (CLUTCH (SE6))

rmr2014-019-056_a rmr2014-019-058_a

1. Inspect thrust surface of inner support plate INSPECT SLOTS IN CLUTCH DRUM FOR WEAR

Clutch Gear Inspect spring cavities for deep grooves, caused

Inspect bearing sleeve surface for scoring and by springs. Replace clutch drum if necessary.
wear. NOTE: Slight markings caused by the springs are
Measure inner diameter of bearing sleeve. normal. Do not replace clutch drum needlessly.

rmr2014-019-059_a
rmr2014-019-057_a

A. Inner diameter 1. Inspect spring cavities

1. Bearing sleeve surface
Clutch Drum Assembly
BEARING SLEEVE INNER DIAMETER
NOTICE Assembly of the clutch drum must
30.015 mm to 30.035 mm be carried out with utmost care. Failure to
NEW
(1.1817 in to 1.1825 in) strictly follow the procedures may cause parts
SERVICE LIMIT 30.040 mm (1.1827 in) to loosen and/or malfunction of the clutch
drum and may lead to serious engine damage.
Inspect teeth condition for pitting or other dam-
age. Assemble the clutch drum in the reverse order of
disassembly. However, pay attention to the fol-
Replace clutch drum drive gear if necessary. lowing details.
Clutch Drum NOTICE The position of the clutch drum,
Inspect slots in clutch drum for damages or wear support plates and clutch gear for assembly
caused by friction plates. Replace if necessary. is clearly indicated with location holes in each
part. During assembly ensure that all location
holes are aligned with each other.

22 rmr2014-019
 Subsection 12 (CLUTCH (SE6))

rmr2014-019-061_a

1. Inner support plate

rmr2014-019-060_a
2. Thrust washer
ALIGNMENT OF LOCATION HOLES FOR CLUTCH DRUM 3. Flat head screws
ASSEMBLY
1. Hole in clutch drum Apply engine oil on the spring discs.
2. Hole in inner support plate
3. Hole in clutch gear
4. Hole in anti backlash gear
Install spring discs with the concave side facing to
5. Hole in outer support plate the thrust washer.
Insert the three M8 x 28 flat head screws from the
inside of the drum. Hold the screws in position as
you install the remaining parts.
For installation align slots of thrust washer with
clutch drum ribs.

rmr2010-015-013_a

1. Concave side of spring discs

rmr2014-019-062_a

1. Clutch drum ribs

2. Slots of thrust washer

Install inner support plate on clutch drum, ensure

the location holes are aligned with each other.

rmr2014-019-063_a

1. Inner support plate

2. Spring discs

rmr2014-019 23
Subsection 12 (CLUTCH (SE6))

Install the clutch gear, ensure the location holes

are aligned with each other.
Install clutch drum springs with spring retainers
into the corresponding spring cavities.
Apply engine oil on contact surface between
clutch gear and anti backlash gear.

rmr2014-019-065_a

1. Distance sleeves
2. Outer support plate
3. Location holes

Tighten nuts to specification.

CLUTCH DRUM NUTS
LOCTITE 648 (GREEN)
Service product
rmr2014-019-069_a (P/N 413 711 400)
1. Clutch gear Tightening torque - 11 N•m ± 1 N•m
2. Lubricate contact surface
3. Location hole STEP A (97 lbf•in ± 9 lbf•in)
4. Clutch drum springs
5. Spring retainers Tightening torque - 29 N•m ± 1 N•m
STEP B (21 lbf•ft ± 1 lbf•ft)
Install anti backlash gear.
NOTICE Ensure that location holes are Clutch Drum Installation
aligned and mark "THIS SIDE VISIBLE" is For installation, reverse the removal procedure.
visible. However, pay attention to the following.
Install anti backlash springs into corresponding Insert the first thrust washer on the clutch shaft
spring cavities. before installing clutch drum.

rmr2014-019-064_a rmr2014-019-066_a

1. Anti backlash gear 1. Thrust washer

2. Anti backlash springs
Apply engine oil on distance sleeves and install
them on clutch drum screws, then outer support
plate. Ensure that the location holes aligned with
each other.
Install clutch drum on the clutch shaft:
1. Engage anti backlash gear in primary drive gear.
2. Turn clutch hub counterclockwise to align
clutch gear with primary drive gear.

24 rmr2014-019
 Subsection 12 (CLUTCH (SE6))

REQUIRED TOOL
CLUTCH HUB TURNING TOOL
(P/N 529 036 291)

3. Push clutch hub completely down.

rmr2014-019-068_a

1. Spring retainers
2. Clutch drum side surface

There must be sliding friction torque between the

contacts.
If free-play has been detected, inspect all clutch
rmr2014-019-067_a drum components (e.g. spring disc, thrust
1. Clutch hub turning tool washer, inner support plate). Refer to CLUTCH
2. Clutch drum DRUM INSPECTION in this subsection.
3. Primary drive gear
Install the clutch drum thrust washer on clutch
After installation of the clutch drum check for slid- shaft.
ing friction torque of the clutch drum to the clutch
gear:
1. Ensure crankshaft is still locked.
2. Turn clutch drum in both directions until spring
retainers contact the clutch drum side surface.
REQUIRED TOOL
CLUTCH HUB TURNING TOOL
(P/N 529 036 291)

rmr2014-019-047_a

1. Clutch drum thrust washer

Install clutch hub and all remaining parts. See pro-

cedures in this subsection.

rmr2014-019-067_b

CHECK FOR SLIDING FRICTION TORQUE

1. Turn in both directions

rmr2014-019 25
 Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

HYDRAULIC CONTROL MODULE (SE6)

SERVICE TOOLS
Description Part Number Page
CLUTCH COVER HOLDING DEVICE ............................................ 529 036 294 ........................................... 11

NEW

6 ± 0.7 N•m
11 ± 1 N•m (53 ± 6 lbf•in)
(97 ± 9 lbf•in) Engine oil
Engine oil 11 ± 1 N•m
(97 ± 9 lbf•in)

14 ± 1 N•m
(124 ± 9 lbf•in)
5 ± 0.6 N•m
NEW (44 ± 5 lbf•in)

NEW

Engine oil

NEW

11 ± 1 N•m
(97 ± 9 lbf•in)

NEW = Component must be replaced when removed.

rmr2014-020-001_a

rmr2014-020 1
Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))
GENERAL
Always disconnect the negative battery cable be-
fore working on the engine.
WARNING
Always disconnect the BLACK (-) cable first
and reconnect last.
Always carry out electrical tests on components
before removing or installing them to ensure their
state of operation.
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a thread locker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
SYSTEM DESCRIPTION
(COMPONENTS)
The gear shifting and clutch clamping system of
the SE6 engine is map-controlled by the transmis-
sion control module (TCM).
The transmission control module (TCM) manages
4 solenoid valves located on the hydraulic control
module (HCM).
These solenoid valves command pilot pressure to
actuate spool valves which are installed inside the
HCM. The spool valves allow opening and closing
of connections between hydraulic channels by us-
ing longitudinal control forces.
2 rmr2014-020
rmr2014-20-003_a
1. Transmission control module (TCM)
2. Hydraulic control module (HCM)
3. Solenoid valves
4. Clutch pressure sensor
5. Oil temperature sensor
6. Clutch piston
7. Shift piston
8. Gearbox
9. CAN network
10. Battery power
HCM Oil Circuit
The pressure pump is integrated in the HCM and
is driven by the balancer shaft.
The suction side of the pressure pump sucks en-
gine oil from the oil tank through an oil sieve lo-
cated in the oil pan for pre-filtering the engine oil.
Engine oil exits the cylinder block, passes the
HCM and goes straight to the suction type HCM
oil filter which is located onto the clutch cover.
Filtered engine oil enters to suction side of the
HCM pressure pump.
The pressure pump generates pressured engine
oil required for the clutch clamping and gear shift-
ing functionality.
The temperature sensor is mounted on the pres-
sure pump inlet and measures the oil temperature
entering the pressure pump.
The oil temperature value is used to determine
which map should be used for the pressure con-
trol.
The clutch pressure sensor is measuring the main
oil pressure entering the clutch piston and is lo-
cated outside the clutch cover.
Both sensors are also used for monitoring and di-
agnostic purposes.
The HCM includes 2 different oil circuits:
– Line Pressure Oil Circuit which is adjusted from
600 kPa to 1 200 kPa (87 PSI to 174 PSI)
– Pilot Pressure Oil Circuit which is adjusted from
0 kPa to 500 kPa (0 PSI to 73 PSI).
 Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))
Pilot Pressure Circuit
Line pressure oil of 600 kPa to 1 200 kPa
(87 PSI to 174 PSI) is directed to the pressure
regulator spool valve (V5) which regulates the line
pressure to a pilot pressure of 500 kPa (73 PSI). In
the pilot circuit solenoid valves regulate the pilot
pressure from 0 kPa to 500 kPa (0 PSI to 73 PSI)
for actuating the spool valves.
The pilot pressure circuit has an additional oil sieve
and a check valve which prevents draining the oil
tank after the engine is switched off.
Following proportional acting solenoid valves are
involved in the pilot pressure circuit:
– The line pressure solenoid valve (V1) triggers pi-
lot pressure oil to move the line pressure spool
(V11). The line pressure spool (V11) adjusts the
line pressure between 600 kPa and 1 200 kPa
(87 PSI and 174 PSI).
– The clutch pressure solenoid valve (V2) trig-
gers pilot pressure oil to move the Clutch
Spool Valve (V21). The clutch spool valve (V21)
controls the pressure on the clutch piston by
regulating the line pressure oil. The clutch
clamping force is proportional to the pressure
on the clutch piston.
Both solenoid valves are conducting pilot pressure
oil between 0 kPa and 500 kPa (0 PSI and 73 PSI)
directly proportional to the solenoid current.
Line Pressure Circuit
The line pressure circuit is providing oil to the
spool valves and also to the clutch and gear shift-
ing piston.
After pressure pump exit, pressure oil is adjusted
from 600 kPa to 1 200 kPa (87 PSI to 174 PSI) by
the line pressure spool valve (V11), excessive
oil is directed back to the suction side of the oil
pump.
The spool valves are actuated by the pilot pres-
sures.
The line pressure spool valve (V11) is controlled by
the line pressure solenoid valve (V1) by using pilot
pressure oil.
A safety valve (V6) releases line pressure oil to the
oil tank to avoid damages due to excessive pres-
sure.
rmr2014-020
Following ON/OFF acting solenoid valves are in-
volved in the line pressure circuit:
– The shifting UP solenoid valve (V4) releases line
pressure oil to move the shifting spool valve
(V34). The shifting spool valve (V34) then re-
leases line pressure oil to the shifting piston
which then moves the shift actuating lever for
turning the shift shaft and shifting up to the next
gear.
– The shifting DOWN solenoid valve (V3) releases
line pressure oil to move the shifting spool valve
(V34) with line pressure oil. The shifting spool
valve (V34) then releases line pressure oil to the
shifting piston which then moves the shift actu-
ating lever for turning the shift shaft and shifting
down to the next gear.
Furthermore the clutch spool valve (V21) regu-
lates line pressure oil to supply clutch piston for
clutch clamping.
rmr2014-20-002_a
1. Gerotor type pressure pump
2. Pressure regulator spool valve (V5)
3. Oil sieve in line pressure oil circuit
4. Check valve prevents draining of line pressure oil circuit
5. Line pressure solenoid valve (V1)
6. Line pressure spool valve (V11)
7. Clutch pressure solenoid valve (V2)
8. Clutch spool valve (V21)
9. Safety valve for main pressure circuit
10. Shifting UP solenoid valve (V4)
11. Shifting spool valve (V34)
12. Shifting DOWN solenoid valve (V3)
13. Shifting piston
14. Shift actuating lever
NOTICE For Troubleshooting guidelines refer
to ELECTRONIC SHIFT SYSTEM (SE6) subsec-
tion.
3
Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

SYSTEM DESCRIPTION (PRINCIPLE OF OPERATION)

The HCU functions with a double pressure stage piloted spool valves concept.
The pilot circuit is made of solenoid valves commanding pilot pressure to actuate the spool valves. The
pilot circuit is a 0 kPa - 500 kPa (0 PSI - 72.52 PSI) circuit.
The main circuit is providing actuation oil pressure to the spool valves. The main oil circuit is a
0 kPa - 1 200 kPa (0 PSI - 174.05 PSI) circuit.
The spool valve is a cylindrical part with different diameters, which matches precisely its mating bores
in the HCU. In response to different longitudinal forces (from return spring, pilot pressure and feedback
pressure), the spool will move along its bore, opening and closing connections between hydraulic chan-
nels. Using piloted spool valves instead of direct acting solenoid valves makes it possible to use smaller
solenoids while guaranteeing high flow rates.
The solenoid valves are used to create the necessary pilot pressure to actuate the spool valves. Two
types are used in the HCU. The ON/OFF type solenoids are sending line pressure when actuated,
and0 kPa (0 PSI) pressure when turned off. They are used for actuating the shifting spool valve. The
proportional solenoids are sending a pilot pressure between 0 kPa - 500 kPa (0 PSI - 72.52 PSI) directly
proportional to the solenoid current. They are used to actuate the clutch pressure and line pressure
spool valves.

4 rmr2014-020
 Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

Hydraulic Operation When Engine is OFF

15 7

A
B
5 6
C
9
D 10
E

13
2 4 12 14

11
1

rmr2014-020-206_a

ENGINE OFF
A. Line pressure (0 kPa - 1 200 kPa (0 PSI - 174 PSI))
B. Valve not activated
C. Pilot pressure circuit (0 kPa - 500 kPa (0 PSI - 72.5 PSI))
D. Return to oil tank
E. Clutch pressure (0 kPa - 1 200 kPa (0 PSI - 174 PSI))
1. Oil Tank
2. Filter
3. Oil Pump
4. Safety Valve
5. Line Pressure Spool
6. Pressure Regulator Spool
7. Line Pressure Valve (Proportional)
8. Clutch Spool
9. Clutch Pressure Valve (Proportional)
10. Clutch Assembly
11. Up Shift Valve (ON - OFF)
12. Down Shift Valve (ON - OFF)
13. Shifting Spool
14. Shift Shuttle
15. Pilot Pressure Circuit (0 - 5 bar)

rmr2014-020 5
Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

Hydraulic Operation When Engine is Running (Idling)

15 7

A
B
5 6
C
9
D 10
E

13
2 4 12 14

11
1

rmr2014-020-207_a

ENGINE RUNNING (IDLING)

A. Line pressure (0 kPa - 1 200 kPa (0 PSI - 174 PSI))
B. Valve not activated
C. Pilot pressure circuit (0 kPa - 500 kPa (0 PSI - 72.5 PSI))
D. Return to oil tank
E. Clutch pressure (0 kPa - 1 200 kPa (0 PSI - 174 PSI))
1. Oil Tank
2. Filter
3. Oil Pump
4. Safety Valve
5. Line Pressure Spool
6. Pressure Regulator Spool
7. Line Pressure Valve (Proportional)
8. Clutch Spool
9. Clutch Pressure Valve (Proportional)
10. Clutch Assembly
11. Up Shift Valve (ON - OFF)
12. Down Shift Valve (ON - OFF)
13. Shifting Spool
14. Shift Shuttle
15. Pilot Pressure Circuit (0 - 5 bar)

6 rmr2014-020
 Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

Hydraulic Operation when Shifting Occurs (Upshift)

15 7

A
B
5 6
C
9
D 10
E

13
2 4 12 14

11
1

rmr2014-020-208_a

CLUTCH ENGAGE
A. Line pressure (0 kPa - 1 200 kPa (0 PSI - 174 PSI))
B. Valve not activated
C. Pilot pressure circuit (0 kPa - 500 kPa (0 PSI - 72.5 PSI))
D. Return to oil tank
E. Clutch pressure (0 kPa - 1 200 kPa (0 PSI - 174 PSI))
1. Oil Tank
2. Filter
3. Oil Pump
4. Safety Valve
5. Line Pressure Spool
6. Pressure Regulator Spool
7. Line Pressure Valve (Proportional)
8. Clutch Spool
9. Clutch Pressure Valve (Proportional)
10. Clutch Assembly
11. Up Shift Valve (ON - OFF)
12. Down Shift Valve (ON - OFF)
13. Shifting Spool
14. Shift Shuttle
15. Pilot Pressure Circuit (0 - 5 bar)

rmr2014-020 7
Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

15 7

A
B
5 6
C
9
D 10
E

13
2 4 12 14

11
1

rmr2014-020-209_a

UPSHIFT 1 OF 2
A. Line pressure (0 kPa - 1 200 kPa (0 PSI - 174 PSI))
B. Valve not activated
C. Pilot pressure circuit (0 kPa - 500 kPa (0 PSI - 72.5 PSI))
D. Return to oil tank
E. Clutch pressure (0 kPa - 1 200 kPa (0 PSI - 174 PSI))
1. Oil Tank
2. Filter
3. Oil Pump
4. Safety Valve
5. Line Pressure Spool
6. Pressure Regulator Spool
7. Line Pressure Valve (Proportional)
8. Clutch Spool
9. Clutch Pressure Valve (Proportional)
10. Clutch Assembly
11. Up Shift Valve (ON - OFF)
12. Down Shift Valve (ON - OFF)
13. Shifting Spool
14. Shift Shuttle
15. Pilot Pressure Circuit (0 - 5 bar)

8 rmr2014-020
 Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

15 7

A
B
5 6
C
9
D 10
E

13
2 4 12 14

11
1

rmr2014-020-210_a

UPSHIFT 2 OF 2
A. Line pressure (0 kPa - 1 200 kPa (0 PSI - 174 PSI))
B. Valve not activated
C. Pilot pressure circuit (0 kPa - 500 kPa (0 PSI - 72.5 PSI))
D. Return to oil tank
E. Clutch pressure (0 kPa - 1 200 kPa (0 PSI - 174 PSI))
1. Oil Tank
2. Filter
3. Oil Pump
4. Safety Valve
5. Line Pressure Spool
6. Pressure Regulator Spool
7. Line Pressure Valve (Proportional)
8. Clutch Spool
9. Clutch Pressure Valve (Proportional)
10. Clutch Assembly
11. Up Shift Valve (ON - OFF)
12. Down Shift Valve (ON - OFF)
13. Shifting Spool
14. Shift Shuttle
15. Pilot Pressure Circuit (0 - 500kPa)

rmr2014-020 9
Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

MAINTENANCE
HCM OIL FILTER
The HCM oil filter is a suction type filter and is
included in the oil filter cover assembly.

1. Oil filter cover screws

2. Oil filter cover assembly

Dispose oil filter cover assembly as per your local

environmental regulations.

HCM Oil Filter Installation

The installation is the reverse of the removal pro-
1. Oil filter cover assembly cedure. Pay attention to the following.
NOTE: The HCM uses the same oil as the engine, Check and clean the oil inlet and outlet orifices
but has its own oil filter. in clutch cover for dirt and contaminations. Refer
to CLUTCH COVER in the CLUTCH (SE6) subsec-
HCM Oil Filter Removal tion.
NOTE: Replace HCM oil filter frequently. Refer to Install oil filter cover assembly and tighten as per
MAINTENANCE SCHEDULE subsection. following sequence.
NOTICE Replace HCM oil filter also in case of
contamination with particles as a result of se-
rious engine damage.
Drain engine oil. Refer to LUBRICATION SYSTEM
subsection.
Remove:
– Oil filter cover screws
– Oil filter cover assembly.

TIGHTENING SEQUENCE

OIL FILTER COVER SCREWS

11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

Activate venting of HCM oil circuit. Refer to vent-

ing procedure in ELECTRONIC SHIFT SYSTEM
(SE6) subsection.

10 rmr2014-020
 Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

INSPECTION HYDRAULIC CONTROL MODULE

(HCM)
PROCEDURES
HCM Access
HCM OIL STRAINER Refer to BODY and remove the following panels
on the RH side:
HCM Oil Strainer Location – Middle side panel
The oil strainer for the suction circuit of the HCM – Top side panel
is located in the oil sump cover. – Bottom rear side panel
– Bottom front side panel
– Rear side panel
– Middle side panel support
– Lateral frame support.

HCM Removal
Make sure gearbox is on N position.
Disconnect HCM and clutch pressure sensor con-
nector.

rmr2014-011-072_b

1. HCM oil strainer

HCM Oil Strainer Inspection

NOTE: The oil sieve needs to be cleaned in case
of serious engine damage with result of contami-
nation.
For removal and installation procedure refer to
OIL SUMP COVER in the LUBRICATION SYSTEM
subsection. rmr2014-019-009_b

1. HCM connector
2. Clutch pressure sensor connector
SHIFT, CLUTCH AND LINE 3. Clutch cover
PRESSURE SOLENOIDS Remove clutch cover. Refer to CLUTCH (SE6)
Solenoid Access subsection.
Refer to BODY and remove the following panels Fix clutch cover holder in a vice and attach clutch
on the RH side: cover using 3 clutch cover bolts.
– Middle side panel REQUIRED TOOL
– Top side panel
– Bottom rear side panel CLUTCH COVER HOLDING
– Bottom front side panel DEVICE (P/N 529 036 294)
– Rear side panel
– Middle side panel support
– Lateral frame support.

Solenoid Replacement
Replace hydraulic control module (HCM). Refer to
procedure in this subsection.

rmr2014-020 11
Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

rmr2014-019-007_a

1. Clutch cover holder 1. Screw

2. Clutch cover 2. Oil temperature sensor
3. Clutch cover bolts (3x) 3. HCM

Remove shift actuating lever assembly. Refer to Disconnect all both shift solenoid connectors (V3
GEARBOX subsection. and V4) and place wiring harness together with
Disconnect the line pressure solenoid connector the oil temperature sensor towards outside.
(V1) and clutch pressure solenoid connector (V2).

1. Shift solenoid connectors V3

2. Shift solenoid connectors V4
3. HCM
1. Line pressure solenoid connector (V1)
2. Clutch pressure solenoid connector (V2)
3. HCM Remove:
– HCM screws
Remove screw and pull oil temperature sensor
out from its bore in the HCM. – HCM together with the suction pump (located
in the back side of the HCM)

12 rmr2014-020
 Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

HCM Installation
The installation is the reverse of the removal pro-
cedure. Pay attention to the following.
Install oil scavenge pump (clutch side) into HCM,
refer to OIL SCAVENGE OIL PUMP (CLUTCH
SIDE) in the LUBRICATION SYSTEM subsection.
Install NEW gaskets in the HCM.

1. Screws
2. HCM
3. Clutch cover

Remove:
– Gaskets (discard them)
– Oil scavenge oil pump (clutch side) from back-
side of HCM. Refer to OIL SCAVENGE OIL
PUMP (CLUTCH SIDE) in the LUBRICATION
SYSTEM subsection.

1. Gaskets
2. Oil scavenge oil pump (clutch side)
3. HCM

Install HCM into clutch cover and tighten screws

as per following sequence.
NOTICE Take care not to damage wiring har-
ness and oil temperature sensor during assem-
bly.

1. Gaskets (discard them)

2. Oil scavenge oil pump (clutch side)
3. HCM

HCM Inspection
If any solenoid valves are defective or if shifting
problems occur caused by the HCM replace HCM
assembly.
For Troubleshooting guidelines refer to ELEC-
TRONIC SHIFT SYSTEM (SE6) subsection.
HCM TIGHTENING SEQUENCE
Clean and inspect clutch cover, refer to CLUTCH
COVER in the CLUTCH (SE6) subsection.

rmr2014-020 13
Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

HCM SCREWS
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

Connect both gearshift solenoid valves (V3 and

V4).
NOTE: The cables shall not touch the HCM and
the clutch cover.
NOTICE Do not interchange the wiring har-
ness connectors. Green cables of the gearshift
solenoid valve connectors must face each
other.
1. O-rings
2. Oil temperature sensor
3. Oil temperature sensor screw

OIL TEMPERATURE SENSOR SCREW

11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

Connect line pressure solenoid connector (V1) and

clutch pressure solenoid connector (V2).
NOTICE Do not interchange the wiring har-
ness connectors. Green cables of the pressure
solenoid connectors must face each other.

1. Gearshift solenoid valves (V3)

2. Gearshift solenoid valves (V4)
3. Green wires
4. Red wires

Apply engine oil on O-rings and install oil temper-

ature sensor.
Locate the oil temperature sensor cable behind
the HCM.
Tighten oil temperature sensor screw to specifica-
tion.

1. Line pressure solenoid connector (V1)

2. Clutch pressure solenoid connector (V2)
3. Green wires
4. Red wires

Install shift actuating lever assembly, refer to

GEARBOX subsection.
Install clutch cover, refer to CLUTCH (SE6) sub-
section.
Reconnect clutch pressure sensor and HCM con-
nector.

14 rmr2014-020
 Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

Remove HCM, see procedure in this subsection.

Remove nut from HCM connector.

rmr2014-019-009_b

1. HCM connector
2. Clutch pressure sensor connector
3. Clutch cover

Refill engine oil, refer to LUBRICATION SYSTEM

subsection.
Activate venting of HCM oil circuit. Refer to vent-
ing procedure in ELECTRONIC SHIFT SYSTEM
(SE6) subsection. 1. Nut
2. HCM connector

OIL TEMPERATURE SENSOR Remove wiring harness with oil temperature sen-
(OTS) AND HCM WIRING sor.
HARNESS
The oil temperature sensor is included in the
wiring harness and is mounted in the HCM near
the HCM pressure pump.
Refer to ELECTRONIC SHIFT SYSTEM (SE6) for
testing procedures.

Oil Temperature Sensor (OTS) and

HCM Wiring Harness Removal
Make sure gearbox is on N position.
Disconnect HCM and clutch pressure sensor con-
nector.

1. Wiring harness
2. Oil temperature sensor
3. Clutch cover

Oil Temperature Sensor (OTS) and

HCM Wiring Harness Installation
The installation is the reverse of the removal pro-
cedure. Pay attention to the following.
Install NEW O-ring on HCM connector and apply
rmr2014-019-009_b
engine oil on it.
1. HCM connector Insert HCM connector through the bore from in-
2. Clutch pressure sensor connector
3. Clutch cover side the clutch cover.

Remove clutch cover. Refer to CLUTCH (SE6) NOTICE Align flat surface of clutch cover
subsection. with flat surface of HCM connector.
rmr2014-020 15
Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

CLUTCH PRESSURE SENSOR

(OPS)
Clutch Pressure Sensor Access
Refer to BODY and remove the following panels
on the RH side:
– Middle side panel
– Top side panel
– Bottom rear side panel
– Bottom front side panel
– Rear side panel
– Middle side panel support
– Lateral frame support.

Clutch Pressure Sensor Removal

Disconnect clutch pressure sensor.
1. Flat surface of clutch cover bore

Tighten nut to specification.

1. OPS connector
2. Clutch cover

Place an oil pan below the clutch pressure sensor.

Unscrew clutch pressure sensor and discard its
1. Nut O-ring.
2. HCM connector

WIRING HARNESS NUT

5 N•m ± 0.6 N•m
Tightening torque
(44 lbf•in ± 5 lbf•in)

Install HCM, refer to procedure in this subsection.

Install clutch cover, refer to CLUTCH (SE6) sub-
section.
Refill engine oil, refer to LUBRICATION SYSTEM
subsection.
Activate venting of HCM oil circuit. Refer to vent-
ing procedure in ELECTRONIC SHIFT SYSTEM
(SE6) subsection.

16 rmr2014-020
 Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

PRESSURE SENSOR HOUSING

Pressure Sensor Housing Removal
Remove clutch pressure sensor. Refer to proce-
dure in this subsection.
Remove:
– Pressure sensor housing screws
– Pressure sensor housing
– Gasket (discard it).

1. OPS
2. O-ring (discard it)
3. Pressure sensor housing

Clutch Pressure Sensor Installation

The installation is the reverse of the removal pro-
cedure. Pay attention to the following.
Install a NEW O-ring onto the clutch pressure sen-
sor.
Screw clutch pressure sensor into pressure sen-
sor housing and tighten to specification.

1. Screws
2. Pressure sensor housing
3. Gasket (discard it)

Pressure Sensor Housing Inspection

Clean pressure sensor housing in a solvent and
blow out oil bore with compressed air.
Check pressure sensor housing for damages.

1. Clutch pressure sensor

2. O-ring
3. Pressure sensor housing

CLUTCH PRESSURE SENSOR

14 N•m ± 1 N•m
Tightening torque
(124 lbf•in ± 9 lbf•in)

rmr2014-020 17
Subsection 13 (HYDRAULIC CONTROL MODULE (SE6))

1. Oil bores
2. Pressure sensor housing

Pressure Sensor Housing Installation

The installation is the reverse of the removal pro-
cedure. Pay attention to the following.
Install a NEW gasket and tighten pressure sensor
housing to specification.

1. Gasket
2. Pressure sensor housing
3. Screws

PRESSURE SENSOR HOUSING SCREWS

11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

18 rmr2014-020
 Subsection 14 (GEARBOX)

GEARBOX
SERVICE TOOLS
Description Part Number Page
CLUTCH COVER HOLDING DEVICE ............................................ 529 036 294 ........................................... 15
CRANKCASE SEAL PUSHER ........................................................ 529 036 092 ........................................... 10
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 7
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ..................................... 10–11
GEARBOX HOLDING DEVICE....................................................... 529 036 296 ..................................... 19, 33
HANDLE ........................................................................................ 420 877 650 ............................................. 9
INDEX SHIM HOLDING DEVICE................................................... 529 036 293 ..................................... 12, 15
MAIN SHAFT PROTECTOR........................................................... 529 036 123 ............................................. 9
MAIN SHAFT SEAL INSTALLER ................................................... 529 036 088 ............................................. 9
OIL SEAL INSTALLER ................................................................... 529 036 070 ............................................. 9
PROTECTION SLEEVE .................................................................. 529 036 071 ............................................. 9

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
SNAP-ON SNAP RING PLIERS ..................................................... SRP3 ............................... 23–24, 33

SERVICE PRODUCTS
Description Part Number Page
DOW CORNING 111 ..................................................................... 413 707 000 ............................................. 9
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ......... 9, 14, 18, 28, 32, 36–37
LOCTITE 5910 ............................................................................... 293 800 081 ..................................... 35, 37
LOCTITE 648 (GREEN) .................................................................. 413 711 400 ............................... 14–15, 18
LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ........................................... 25

rmr2014-021 1
Subsection 14 (GEARBOX)

7 ± 1 N•m
(62 ± 9 lbf•in)

NEW
1.8 ± 0.2 N•m
(16 ± 2 lbf•in)

NEW = Component must be replaced when removed.

rmr2014-021-100_a

2 rmr2014-021
 Subsection 14 (GEARBOX)

NEW

Engine oil

Engine oil

NEW

Engine oil
Engine oil
NEW
Engine oil
Engine oil
Engine oil
17 ± 1 N•m
11 ± 1 N•m (150 ± 9 lbf•in)
(97 ± 9 lbf•in)
Engine oil NEW

Engine oil
Engine oil

Engine oil
Engine oil
Loctite 243

NEW = Component must be replaced when removed.

rmr2014-021-001_a

rmr2014-021 3
Subsection 14 (GEARBOX)

24 ± 2 N•m
(18 ± 1 lbf•ft)
Loctite 243

Engine oil
NEW 60 ± 2 N•m
NEW (44 ± 1 lbf•ft)

Engine oil

8,5 ± 0,5 N•m

(75 ± 4 lbf•in) Loctite 5910

Loctite 243
11 ± 1 N•m Loctite 648
Loctite 243 (97 ± 9 lbf•in)

60 ± 2 N•m
(44 ± 1 lbf•ft)

Loctite 5910 Loctite 243 11 ± 1 N•m NEW

(97 ± 9 lbf•in)

11 ± 1 N•m
(97 ± 9 lbf•in)
Engine oil

SE 6
11 ± 1 N•m only
(97 ± 9 lbf•in)
Multi purpose grease LS3
6 ± 0,7 N•m
Loctite 243 (53 ± 6 lbf•in)

NEW = Component must be replaced when removed.

rmr2014-021-002_a

4 rmr2014-021
 Subsection 14 (GEARBOX)

SE 6
only

11 ± 1 N•m
(97 ± 9 lbf•in)

NEW Loctite 648

Engine oil

NEW
Loctite 243
Loctite 243 11 ± 1 N•m
(97 ± 9 lbf•in)
Loctite 243
11 ± 1 N•m
(97 ± 9 lbf•in)
Engine oil

30 ± 3 N•m 11 ± 1 N•m
(22 ± 2 lbf•ft) (97 ± 9 lbf•in)

Loctite 648 NEW

NEW
Engine oil

Loctite 243

11 ± 1 N•m
(97 ± 9 lbf•in)

Engine oil

NEW = Component must be replaced when removed.

rmr2014-021-003_a

rmr2014-021 5
Subsection 14 (GEARBOX)
GENERAL
NOTE: For a better understanding, the following
illustrations are taken with engine out of vehicle.
However, it is not always necessary to remove en-
gine from vehicle to perform some instructions.
Always disconnect the BLACK (-) cable from the
battery before working on the engine.
WARNING
Always disconnect BLACK (-) cable first and
reconnect last.
During assembly/installation, use torque values
and service products as in the exploded views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
NOTICE Hoses, cables or locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.
TROUBLESHOOTING
TROUBLESHOOTING
GUIDELINES
Gearbox Does not Shift Into Reverse
SM6 Models
Check fuse F7 of the front fuse box.
Check REVERSE ACTUATOR CABLE ADJUST-
MENT. See procedure in this subsection.
SM6 and SE6 Models
Carry out a REVERSE BUTTON TEST WITH
B.U.D.S. See procedure in this subsection.
Error Code (E) Displayed in Gauge
1. Proceed with ECM FIRST INITIALIZATION.
Refer to ELECTRONIC FUEL INJECTION (EFI)
subsection.
2. Check GBPS. See GEARBOX POSITION SEN-
SOR TEST in this subsection.
6 rmr2014-021
3. On SE5 models, inspect HCM operation. Refer
to HYDRAULIC CONTROL MODULE (SE5) sub-
section.
PROCEDURES
REVERSE BUTTON
Reverse Button Test with B.U.D.S.
Connect vehicle to B.U.D.S.
Select the TCM tab in the Monitoring page.
Check the Switch Inputs.
If LED turns ON when the reverse button is
pressed in, it indicates that the button sends the
message.
– On SM6 model, carry out the REVERSE ACTU-
ATOR ACTIVATION WITH B.U.D.S. in this sub-
section.
– On SE6 model, verify the shift system oper-
ation. Refer to ELECTRONIC SHIFT SYSTEM
(SE6) and HYDRAULIC CONTROL MODULE
(SE6) subsections.
If LED does not turn ON when reverse button is
pressed in:
– Check left multifunction switch (MSL), refer to
LIGHTS, GAUGE AND ACCESSORIES subsec-
tion.
GEARBOX POSITION SENSOR
(GBPS)
GBPS Reset
To reset GBPS, refer to ECM FIRST INITIALIZA-
TION in the ELECTRONIC FUEL INJECTION (EFI)
subsection.
GBPS Test
Check fault codes in B.U.D.S. software.
Ensure vehicle is on NEUTRAL.
Unplug the GBPS connector.
Perform the following tests.
 Subsection 14 (GEARBOX)

GBPS Input Voltage Test RESISTANCE

MULTIMETER PROBE
@ 20°C
MULTIMETER PROBE POSITIONS VOLTAGE POSITIONS
(68°F)
GBPS connector (pin 1) and GBPS GBPS connector (pin 2) and ECM
connector (pin 3) adapter tool on ECM A (pin F4)

Below 1
5 volts

If resistance is out of specification, check wires

If voltage is adequate, check GBPS communica- and connector pins. Repair and reset fault codes.
tion link (CAN). If resistance is good, replace the GBPS and reset
If there is no voltage, check each GBPS input as fault codes.
follows.
GBPS Removal
MULTIMETER PROBE POSITIONS VOLTAGE
Make sure that gearbox is in NEUTRAL position.
GBPS connector (pin 1) and
battery ground Disconnect GBPS
Remove GBPS screws.
Remove the GBPS.
5 volts

GBPS connector (pin 3) and

battery + terminal

Battery
voltage

If there is no voltage, check wires and connector rmr2014-021-005_a

pins. 1. Screws
2. Gearbox position sensor (GBPS)
Replace or repair defective parts and reset fault
codes. GBPS Installation
GBPS Communication Link Continuity Test For installation reverse the removal procedure.
Unplug “A” connector from ECM and connect it However, pay attention to the following.
to the adapter. Align GBPS with the flat on the shift drum shaft.
REQUIRED TOOL

ECM ADAPTER TOOL

(P/N 529 036 166)

rmr2014-021 7
Subsection 14 (GEARBOX)

rmr2014-021-006_a rmr2014-021-007_a

1. Flat on shift drum shaft 1. Main shaft oil seal

Proceed with ECM FIRST INITIALIZATION in the
ELECTRONIC FUEL INJECTION (EFI) subsection.
OIL SEALS
Oil Seals Access
Main Shaft Oil Seal
Remove FRONT SPROCKET. Refer to DRIVE
BELT AND REAR WHEEL subsection.
Gear Locking Shaft Oil Seal
Refer to BODY and remove the following:
– Rear side panel
– Bottom rear side panel.
2. Gear locking shaft oil seal
3. Shift shaft oil seal
4. Shift drum shaft oil seal (underneath GBPS)
Oil Seals Inspection
Replace oil seals if they are brittle, hard or dam-
aged.
Check running surface of shafts for scratches. Re-
place if necessary, refer to SHIFTING SYSTEM or
GEARBOX in this subsection.
Oil Seals Removal
Use a small flat screwdriver to remove oil seals.
NOTICE Avoid scoring surfaces when replac-
ing oil seals.

Shift Shaft Oil Seal Gear Locking Shaft Oil Seal

Remove:
SM6 Models
– Control lever screw
Remove gearshift lever.
– Washer
SE6 Models – Control lever
Refer to BODY and remove the following: – Spring.
– Rear side panel
– Bottom rear side panel.
Shift Drum Shaft Oil Seal
Remove the GEARBOX POSITION SENSOR. See
procedure in this subsection.

8 rmr2014-021
 Subsection 14 (GEARBOX)

REQUIRED TOOL
PROTECTION SLEEVE
(P/N 529 036 071)

Push oil seal into place.

REQUIRED TOOL
OIL SEAL INSTALLER
(P/N 529 036 070)

Install control lever spring as shown in the next

illustration.
Place control lever onto spring hook and tighten
rmr2014-021-008_a
control lever screw to specification.
1. Control lever screw
2. Washer NOTE: The slot of the control lever must shown
3. Control lever
4. Spring towards the outside.

Oil Seals Installation

NOTICE All oil seals must be installed with
sealing lip towards gearbox.
Lubricate each oil seal inside.
OIL SEALS LUBRICATION
DOW CORNING 111
Service product
(P/N 413 707 000)

After oil seal installation proceed with assembly of

removed parts.
For installation reverse the removal procedure.
However, pay attention to the following. rmr2014-021-009_a

1. Engage control lever spring end here

Main Shaft Oil Seal 2. Spring hook
3. Control lever
Protect main shaft (PTO side) and move oil seal on 4. Slot
shaft.
CONTROL LEVER SCREW
REQUIRED TOOL
LOCTITE 243 (BLUE)
Service product
MAIN SHAFT PROTECTOR (P/N 293 800 060)
(P/N 529 036 123)
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)
Push oil seal in place.
REQUIRED TOOL Shift Shaft Oil Seal
Protect gear locking shaft and move oil seal on
MAIN SHAFT SEAL INSTALLER
(P/N 529 036 088)
shaft.
REQUIRED TOOL
HANDLE (P/N 420 877 650)
PROTECTION SLEEVE
(P/N 529 036 071)
Gear Locking Shaft Oil Seal
Protect gear locking shaft and move oil seal on Push oil seal into place.
shaft. REQUIRED TOOL
OIL SEAL INSTALLER
(P/N 529 036 070)

rmr2014-021 9
Subsection 14 (GEARBOX)

Shift Drum Shaft Oil Seal Reverse Actuator Input Voltage Test
Put oil seal on shift drum shaft and push oil seal 1. Make sure fuse F7 is good.
into place. 2. Disconnect the reverse actuator connector.
REQUIRED TOOL
CRANKCASE SEAL PUSHER
(P/N 529 036 092)

REVERSE ACTUATOR (SM6

MODEL)
Reverse Actuator Access
Refer to BODY subsection and remove the follow-
ing panels:
– LH rear side panel
– LH bottom rear side panel.
rmr2014-021-101_a
Reverse Actuator Activation with 1. Reverse actuator connector
B.U.D.S.
3. Set the multimeter to Vdc.
1. Connect vehicle to B.U.D.S.
2. Select the Activation and ACC tabs. REQUIRED TOOL
3. Keep an eye on the reverse actuator. FLUKE 115 MULTIMETER
4. Click on the Reverse actuator button. (P/N 529 035 868)

4. Measure voltage as follows.

REVERSE ACTUATOR INPUT VOLTAGE TEST
TEST PROBES RESULT
Actuator
Battery
connector pin Battery voltage
negative (-) post
2 (BU)

If voltage is as specified:
– Carry out a REVERSE ACTUATOR CONTROL
CIRCUIT TEST.
If voltage is not as specified:
– Check open circuit between fuse F7 and re-
rmr2010-036-201_c
verse actuator connector.
TYPICAL
Step 1: Activation tab Reverse Actuator Control Circuit Test
Step 2: ACC tab
Step 3: Reverse actuator button 1. Disconnect the reverse actuator connector.

If actuator operates:
– Check control lever.
– Check actuator cable and bracket condition.
– Check REVERSE ACTUATOR CABLE ADJUST-
MENT.
If actuator does not operate:
– Carry out a REVERSE ACTUATOR INPUT VOLT-
AGE TEST.

10 rmr2014-021
 Subsection 14 (GEARBOX)

rmr2014-021-102_a
rmr2014-021-101_a

1. Reverse actuator connector 1. Reverse actuator connector

2. Support bracket
3. Reverse actuator mounting screws
2. Set multimeter to Vdc. 4. Support bracket mounting screws

REQUIRED TOOL 4. Detach actuator cable from control lever.

FLUKE 115 MULTIMETER 5. Installation is the reverse of removal however, it
(P/N 529 035 868) is critical to carry out the REVERSE ACTUATOR
CABLE ADJUSTMENT.
3. Have an assistant: NOTE: Start adjustment procedure before in-
stalling the new actuator on the vehicle.
– Taking place on the vehicle.
– Holding the clutch and selecting the first gear
with the engine running.
SHIFTING MECHANISM
– Pressing the reverse button. Parts of the shifting mechanism can be replaced
NOTE: Vehicle must not be moving and engine without removing the engine:
speed must be below 1800 RPM. – Shift shaft
4. Measure voltage while button is pressed. – Index lever
– Index shim
NOTE: Once reverse button is pressed, the
ground signal (control) will be held for 2 to 3 – Index spring
seconds wether the button is held or not. After a – Shift activating lever assembly (SE6 models
few attempts, it is normal for the system to shut only).
down the reverse function for a few minutes.
Shifting Mechanism Removal
REVERSE ACTUATOR CONTROL CIRCUIT TEST
Remove clutch cover and clutch drum. Refer to
TEST PROBES
RESULT (REVERSE CLUTCH (SM6) or CLUTCH (SE6) subsection.
BUTTON PRESSED)
Pull out shift shaft assembly from gearbox hous-
Actuator Battery ing.
connector pin positive (+) Battery voltage
1 (RD) post

If voltage is as specified:
– Replace reverse actuator.
If voltage is not as specified:
– Check open circuit between reverse actuator
connector and cluster connector pin 3.

Reverse Actuator Replacement

1. Disconnect the reverse actuator connector.
2. Remove reverse actuator mounting screws.
3. Remove support bracket mounting screws.
rmr2014-021 11
Subsection 14 (GEARBOX)

rmr2014-021-010_a rmr2014-021-012_a

1. Shift shaft assembly SM6

1. 1st gear position
2. Neutral position
While turning the gearbox shafts switch gearbox 3. Index washer
into 1st gear. 4. Index lever

NOTE: SE6 and SM6 have different shifting se-
quence.
Block index shim.
NOTICE Index shim must be blocked to avoid
damages on shift drum and shift forks during
removal and installation.
REQUIRED TOOL

INDEX SHIM HOLDING

DEVICE (P/N 529 036 293)

Remove index shim screw.

rmr2014-021-011_a

SE6
1. 1st gear position
2. Neutral position
3. Index washer
4. Index lever

rmr2014-021-013_a

1. Index shim holding device

2. Index shim screw
3. Index shim

Insert a flat screwdriver into slot and turn index

lever counterclockwise while removing index
shim.

12 rmr2014-021
 Subsection 14 (GEARBOX)

rmr2014-021-014_a rmr2014-021-016_a

1. Index lever 1. Pawl

2. Slot 2. Spring
3. Index shim 3. Check for free movement
4. Hair pin spring
Remove:
Index Lever
– Screw
– Washer Roller of index lever must move freely. Replace if
necessary.
– Index lever
– Step ring Index Shim
– Index spring. Check pins of index shim if bent or cracked.
Check teeth of index shim for wear.
Replace if necessary.

rmr2014-021-015_a

1. Screw
2. Washer
3. Index lever
rmr2014-021-017_a
4. Step ring
5. Index spring 1. Pins
2. Teeth
3. Index shim
Shifting Mechanism Inspection
Shift Shaft Shifting Mechanism Installation
Check shift shaft for worn splines or other dam- The installation is the reverse of the removal pro-
ages. cedure. However, pay attention to the following.
Check pawl and pawl spring for wear and proper Install:
operation. – Index spring
Check hair pin spring for any damages. Replace if – Step ring
necessary. – Index lever
– Washer
– Screw.

rmr2014-021 13
Subsection 14 (GEARBOX)

Tighten screw to specification. INDEX SHIM SCREW

INDEX LEVER SCREW LOCTITE 648 (GREEN)
Service product
(P/N 413 711 400)
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060) Tightening torque hand tight
11 N•m ± 1 N•m
Tightening torque NOTICE Do not yet torque to specification to
(97 lbf•in ± 9 lbf•in)
avoid damages on shift drum and shift forks.
While turning the gearbox shafts switch gearbox
into 1st gear.
NOTE: SE6 and SM6 have different shifting se-
quence.

rmr2014-021-015_b

1. Index spring
2. Step ring
3. Index lever
4. Washer
5. Screw

Insert a flat screwdriver into slot and turn index rmr2014-021-011_a

lever counterclockwise while installing index SE6
shim. 1. 1st gear position
2. Neutral position
NOTE: Position index shim correctly in the recess 3. Index washer
4. Index lever
of the shift drum.

rmr2014-021-012_a
rmr2014-021-014_b

1. Index lever SM6

2. Slot 1. 1st gear position
3. Index shim 2. Neutral position
4. Recess in shift drum 3. Index washer
4. Index lever
Apply thread locker on index shim screw and in- Block index shim.
stall it hand tight.

14 rmr2014-021
 Subsection 14 (GEARBOX)

NOTICE Index shim must be blocked to avoid

damages on shift drum and shift forks during
removal and installation.
REQUIRED TOOL

INDEX SHIM HOLDING

DEVICE (P/N 529 036 293)

Tighten index shim screw to specification.

INDEX SHIM SCREW
LOCTITE 648 (GREEN)
Service product rmr2014-021-019_a
(P/N 413 711 400) SM6
1. Neutral position
30 N•m ± 3 N•m 2. 1st gear position
Tightening torque
(22 lbf•ft ± 2 lbf•ft) 3. Index washer
4. Index lever
Install shift shaft assembly. Install all other remaining parts.
After installation, check if the gears engagement
is accurate and shifting system works properly. SHIFT ACTUATING LEVER
Shift gear box to neutral position. ASSEMBLY
Shift Actuating Lever Assembly
Removal
Remove clutch cover. Refer to CLUTCH COVER
in the CLUTCH (SE6) subsection.
Fix clutch cover holder in a vice and attach clutch
cover using 3 clutch cover bolts.
REQUIRED TOOL

CLUTCH COVER HOLDING

DEVICE (P/N 529 036 294)

rmr2014-021-018_a

SE6
1. Neutral position
2. 1st gear position
3. Index washer
4. Index lever

rmr2014-019-007_a

1. Clutch cover holder

2. Clutch cover
3. Clutch cover bolts (3x)

rmr2014-021 15
Subsection 14 (GEARBOX)

Remove:
– Shift actuating lever screw
– Washer.

rmr2014-021-097_a

1. Needle bearing
2. Step sleeve

Unscrew step sleeve screw by approximately 6

turns.

rmr2014-021-086_a

1. Shift actuating lever screw

2. Washer
3. Shift actuating lever

Remove shift actuating lever assembly from its ar-

rest in the step sleeve and spring in the clutch
cover.

rmr2014-021-089_a

UNSCREW 6 TURNS
1. Screw
2. Step sleeve

Move right spring end outwards by using a pliers

to release stress to the spring.

rmr2014-021-088_a

1. Shift actuating lever assembly

2. Step sleeve
3. Spring

Remove:
– Needle bearing
– Step sleeve.

16 rmr2014-021
 Subsection 14 (GEARBOX)

rmr2014-021-092_a

SHIFT ACTUATING LEVER ASSEMBLY

1. Shift actuating lever
2. Gear shift lever assembly

Check needle bearing and step sleeve visually for

wear, pitting and/or scoring. Replace parts if nec-
rmr2014-021-089_b
essary
1. Right spring end Check spring and step sleeve for wear, cracks or
other damages. Replace if necessary.
Remove:
– Step sleeve screw Check ball bearing for smooth operation, exces-
sive play and/or pitting. Replace gear shift lever
– Step sleeve assembly if necessary.
– Spring.
NOTICE Remove step sleeve and spring only
if necessary.

rmr2014-021-094_a

PARTS FOR CLARITY REMOVED

1. Splines
2. Ball bearing
rmr2014-021-090_a 3. Gear shift lever assembly
1. Step sleeve screw
2. Step sleeve Gear Shift Lever Assembly Replacement
3. Spring
Heat up nut with a heat gun to break threadlocker.
Shift Actuating Lever Assembly Remove fitting bolt and nut.
Inspection Separate shift actuating lever from gear shift lever
Check shift actuating lever and gear shift lever for assembly.
cracks or other damages.
Check splines of gear shift lever for wear.
Replace parts as necessary.

rmr2014-021 17
Subsection 14 (GEARBOX)

rmr2014-021-090_b

1. Spring
2. Step sleeve
3. Step sleeve screw
rmr2014-021-095_a

1. Nut
2. Fitting bolt
Tighten step sleeve screw to specification.
3. Shift actuating lever
4. Gear shift lever assembly STEP SLEEVE SCREW

Insert fitting bolt to gear shift lever assembly and 11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)
fit shift actuating lever.
Tighten nut to specification. Insert step sleeve and needle bearing into shifting
NUT piston of HCM.

LOCTITE 648 (GREEN)

Service product
(P/N 413 711 400)
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

Shift Actuating Lever Assembly

Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Insert spring and step sleeve into clutch cover.
Apply threadlocker onto thread of step sleeve
screw.
rmr2014-021-096_a
STEP SLEEVE SCREW 1. Step sleeve
2. Needle bearing
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060) Install washer and tighten shift actuating lever
screw to specification.
Screw in step sleeve screw by 3 turns.
SHIFT ACTUATING LEVER SCREW
Stress the spring by moving the left spring end to
its seat onto the right side of the step sleeve by LOCTITE 243 (BLUE)
Service product
using a pliers. (P/N 293 800 060)
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

Install clutch cover. Refer to CLUTCH COVER in

the CLUTCH (SE6) subsection.

18 rmr2014-021
 Subsection 14 (GEARBOX)

GEARBOX

rmr2014-021-029_a

1. Gear housing M6 screws

2. Gear housing
rmr2014-021-020_a
NOTICE Before removing the last gear hous-
1. 1st speed
2. 2nd speed ing screw support gearbox assembly thor-
3. 3rd speed oughly to avoid injury.
4. 4th speed
5. 5th speed
6. 6th speed
7. R (Reverse speed)

Gearbox Disassembly
Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION subsection.
Remove FRONT SPROCKET. Refer to DRIVE
BELT AND REAR WHEEL subsection.
Remove intake manifold. Refer to AIR INTAKE
SYSTEM subsection.
Remove alternator. Refer to ALTERNATOR sub-
section.
Remove oil tank cover. Refer to LUBRICATION
SYSTEM subsection. rmr2014-021-021_a

1. Gear housing M10 screws

Remove clutch cover and clutch drum. Refer to 2. Gear housing
CLUTCH (SE6) or CLUTCH (SM6) subsection.
Remove gearbox assembly from cylinder block.
SM6 Models
Fix gearbox assembly in holding device.
Remove clutch release rod. Refer to CLUTCH
(SM6) subsection. REQUIRED TOOL

All Models
GEARBOX HOLDING DEVICE
Remove index shim. See SHIFTING MECHA- (P/N 529 036 296)
NISM in this subsection.
NOTICE Remove index lever only if neces-
sary.
Remove and discard gear housing M10 screws.

rmr2014-021 19
Subsection 14 (GEARBOX)

rmr2014-021-022_a rmr2014-021-024_a

1. Gearbox assembly 1. Cover

2. Holding device 2. O-ring (discard it)
3. Washer 3. Retaining ring (discard it)
4. Nut 4. Main shaft
5. Vice
Remove gear housing screws.
Remove control lever from gear locking shaft. Re-
fer to OIL SEALS in this subsection.
Remove GBPS. Refer to GEARBOX POSITION
SENSOR (GBPS) in this subsection.

rmr2014-021-025_a

1. Gear housing screws

2. Gear housing

rmr2014-021-023_a

1. Control lever
2. GBPS

Remove:
– Cover
– O-ring (discard it)
– Retaining ring (discard it).

rmr2014-021-026_a

1. Gear housing screws

2. Gear housing

20 rmr2014-021
 Subsection 14 (GEARBOX)

Use a big flat screw driver and a soft hammer to Disengage shift forks from shift drum.
lift PTO side (left side) gear housing. Remove shift drum and bearing.
NOTE: Do not damage the oils seals during disas-
sembly.

rmr2014-021-032_a

1. Shift forks
2. Gear locking shaft
rmr2014-021-027_a
3. Shift drum
LIFT HERE 4. Bearing
1. Big flat screw driver
Turn shift fork 1st/4th gear clockwise and remove
gear locking shaft assembly.

rmr2014-021-028_a

PUSH HERE
1. Soft hammer
rmr2014-021-033_a

Remove both shift fork shafts from shift forks. 1. Shift fork 1st/4th gear
2. Gear locking shaft assembly

Remove shift forks from main shaft and clutch

shaft.
NOTE: Lift shifting gear with shift fork upwards to
ease removal of shift fork.

rmr2014-021-031_a

1. Shift fork shafts

2. Shift forks

rmr2014-021 21
Subsection 14 (GEARBOX)

rmr2014-021-034_a rmr2014-021-036_a

1. Shift fork 2nd/ reverse gear 1. Fixed gear 13T (reverse gear)
2. Shift fork 1st/4th gear 2. Free pinion 28T (5th gear)
3. Shift fork 5th 3. Needle bearing
4. Shift fork 3rd/6th gear 4. Thrust washer
5. Main shaft 5. Gear pinion 17T (2nd gear)
6. Clutch shaft
Tap clutch shaft to assist withdrawing clutch shaft
Withdraw the following parts from main shaft: assembly together with main shaft assembly.
– Free pinion 32T (reverse gear)
– Needle bearing NOTICE Hold gearbox with hands during
driving out.
– Thrust washer
– Shifting gear 30T (5th gear). NOTICE Ensure retaining ring of main shaft
is removed.
REQUIRED TOOL
SOFT HAMMER

rmr2014-021-035_a

1. Free pinion 32T (reverse gear)

2. Needle bearing
3. Thrust washer
4. Shifting gear 30T (5th gear)

Withdraw the following parts from clutch shaft: rmr2014-021-038_a

1. Main shaft assembly

– Fixed gear 13T (reverse gear) 2. Clutch shaft assembly
– Free pinion 28T (5th gear) 3. Soft hammer

– Needle bearing Remove:

– Thrust washer – Plug screw
– Gear pinion 17T (2nd gear). – Sealing ring (discard it).

22 rmr2014-021
 Subsection 14 (GEARBOX)

rmr2014-021-046_a

1. Plug screw
2. Sealing ring (discard it)
rmr2014-021-048_a

1. Hydraulic cylinder
SE6 Models
NOTE: Remove cover SE6 only if necessary. Clutch Shaft
Remove: NOTICE Discard removed retaining rings and
– Cover screws groove rings from gearbox shafts.
– Cover
Remove the following parts from clutch shaft:
– O-ring (discard it).
– Groove ring
– Thrust washer 1.5 mm (.059 in)
– Free pinion 23T (3rd gear)
– Needle bearing
– Thrust washer 1.5 mm (.059 in)
– Shifting gear 26T (4th gear).
RECOMMENDED TOOL
SNAP-ON SNAP RING PLIERS (P/N SRP3)

rmr2014-021-047_a

1. Screws
2. Cover
3. O-ring (discard it)

SM6 Models
NOTE: Remove SM6 hydraulic cylinder only if
necessary.
For removal refer to CLUTCH SM6 subsection.

rmr2014-021-039_a

1. Groove ring
2. Thrust washer 1.5 mm (.059 in)
3. Free pinion 23T (3rd gear)
4. Needle bearing
5. Thrust washer 1.5 mm (.059 in)
6. Shifting gear 26T (4th gear)
7. Clutch shaft assembly

Remove:
– Retaining ring

rmr2014-021 23
Subsection 14 (GEARBOX)

– Free pinion 32T (6th gear) – Thrust washer 1.5 mm (.059 in)
– Needle bearing. – Shifting gear 29T (6th gear).

rmr2014-021-040_a rmr2014-021-042_a

1. Retaining ring 1. Thrust washer 1.5 mm (.059 in)

2. Free pinion 32T (6th gear) 2. Free pinion 37T (1st gear)
3. Needle bearing 3. Needle bearing
4. Clutch shaft (1st gear) 4. Thrust washer 1.5 mm (.059 in)
5. Shifting gear 29T (6th gear)
Main Shaft 6. Main shaft assembly

NOTICE Discard removed retaining rings and Remove:

groove rings from gearbox shafts. – Retaining ring
– Free pinion 33T (4th gear)
Remove the following parts from main shaft:
– Needle bearing.
– Retaining ring
– Free pinion 32T (2nd gear)
– Needle bearing.
RECOMMENDED TOOL
SNAP-ON SNAP RING PLIERS (P/N SRP3)

rmr2014-021-043_a

1. Retaining ring
2. Free pinion 33T (4th gear)
3. Needle bearing
4. Main shaft assembly

Reverse Intermediate Gear

rmr2014-021-041_a
NOTE: Remove reverse intermediate gear only if
1. Retaining ring necessary.
2. Free pinion 32T (2nd gear)
3. Needle bearing Remove:
4. Main shaft assembly – Screws
Remove: – Retaining plate
– Thrust washer 1.5 mm (.059 in) – Reverse intermediate gear 14T
– Free pinion 37T (1st gear) – Needle bearing.
– Needle bearing

24 rmr2014-021
 Subsection 14 (GEARBOX)

rmr2014-021-045_a rmr2014-021-051_a
1. Screws CLUTCH SIDE HALF - CLUTCH COVER MATING SURFACE
2. Retaining plate 1. Oil orifices
3. Reverse intermediate gear
4. Needle bearing
NOTE: To check main shaft bearing oil orifice of
Gear Housing Inspection and Cleaning the clutch side half the ball bearing must be re-
moved.
Clean gear housing halves sealing surfaces and
cylinder block mating surfaces using a combi-
nation of LOCTITE CHISEL (GASKET REMOVER)
(P/N 413 708 500) and a brass brush. First brush
in one direction then make the final brushing
perpendicularly (90°) to the first pass.
Clean gear housing halves components in solvent.
Dry gear housing halves by using compressed air.
Blow out the oil supply bores and oil orifices and
check if they are not clogged.

WARNING
Always wear skin and eye protection. Chem-
icals can cause skin rash, skin burns and se-
vere eye injury.
rmr2014-021-052_a

CLUTCH SIDE HALF

1. Main shaft ball bearing

rmr2014-021-050_a

CLUTCH SIDE HALF - CYLINDER BLOCK MATING SURFACE

1. Oil bore

rmr2014-021 25
Subsection 14 (GEARBOX)

rmr2014-021-054_a

PTO SIDE HALF - GEAR HOUSING MATING SURFACE

1. Oil orifices
rmr2014-021-030_a

CLUTCH SIDE HALF - MAIN SHAFT BEARING SEAT

1. Oil orifice
2. Main shaft bearing seat

rmr2014-021-055_a

PTO SIDE HALF - PTO SIDE

1. Oil orifices

Check gear housing halves for cracks or other

rmr2014-021-053_a
damages. Replace if necessary.
CLUTCH SIDE HALF - GEAR HOUSING MATING SURFACE
1. Oil orifices Check gear housing mating surfaces and cylinder
block mating surface of clutch side gear housing
for damages.
Check ball bearings for smooth operation, exces-
sive play and/or pitting. Replace if necessary.
Ball Bearing Replacement
Remove flat head screws securing the ball bear-
ings.

26 rmr2014-021
 Subsection 14 (GEARBOX)

Install NEW ball bearings on block.

Before installation lubricate ball bearings on outer
diameter with engine oil.
NOTE: Sealing ring of main shaft ball bearing
clutch side must face towards inside the gear
housing.

rmr2014-021-060_a

CLUTCH SIDE GEAR HOUSING

1. Flat head screws
2. Ball bearings

rmr2014-021-062_a

CLUTCH SIDE GEAR HOUSING

1. Sealing ring
2. Main shaft ball bearing, clutch side

NOTE: Sealing ring of the clutch shaft ball bear-

ing PTO side must face towards outside the gear
housing.

rmr2014-021-061_a

CLUTCH SIDE GEAR HOUSING

1. Countersunk screw
2. Washer
3. Ball bearing

Heat up gear housing halves up to 120°C (248°F).

Press out ball bearings and discard them.
NOTE: For PTO side main shaft ball bearing re-
moval the oil seal must be removed. Refer to OIL
SEALS in th rmr2014-021-063_a

REQUIRED TOOL PTO SIDE GEAR HOUSING

1. Sealing ring
2. Clutch shaft ball bearing, PTO side
Suitable punch
Press REQUIRED TOOL
Suitable punch
NOTICE Always support gear housing halves
properly when ball bearings are removed and Press
installed. Damages to gear housing halves
may occur if this procedure is not performed Tighten flat head screws to specification.
correctly.
Heat up gear housing halves up to 120°C (248°F).

rmr2014-021 27
Subsection 14 (GEARBOX)

FLAT HEAD SCREWS Gearbox Inspection

LOCTITE 243 (BLUE) Always check the following when inspecting gear-
Service product box components:
(P/N 293 800 060)
– Gear teeth damage
11 N•m ± 1 N•m
Tightening torque – Worn or scored bearing surfaces
(97 lbf•in ± 9 lbf•in)
– Rounded edges of engagement dogs and slots
– Worn shift fork engagement groove
– Worn tracks on shift drum
– Worn shift fork engagement pins
– Worn splines on shafts and gears
– Bent, worn or scored shift fork shafts
– Bent, worn or scored shift fork.

rmr2014-021-060_b

CLUTCH SIDE GEAR HOUSING

1. Flat head screws

Tighten countersunk screw to specification.

COUNTERSUNK SCREW
rmr2014-021-064_a
LOCTITE 243 (BLUE) TYPICAL — FREE PINION
Service product
(P/N 293 800 060) 1. Teeth
2. Bearing surface
8.5 N•m ± 0.5 N•m 3. Engagement slot
Tightening torque 4. Edges
(75 lbf•in ± 4 lbf•in)

rmr2014-021-065_a

TYPICAL — SHIFTING GEAR

1. Engagement dog
2. Edges
rmr2014-021-061_b 3. Shift fork engagement groove
CLUTCH SIDE GEAR HOUSING 4. Inner splines
1. Washer
2. Countersunk screw Shift Drum
Check shift drum tracks for:
– scouring

28 rmr2014-021
 Subsection 14 (GEARBOX)

– heavy wear Shift Fork

– rounded engagement slots. Check shift forks for visible damage, wear or bent
Check shift drum shaft for: shift fork claws.
– tight fitting Measure the shift fork claw thickness.
– wear or damages on oil seal running surface.
Check ball bearing for smooth operation, exces-
sive play and/or pitting. Replace if necessary.

vmr2006-022-075_a

TYPICAL
1. Micrometer
A. Shift fork claw thickness
rmr2014-021-066_a

1. Track for gear locking shaft SHIFT FORK CLAW THICKNESS

2. Track for 1st/4th gear shift fork
3. Track for 3rd/6th gear shift fork 5.825 mm to 5.900 mm
4. Track for 5th gear shift fork NEW
5. Track for 2nd/Reverse gear shift fork (.2293 in to .2323 in)
6. Shift drum shaft
7. Oil seal running surface SERVICE LIMIT 5.750 mm (.2264 in)
8. Ball bearing

Gear Locking Shaft Measure the shift fork engagement pin diameter.
Roller of gear locking shaft must move freely. Re-
place as necessary.
Check correct position and tightness of retaining
ring. Replace if necessary.
Check flat surfaces for control lever positioning.

vmr2006-022-076_a

TYPICAL
1. Micrometer
A. Shift fork engagement pin diameter

SHIFT FORK ENGAGEMENT PIN DIAMETER

5.958 mm to 5.970 mm
rmr2014-021-068_a
NEW
1. Retaining ring (.2346 in to .235 in)
2. Flat surfaces
3. Roller SERVICE LIMIT 5.940 mm (.2339 in)
4. Gear locking shaft

rmr2014-021 29
Subsection 14 (GEARBOX)

Gears
Measure the width of shift fork engagement
groove.

rmr2014-021-069_a
vmr2008-019-054_a
MAIN SHAFT — FREE PINIONS
TYPICAL — SHIFTING GEAR 1. 1st gear
A. Width of shift fork engagement groove 2. 4th gear
3. 2nd gear
WIDTH OF SHIFT FORK ENGAGEMENT GROOVE 4. Reverse gear

6.100 mm to 6.200 mm CLUTCH SHAFT FREE PINIONS

NEW
(.2402 in to .2441 in)
NEW
SERVICE LIMIT 6.230 mm (.2453 in)
33.000 mm to 33.016 mm
3rd GEAR
Check free pinions for wear. (1.2992 in to 1.2998 in)
Measure the inside diameter of free pinion. 26.000 mm to 26.013 mm
5th GEAR
(1.0236 in to 1.0241 in)
35.000 mm to 35.016 mm
6th GEAR
(1.378 in to 1.3786 in)
SERVICE LIMIT
3rd GEAR 33.020 mm (1.3 in)
5th GEAR 26.020 mm (1.0244 in)
6th GEAR 35.020 mm (1.3787 in)

vmr2008-019-055_a

TYPICAL
A. Diameter free pinion bearing

MAIN SHAFT FREE PINIONS

NEW
1st GEAR
2nd GEAR 42.000 mm to 42.016 mm
4th GEAR (1.6535 in to 1.6542 in)
REVERSE GEAR
SERVICE LIMIT rmr2014-021-070_a

CLUTCH SHAFT — FREE PINIONS

1st
GEAR 1. 5th gear
2nd GEAR 2. 3rd gear
42.020 mm (1.6543 in) 3. 6th gear
4th GEAR
REVERSE GEAR Main Shaft
Check main shaft for wear.
Check retaining ring grooves.
Check splines for wear and/or damages.
30 rmr2014-021
 Subsection 14 (GEARBOX)

Blow out the oil orifices and check if they are not Clutch Shaft
clogged. Check clutch shaft for wear.
Check retaining ring groove.
Check splines for wear and/or damages.
Blow out the oil orifices and check if they are not
clogged.

rmr2014-021-071_a

1. Retaining ring grooves

2. Splines
3. Oil orifices
4. Oil supply bore

Measure diameters of main shaft bearing journals.

rmr2014-021-072_a

1. Retaining ring groove

2. Splines
3. Oil orifices
4. Oil supply bore

Measure diameters of clutch shaft bearing jour-

nals.

rmr2014-021-071_b

A. Clutch side bearing journal

B. Free pinion bearing journal
C. PTO side bearing journal

MAIN SHAFT BEARING JOURNAL

NEW
rmr2014-021-072_b
CLUTCH SIDE 29.987 mm to 30.000 mm A. Clutch drum gear journal
BEARING JOURNAL (1.1806 in to 1.1811 in) B. Clutch side bearing journal
C. Free pinion bearing journal (6th gear)
FREE PINION BEARING 36.989 mm to 37.000 mm D. Free pinion bearing journal (3rd gear)
E. Free pinion bearing journal (4th gear)
JOURNAL (1.4563 in to 1.4567 in) F. PTO side bearing journal
PTO SIDE BEARING 34.986 mm to 34.997 mm
JOURNAL (1.3774 in to 1.3778 in)
SERVICE LIMIT
CLUTCH SIDE
29.980 mm (1.1803 in)
BEARING JOURNAL
FREE PINION BEARING
36.984 mm (1.4561 in)
JOURNAL
PTO SIDE BEARING
34.980 mm (1.3772 in)
JOURNAL

rmr2014-021 31
Subsection 14 (GEARBOX)

CLUTCH SHAFT BEARING JOURNAL

NEW
CLUTCH DRUM GEAR 29.980 mm to 29.993 mm
JOURNAL (1.1803 in to 1.1808 in)
CLUTCH SIDE 34.975 mm to 34.991 mm
BEARING JOURNAL (1.377 in to 1.3776 in)
FREE PINION BEARING 29.991 mm to 30.000 mm
JOURNAL (6th GEAR) (1.1807 in to 1.1811 in)
FREE PINION BEARING 27.991 mm to 28.000 mm
JOURNAL (3rd GEAR) (1.102 in to 1.1024 in)
FREE PINION BEARING 21.991 mm to 22.000 mm rmr2014-021-046_b

JOURNAL (5th GEAR) (.8658 in to .8661 in) PTO SIDE GEAR HOUSING
1. Sealing ring
PTO SIDE BEARING 19.987 mm to 20.000 mm 2. Plug screw
JOURNAL (.7869 in to .7874 in)
Install following parts into PTO side gear housing:
SERVICE LIMIT – Needle bearing
CLUTCH DRUM GEAR
29.975 mm (1.1801 in)
– Reverse intermediate gear 14T
JOURNAL – Retaining plate.
CLUTCH SIDE Tighten flat head screw and countersunk screws
34.970 mm (1.3768 in)
BEARING JOURNAL to specification.
FREE PINION BEARING FLAT HEAD SCREW
29.985 mm (1.1805 in)
JOURNAL (6th GEAR)
LOCTITE 243 (BLUE)
FREE PINION BEARING Service product
27.985 mm (1.1018 in) (P/N 293 800 060)
JOURNAL (3rd GEAR)
17 N•m ± 1 N•m
FREE PINION BEARING Tightening torque
21.985 mm (.8656 in) (150 lbf•in ± 9 lbf•in)
JOURNAL (5th GEAR)
PTO SIDE BEARING COUNTERSUNK SCREWS
19.980 mm (.7866 in)
JOURNAL
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
Reverse Intermediate Gear
11 N•m ± 1 N•m
Check reverse intermediate gear, needle bearing Tightening torque
(97 lbf•in ± 9 lbf•in)
and bearing pin visually for wear, pitting and/or
scoring. Replace parts if necessary.

Gearbox Assembly
For assembly and installation, reverse the disas-
sembly and removal procedures. However, pay
attention to the following.
Gear Housing Assembly
Install plug screw with NEW sealing ring onto gear
housing PTO side.
PLUG SCREW
Sealing ring NEW
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

32 rmr2014-021
 Subsection 14 (GEARBOX)

– Bearing seats of free pinions

– Bearing seats on the shafts.
NOTE: After assembly always check shifting
gears for free movement on the shaft splines.

Gearbox Installation
Fix Gear housing clutch side in holding device.
REQUIRED TOOL

GEARBOX HOLDING DEVICE

(P/N 529 036 296)

rmr2014-021-045_b

1. Needle bearing
2. Reverse intermediate gear
3. Retaining plate
4. Flat head screw
5. Countersunk screws

Ensure that both positioning pins are installed.

Lubricate ball bearings with engine oil.

rmr2014-021-073_a

1. Gear housing clutch side

2. Holding device
3. Nut and washer
4. Vice

Put pre assembled clutch shaft and main shaft to-

gether and align gear pairs.
NOTE: Ensure that thrust washer is installed on
rmr2014-021-044_a main shaft.
1. Positioning pins
2. Ball bearings

Clutch Shaft and Main Shaft Assembly

For assembly reverse the disassembly proce-
dures. However pay attention to the following.
Install NEW retaining rings.
NOTICE Retaining rings must be installed us-
ing a retaining ring pliers only. Take care not to
overstress them during installation. After as-
sembly always check if they are fitted correct
in gear shaft grooves.
RECOMMENDED TOOL rmr2014-021-074_a

SNAP-ON SNAP RING PLIERS (P/N SRP3) 1. Clutch shaft assembly

2. Main shaft assembly
3. Thrust washer
During installation apply engine oil on:
– Needle bearings

rmr2014-021 33
Subsection 14 (GEARBOX)

Install clutch shaft and main shaft assembly into

the ball bearing seats in the clutch side gear hous-
ing by alternately tapping with a soft hammer on
both shaft ends.

rmr2014-021-034_a

1. Shift fork 2nd/ reverse gear

2. Shift fork 1st/4th gear
3. Shift fork 5th
4. Shift fork 3rd/6th gear
5. Main shaft
6. Clutch shaft
rmr2014-021-075_a

1. Clutch shaft assembly Apply engine oil in gear locking shaft bearing bore
2. Main shaft assembly in the gear housing clutch side.
3. Gear housing clutch side
Install gear locking shaft assembly.
Install remaining parts on main shaft and clutch
shaft assembly, refer to the disassembly proce-
dure in this subsection.
NOTICE The collar of the fixed gear 13T
(reverse gear) must show towards inside gear-
box.

rmr2014-021-033_b

1. Bearing bore
2. Gear housing clutch side
3. Gear locking shaft assembly

Lubricate tracks of shift drum with engine oil.

Install shift drum into ball bearing of clutch side
rmr2014-021-076_a gear housing.
1. Fixed Gear
2. Collar
3. Clutch shaft assembly
4. Gear housing clutch side

NOTE: After installation turn both shafts and

check for free movement. Also check shift-
ing gears for free axial movement on the shaft
splines.
Apply engine oil on the shift forks and install them
into their gear pinion grooves.

34 rmr2014-021
 Subsection 14 (GEARBOX)

NOTICE Ensure not to apply too much

sealant, as it will spread out inside gear hous-
ing. Do not apply sealant into the oil supply
bore.

rmr2014-021-077_a

1. Gear locking shaft assembly

2. Shift drum
3. Ball bearing

Engage shift fork engagement pins into their

tracks in shift drum. rmr2014-021-078_a

Lubricate both shift fork shafts with engine oil and 1. Clutch side gear housing
2. Mating surface
install them. 3. Oil supply bore
4. Apply LOCTITE 5910 (P/N 293 800 081) following this
pattern

Lubricate all bearing seats on shafts with engine

oil.
Install gear housing PTO side onto gear housing
clutch side by using a soft hammer.
Turn clutch shaft while driving the PTO side hous-
ing to align the teeth of the reverse intermediate
gear with the reverse gear on the clutch and main
shaft.

rmr2014-021-031_a

1. Shift fork shafts

2. Shift forks

Put the PTO side gear housing in an oven and heat

it up to 70°C (158°F).
Apply sealant on mating surface of clutch side
gear housing as shown on next illustration.
CLUTCH SIDE GEAR HOUSING MATING
SURFACE
LOCTITE 5910 (P/N 293
Service product rmr2014-021-079_a
800 081)
1. Gear housing PTO side
2. Soft hammer
IMPORTANT: When beginning the application of
the gear housing sealant, the assembly and the Tighten gear housing screws according to follow-
first torquing should be done within 10 minutes. ing procedure.
It is suggested to have all you need on hand to
save time.

rmr2014-021 35
Subsection 14 (GEARBOX)

SE6 Models
Install cover with NEW O-ring and tighten to spec-
ification.
COUNTERSUNK SCREWS
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
6 N•m ± 0.7 N•m
Tightening torque
(53 lbf•in ± 6 lbf•in)

rmr2014-021-081_a

TIGHTENING SEQUENCE - STEP A

GEAR HOUSING SCREWS TIGHTENING

PROCEDURE
5 N•m ± 0.6 N•m
STEP A
(44 lbf•in ± 5 lbf•in)

rmr2014-021-082_a

1. Cover
2. Screws

SM6 Models
rmr2014-021-081_b

TIGHTENING SEQUENCE - STEP B Install hydraulic cylinder, refer to HYDRAULIC

CYLINDER in the CLUTCH (SM6) subsection.
All Models
Install GBPS, refer to procedure in this subsection.
Install control lever spring as shown in the next
illustration.
Place control lever onto spring hook and tighten
control lever screw to specification.
NOTE: The slot of the control lever must show
towards the outside.

rmr2014-021-080_a

TIGHTENING SEQUENCE - STEP B

GEAR HOUSING SCREWS TIGHTENING

PROCEDURE
11 N•m ± 1 N•m
STEP B
(97 lbf•in ± 9 lbf•in)

36 rmr2014-021
 Subsection 14 (GEARBOX)

CYLINDER BLOCK GEAR HOUSING

MATING SURFACE
LOCTITE 5910 (P/N 293
Service product
800 081)

IMPORTANT: When beginning the application of

the gear housing sealant, the assembly and the
first torquing should be done within 10 minutes.
It is suggested to have all you need on hand to
save time.
NOTICE Ensure not to apply too much
sealant, as it will spread out inside cylinder
rmr2014-021-009_a
block. Do not apply sealant into the oil supply
1. Engage control lever spring end here bore.
2. Spring hook
3. Control lever
4. Slot

CONTROL LEVER SCREW

LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

Install NEW retaining ring onto main shaft clutch

side.
Install cover with NEW O-ring.
rmr2014-021-083_a

1. Cylinder block
2. Gear housing mating surface
3. Oil supply bore
4. Apply LOCTITE 5910 (P/N 293 800 081) following this
pattern
5. Location pins

Check if location pins are mounted in cylinder

block.
Attach gear housing assembly onto cylinder block.
Install NEW gear housing M10 screws and tighten
crosswise to following specification.
NOTICE This assembly uses stretch screws.
Always use NEW screws and strictly adhere to
rmr2014-021-024_b
the tightening procedure.
1. Retaining ring
2. Main shaft
3. O-ring
GEAR HOUSING M10 SCREWS
4. Cover
60 N•m ± 2 N•m
Tightening torque
Install shifting mechanism and check gear shifting (44 lbf•ft ± 1 lbf•ft)
afterwards. Refer to SHIFTING MECHANISM IN-
STALLATION in this subsection.
Remove gear housing assembly from holding de-
vice.
Apply sealant on cylinder block on gear housing
mating surface as shown on next illustration.

rmr2014-021 37
Subsection 14 (GEARBOX)

rmr2014-021-021_a

1. Gear housing M10 screws

2. Gear housing

GEAR HOUSING M6 SCREWS

11 N•m ± 1 N•m
Tightening torque
(97 lbf•in ± 9 lbf•in)

rmr2014-021-029_a

1. Gear housing M6 screws

2. Gear housing

Proceed with assembly of the remaining parts and

install engine to vehicle, reverse the disassembly
and removal procedures. Refer to the appropriate
subsections.

38 rmr2014-021
 Subsection 01 (OVERVIEW)

OVERVIEW
GENERAL
The vehicle senses its surroundings utilizing mul-
tiple on-board electronic control modules. These
sophisticated systems monitor and control a
broad range of functions.
The vehicle features the following systems:
– EMS (Engine Management System)
– VSS (Vehicle Stability System)
– DPS (Dynamic Power Steering).

rmr2014-022 1
Subsection 01 (OVERVIEW)

ENGINE MANAGEMENT SYSTEM (EMS)

SM6 Model

FRONT
FRONT

Reverse gear interlock actuator

Clutch assist solenoid valve
Lambda sensor heater

Starter solenoid
Cooling fan
Fuel pump

Ignition
EVAP

switch

D.E.S.S. MAPTS
GBPS
TPS ETA
CPS

Starter button Basic data

OPS (engine)
TAS CAPS
Clutch switch Ignition coils/injectors

Brake light switch Engine stop switch

CTS CAN DPS, VCM

Correction CLUSTER + LCD
HO2S factors
RADIO
AAPTS
WPM OR PBM
inputs outputs ECM KS
ECM ECM

rmr2014-022-502_aen

AAPTS (Ambient Air Pressure and Temperature Sensor) GBPS (Gearbox Position Sensor)
CAN (Controller Area Network) HO2S (Heated Oxygen Sensor)
CAPS (Camshaft Position Sensor) KS (Knock Sensor)
CPS (Crankshaft Position Sensor) MAPS (Manifold Absolute Pressure Sensor)
CTS (Coolant Temperature Sensor) OPS (Oil Pressure Switch)
D.E.S.S. (Digital Encoded Security System) TPS (Throttle Position Sensor)
DPS (Dynamic Power Steering) TAS (Throttle Accelerator Sensor)
ECM (Engine Control Module) VCM (Vehicle Control Module)
ETA (Electric Throttle Actuator) WPM or PBM (Windshield Parking Brake Module or Parking Brake
EVAP Valve (Evaporative Emissions) Module)

2 rmr2014-022
 Subsection 01 (OVERVIEW)

SE6 Model

FRONT FRONT

Reverse gear interlock actuator

Clutch assist solenoid valve
Lambda sensor heater

Starter solenoid
Cooling fan
Fuel pump

EVAP

Ignition
switch

MAPTS
D.E.S.S. GBPS ETA
TPS
OPS (clutch)
CPS Basic data
OPS (engine)
Starter button CAPS
TAS Ignition coils/injectors
Brake light switch
Engine stop switch

CTS CAN DPS, VCM, TCM

Correction CLUSTER + LCD
HO2S factors
RADIO
AAPTS
WPM OR PBM
inputs outputs ECM KS
ECM ECM

rmr2014-022-503_aen

AAPTS (Ambient Air Pressure and Temperature Sensor) GBPS (Gearbox Position Sensor)
CAN (Controller Area Network) HO2S (Heated Oxygen Sensor)
CAPS (Camshaft Position Sensor) KS (Knock Sensor)
CPS (Crankshaft Position Sensor) MAPS (Manifold Absolute Pressure Sensor)
CTS (Coolant Temperature Sensor) OPS (Oil Pressure Switch)
D.E.S.S. (Digital Encoded Security System) TPS (Throttle Position Sensor)
DPS (Dynamic Power Steering) TAS (Throttle Accelerator Sensor)
ECM (Engine Control Module) VCM (Vehicle Control Module)
ETA (Electric Throttle Actuator) WPM or PBM (Windshield Parking Brake Module or Parking Brake
EVAP Valve (Evaporative Emissions) Module)

rmr2014-022 3
Subsection 01 (OVERVIEW)
A highly advanced engine management system
(EMS) has been used to ensure a high power out-
put with cleaner combustion.
There are 6 main systems that are controlled by
the engine management system (EMS):
1. Electronic Fuel Injection (EFI)
2. Cooling system
3. Evaporative emission control system (EVAP)
4. Ignition system
5. Starting system
6. Engine clutch system.
Engine Control Module (ECM)
The ECM is the central point of the engine man-
agement system. It reads the inputs, makes
computations, uses pre-determined parameters
and sends the proper signals to the outputs for
proper engine management.
smr2009-027-005
TYPICAL - ECM
The ECM is located on the LH side of the engine.
rmr2014-022-010_a
1. ECM location
The ECM features a permanent memory that will
keep the fault codes, customer information and
other engine information, even when the battery
is removed from the vehicle.
4 rmr2014-022
Drowned Mode
This special mode can be activated to prevent fuel
injection and ignition while cranking. Proceed as
follows to activate it.
With ignition switch turned ON while engine is
stopped, twist and HOLD throttle at WOT posi-
tion.
Press the start button and hold to crank engine.
The mode is now on.
Once it's activated, it stays as long as the start
button is pressed.
VEHICLE STABILITY SYSTEM
(VSS)
The VSS helps to maintain vehicle control in nor-
mal riding conditions as well as in emergency
avoidance maneuvers.
To maintain vehicle stability, the VSS interacts
with the several other subsystems as well as
with the engine management system. Refer to
the VEHICLE STABILITY SYSTEM (VSS) subsec-
tion for more details.
DYNAMIC POWER STEERING
(DPS)
The Dynamic Power Steering (DPS) system pro-
vides a computer controlled, variable steering as-
sist achieved by an electric motor to optimize the
amount of steering input required by the rider.
Refer to the STEERING, DPS AND FRONT
WHEELS subsection for more details.
ELECTRONIC SHIFT SYSTEM
(SE6)
The SE6 engine features a sequential electroni-
cally controlled mechanical6-speed gearbox with
a hydraulically-actuated type clutch system.
NOTE: The SE6 is an electronically controlled ver-
sion of a sequential manual gearbox.
Refer to the ELECTRONIC SHIFT SYSTEM (SE6
subsection for more details.
 Subsection 02 (CONTROLLER AREA NETWORK (CAN))

CONTROLLER AREA NETWORK (CAN)

GENERAL
SYSTEM DESCRIPTION
The CAN (Controller Area Network) protocol is an ISO standard for serial data communication. CAN lines
consisting of a pair of twisted wires (WHITE/BEIGE and WHITE/BLACK), link several electronic modules
(ECU's) and sensors in the vehicle. This allows the various modules and components of the system
to be in constant communication with each other. Refer to COMMUNICATION BETWEEN MODULES
THROUGH THE CAN BUS in this subsection.
If a component or system malfunction is detected, a module and/or sensor may generate a fault code,
which it transmits through the CAN bus as a coded signal. The fault signal may be used for various func-
tions such as triggering the display of an error message in the multifunction gauge cluster, turning on a
fault indicator light, and limiting or inhibiting vehicle or engine operation.
Fault codes can be displayed in the multifunction gauge or in B.U.D.S. for troubleshooting.
The CAN is monitored by the:
– ECM (engine control module)
– Multifunction gauge cluster
– VCM (vehicle control module)
– TCM (transmission control module)
– DPS (dynamic power steering)
– Radio
– WPM (windshield parking brake module).
The dynamic link connector (DLC) is mainly used by technicians for connecting the vehicle to B.U.D.S.
for viewing fault codes, troubleshooting various systems, changing certain vehicle parameters or for up-
dating module software.

WH/BG

ECM DPS SAS YRS DLC MSL RDO TCM VCM

CLUSTER WPM

WH/BK

rmr2014-023-001

CLUSTER: Multifunction Gauge

DLC: Diagnostic Link Connector
DPS: Dynamic Power Steering
ECM: Engine Control Module
MSL: Multifunction Switch Left
RDO: Radio
SAS: Steering Angle Sensor
TCM: Transmission Control Module (SE6 model)
VCM: Vehicle Control Module
WH/BG: White/Beige
WH/BK: White/Black
WPM: Windshield Parking Brake Module
YRS: Yaw Rate Sensor

rmr2014-023 1
Subsection 02 (CONTROLLER AREA NETWORK (CAN))

The MSL broadcast the following signals through

CAN:
– Reverse
– Push to talk (CB PTT)
– Mode
– Set
– Cruise
– Upshift/downshift (SE6 model)
– Windshield up/down
– RECC left/right and up/down (Roadster Elec-
tronic Command Center)
– LH/RH turn signal reset.
NOTE: D.E.S.S. is not linked to CAN, it communi-
cates via radio wave signal with the key antenna.
For more information, refer to DIAGNOSTIC AND
FAULT CODES.
Communication Between Modules
Through the CAN Bus
The following table shows what modules commu-
nicate with each other.
COMMUNICATE WITH
MODULE/SENSOR
MODULE/SENSOR
ECM (engine control
All except SAS and YRS
module)
Multifunction cluster
All
gauge
VCM (vehicle control
All
module)
TCM (transmission
All except SAS
control module) (SE6)
SAS (steering angle Multifunction cluster
sensor) gauge, VCM, DPS
VCM, TCM, DPS,
YRS (yaw rate sensor) Multifunction cluster
gauge
DPS (dynamic power
All except MSL
steering)
ECM, multifunction
Radio cluster gauge, TCM,
DPS, VCM
MSL (multifunction All except SAS, YRS,
switch LH side) DPS and radio
WPM (windshield and All except SAS, YRS,
parking brake module) and radio

2 rmr2014-023
 Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.)

COMMUNICATION TOOLS AND

B.U.D.S.
SERVICE TOOLS
Description Part Number Page
MPI-2 DIAGNOSTIC CABLE.......................................................... 710 000 851 ........................................... 3
MPI-2 INTERFACE CARD .............................................................. 529 036 018 ........................................... 3

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
MALE-FEMALE EXTENSION SERIAL CABLE............................... DB9 ........................................... 3

GENERAL Prerequisite for CAN Communication:

Refer to PROCEDURES in this subsection for in- 1. MPI-2 connected to the vehicle communication
structions on using the communication tools. connector.
If communication problems occur, refer to TROU- 2. Ignition key turned ON.
BLESHOOTING in this subsection. 3. B.U.D.S. started and logged.
COMMUNICATION PROBLEM (CAN)
TROUBLESHOOTING
STATUS WHAT TO DO
DIAGNOSTIC TIPS – Check connection between MPI-2
and diagnostic cable connector.
MPI-2 Connection Troubleshooting Light is
– Check connection between diagnostic
OFF
The MPI-2 includes 2 status lights to indicate the cable connector and vehicle
connection condition: USB and CAN. Both lights communication connector.
must be GREEN for the MPI-2 to function prop-
Light is – Check CAN wires/connectors
erly. Otherwise, refer to the following charts.
RED on vehicle.

Communication Problems when Using

B.U.D.S.
Missing Module
Ensure the appropriate number of modules is
shown at the bottom of B.U.D.S. screen.

vdd2006-001-151_b
MODEL NUMBER OF MODULES

Prerequisite for USB Communication: RS MODELS

– PC Computer turned ON 5
SM5
– MPI-2 connected to PC computer. (ECM, VCM, DPS, LCD
Model
(RS-S only) and multifunction gauge)
COMMUNICATION PROBLEM (USB)
6
STATUS WHAT TO DO SE5
(ECM, VCM, DPS, TCM,
Model
LCD and multifunction gauge)
– Check USB connection between
Light is MPI-2 and PC computer.
OFF – Check USB operation on PC computer
(hardware or Windows drivers).

rmr2013-020 1
Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.)

MODEL NUMBER OF MODULES

ST MODELS
6
SM5
(ECM, VCM, DPS, PBM,
Model
LCD and multifunction gauge) rmr2010-020-010_a

7
SE5
Model
(ECM, VCM, DPS, TCM, PROCEDURES
PBM, LCD and multifunction gauge)
RT MODELS MULTI-PURPOSE INTERFACE-2
6 (MPI-2)
SM5 (ECM, VCM, DPS, WPM,
The MPI-2 (Multi-Purpose Interface-2) in conjunc-
LCD and multifunction gauge)
tion with the MPI-2 diagnostic cable is used with
7 B.U.D.S. to communicate with the Electronic Con-
SE5 (ECM, VCM, DPS, TCM, trol Units (ECUs).
WPM, LCD and multifunction gauge)
MPI-2 Power
The MPI-2 interface card uses the power from the
PC computer's USB port.

Connecting the PC to the Vehicle

WARNING
rmr2011-020-002_a
If the computer you are using is connected to
1. Number of modules
a power outlet, there is a potential risk of elec-
trocution when working in contact with water.
NOTE: The LCD (liquid crystal display) is part of Be careful not to touch water while working
the cluster. with the computer.
If one or more “ECU” is not communicating
with the MPI, refer to DIAGNOSTIC AND FAULT 1. Open front storage compartment cover.
CODES. 2. Remove the RH service cover.
No Vehicle is Detected
If an “X” is shown in the status bar and the pro-
tocol indication is blinking between Kw2000 500K
and KW2000, it means that no "ECU" is communi-
cating with the MPI.

rmr2010-020-009 rmr2010-020-002_a

1. Service cover
Check the following:
– Connections between the PC computer and the 3. Locate the vehicle communication connector.
vehicle
– The multifunction gauge is powered up.
If B.U.D.S. does not automatically exit the follow-
ing message box, click the Try active detection
mode button. This will manually establish the
communication with the vehicle.

2 rmr2013-020
 Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.)

529036018

rmr2010-020-005_a

TYPICAL
1. Vehicle communication connector location

Remove the communication connector from its

holder (protective cap). vdd2006-001-151

Connect one end of the MPI-2 DIAGNOSTIC CABLE

(P/N 710 000 851) to the vehicle communication Connect the MPI-2 USB connector to the USB
connector. port on the PC (personal computer).

710000851

mmr2006-079-200

Use B.U.D.S. as described further in B.U.D.S.

topic.
NOTE: An optional MALE-FEMALE EXTENSION SE-
RIAL CABLE (P/N DB9) available at electronic retail
outlets can be used between diagnostic cable and
MPI-2 interface. Do not exceed 7.6 m (25 ft) or
communication between the vehicle and the PC
computer may be lost.

rmr2010-020-006_a

TYPICAL - MPI-2 CONNECTION TO VEHICLE COMMUNICATION

CONNECTOR

Connect the other end of the diagnostic cable to

the MPI-2 INTERFACE CARD (P/N 529 036 018) con-
nector.

rmr2013-020 3
Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.)

vmr2006-012-100_aen

529035697

OPTIONAL MALE-FEMALE EXTENSION SERIAL CABLE Writing Changes in an ECU

If the word Modified appears at the end of the
B.U.D.S. vehicle file name at the top of the B.U.D.S. page,
B.U.D.S. (BRP Utility and Diagnostic Software) is then a change has been made that requires it to
designed to allow electrical and electronic compo- be saved to the proper electronic module.
nent monitoring, activation of certain components
for testing and diagnostic purposes, and to carry
out setting changes.
Always use the latest applicable B.U.D.S. version
available on BOSSWeb.

Reading the Electronic Control Units rmr2010-020-008_a

Using B.U.D.S. 1. Indicate setting or data modified; Write Data to save
IMPORTANT: Ensure all connections have been
Click the Write Data button.
made before starting B.U.D.S. to allow proper
operation. Refer to CONNECTING THE PC TO
THE VEHICLE in this subsection.
1. Turn ignition key to ON.
2. Start B.U.D.S. and logon.
NOTE: B.U.D.S. will automatically choose the ap-
propriate MPI 2 protocol.
3. Ensure the appropriate number of modules is
shown in the status bar.

vmr2006-012-100_ben

NOTE: A message box will confirm a successful

operation.
Disconnect the MPI connections and store the
communication connector in its protective cap.
rmr2011-020-002_a

TYPICAL — CONNECTION SUCCESSFUL

1. Number of modules

If the number is less than indicated in table above,

refer to TROUBLESHOOTING in this subsection.
4. Read the ECUs by clicking the Read Data but-
ton.

4 rmr2013-020
 Subsection XX (COMMUNICATION TOOLS AND B.U.D.S.)

rmr2011-070-010

rmr2010-020-005_a
TYPICAL - MODULE SUBMENU LIST, SE5 MODEL ILLUSTRATED
1. Communication connector stored in protective cap
1. If the Update option is greyed out, no update
NOTICE Failure to secure the diagnostic con- file is available for this module.
nector in its protective cap may result in corro- 2. If the Update option is black, an update file is
sion or other damage to the terminals. available for this module. Select the update op-
tion and load the proper file.
Electronic Modules (ECU) Update
Whenever B.U.D.S. is first connected to a vehicle,
check for an update icon in the B.U.D.S. status bar
at the bottom of the Vehicle page.

rmr2010-020-004_a

TYPICAL
1. Greyed out: No update to perform
Black: Update file available

rmr2010-020-003_a

TYPICAL - UPDATE ICON

If the update icon is visible, B.U.D.S. indicates that

a file is available to update at least one of the elec-
tronic modules.
NOTE: If an update file is available on BOSSWeb
but B.U.D.S. being used is not up to date, the up-
date icon will not appear. Refer to the service bul-
letins to see if there is an update available.
Use the Module submenu and check all modules
one at a time to see which module(s) can be up-
dated.

rmr2013-020 5
 Subsection 04 (DIAGNOSTIC AND FAULT CODES)

DIAGNOSTIC AND FAULT CODES

For the latest fault code table, use the Info Cen-
ter submenu in BOSSWeb and enter the following
search criteria:
– Enclose the search within quotes " "
– Enter: "Roadster DTC ECM 2014", or "Roadster
DTC TCM 2014".

rmr2014-038 1
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

DIAGNOSTIC AND FAULT CODES

GENERAL
FAULT CODE TABLES
ECM Module
PCODE MODULE DESCRIPTION CAUSE ACTION
Communication
intermittent/erratic
External troubleshooting
and/or Check Sum Error.
VCM error or failure is not possible.
C006C ECM May be triggered by U0122
reported Check for communication fault.
(ECM) or U220B (ECM)
or any VCM DTC
Blown fuse
Check fuse.
Disconnect HO2S1.

Measure voltage
between harness connector
HO2S1-C and ground (expected
value = 11 to 13 volts).
Blown fuse,
Measure resistance between
HO2S heater control defective O2 sensor,
P0031 ECM HO2S1 pin C and D (expected
shorted to ground damaged circuit wires,
value: 7 to 12 ohms)
damaged ECM output pins.
Disconnect ECM-B.
Measure resistance between
harness connector HO2S1-D and
ground (expected value > open).
Measure resistance from harness
connector: HO2S1-D to ECMB-L2
(expected value: < 2 ohms).
Check fuse.
Disconnect HO2S1.

Measure voltage
between harness connector
HO2S1-C and ground (expected
value = 11 to 13 volts).
Defective O2 sensor, Measure resistance between
HO2S heater control
P0032 ECM damaged circuit wires, HO2S1 pin C and D (expected
shorted to battery
damaged ECM output pins. value: 7 to 12 ohms)
Disconnect ECM-B.
Measure resistance between
harness connector HO2S1-D and
ground (expected value > open).
Measure resistance from harness
connector: HO2S1-D to ECMB-L2
(expected value: < 2 ohms).

tmr2013-077 1
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Vacuum leakage between
throttle body and plenum (ex:
rubber hose disconnected,
loose screws, missing
check if Purge valve hose is
gasket at cylinder
disconnected or Damaged
head flange, missing
Make sure sensor
Manifold air pressure injector o-rings, cracks)
P0106 ECM connector is fully inserted.
not plausible Air intake duct or
Measure voltage between
filter severely clogged
harness connector pins 1 and 2
MAP sensor defective
(expected value: 4.8 to 5.1 volts).
Damaged circuit wires,
damaged connector or
damaged ECM pins, ECM
voltage supply.
Make sure sensor
connector is fully inserted.
Measure voltage between
harness connector pins 1 and 2
Sensor disconnected
(expected value: 4.8 to 5.1 volts).
or short to ground
Measure resistance from
Manifold air pressure Defective sensor,
connector: ECMA-G4 to MAPS-3
P0107 ECM sensor voltage too damaged circuit wires,
(expected value: < 2 ohms).
Low damaged connector or
Measure resistance from
damaged ECM pins, ECM
connector: ECMA-H2 to MAPS-2
voltage supply Low.
(expected value: < 2 ohms)
Measure resistance from
connector: ECMA-B4 to MAPS-1
(expected value: < 2 ohms).
Make sure sensor
connector is fully inserted.
Measure voltage between
harness connector pins 1 and 2
(expected value: 4.8 to 5.1 volts).
Defective sensor, wires Measure resistance from
Manifold air pressure
shorted to battery +, connector: ECMA-G4 to MAPS-3
P0108 ECM sensor voltage too
ECM voltage supply too (expected value: < 2 ohms).
High
High. Measure resistance from
connector: ECMA-H2 to MAPS-2
(expected value: < 2 ohms).
Measure resistance from
connector: ECMA-B4 to MAPS-1
(expected value: < 2 ohms).

2 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Make sure sensor
connector is fully inserted.
Measure voltage between
harness connector pins 1 and 3
(expected value: 4.8 to 5.1 volts).
Measure resistance from
Defective sensor,
connector: ECMA-F2 to AAPTS-1
damaged circuit wires,
Intake manifold air (expected value: < 2 ohms).
wire short to ground
P0112 ECM temperature sensor Measure resistance from
damaged connector or
circuit low connector: ECMA-H4 to AAPTS-2
damaged ECM pins, ECM
(expected value: < 2 ohms).
voltage supply Low.
Measure resistance from
connector: ECMA-G3 to AAPTS-4
(expected value: < 2 ohms).
Measure resistance from
connector: ECMA-B4 to AAPTS-3
(expected value: < 2 ohms).
Make sure sensor
connector is fully inserted.
Measure voltage between
harness connector pins 1 and 3
(expected value: 4.8 to 5.1 volts).
Measure resistance from
Sensor disconnected
connector: ECMA-F2 to AAPTS-1
Defective sensor,
Intake manifold air (expected value: < 2 ohms).
damaged wires, wire
P0113 ECM temperature sensor Measure resistance from
shorted to battery +,
circuit high connector: ECMA-H4 to AAPTS-2
ECM voltage supply too
(expected value: < 2 ohms).
High.
Measure resistance from
connector: ECMA-G3 to AAPTS-4
(expected value: < 2 ohms).
Measure resistance from
connector: ECMA-B4 to AAPTS-3
(expected value: < 2 ohms).
Disconnect the sensor and check
for a change in the fault code. If
the fault code stays the same, look
for a short circuit on the harness.
If the fault code is different,
replace the sensor.
Engine coolant Engine temperature sensor Measure resistance from
P0117 ECM temperature sensor 1 or circuit wires shorted to connector: ECMA-A1 to CTS-1
circuit Low ground. (expected value: < 2 ohms).
Measure resistance from
connector: ECMA-J2 to CTS-2
(expected value: < 2 ohms).
Measure CTS resistance value
(expected value: 2280 to 2736
ohms at 19 to 21°C (66 to 70°F)).

tmr2013-077 3
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check for disconnected
engine temperature sensor.
Measure resistance from
connector: ECMA-A1 to CTS-1
Engine coolant Disconnected sensor, circuit (expected value: < 2 ohms).
P0118 ECM temperature sensor 1 wire short to battery + or Measure resistance from
circuit High sensor resistance too High. connector: ECMA-J2 to CTS-2
(expected value: < 2 ohms).
Measure CTS resistance value
(expected value: 2280 to 2736
ohms at 19 to 21°C (66 to 70°F)).
Make sure sensor
connector is fully inserted.
Measure voltage between
Sensor disconnected
harness connector pins 1 and 4 .
Defective sensor,
Ambient Air (Expected value: 4.8 to 5.1 volts)
damaged wires, wire
P011C ECM Temperature Sensor Measure resistance from
shorted to battery +,
circuit high connector: ECMA-H4 to AAPTS-1
ECM voltage supply too
(Expected value: < 2 ohms)
High.
Measure resistance from
connector: ECMA-J4 to AAPTS-2
(Expected value: < 2 ohms)
Make sure sensor
connector is fully inserted.
Measure voltage between
Defective sensor,
harness connector pins 1 and 4 .
damaged circuit wires,
Ambient Air (Expected value: 4.8 to 5.1 volts)
wire short to ground
P011D ECM Temperature Sensor Measure resistance from
damaged connector or
circuit low connector: ECMA-H4 to AAPTS-1
damaged ECM pins, ECM
(Expected value: < 2 ohms)
voltage supply Low.
Measure resistance from
connector: ECMA-J4 to AAPTS-2
(Expected value: < 2 ohms)
Make sure sensor
connector is fully inserted.
Measure resistance from
connector: ECMB-K1 to TAS-A
First Throttle Damaged circuit wires,
(expected value: < 2 ohms).
Accelerator Sensor damaged throttle position
P0122 ECM Measure resistance from
(TAS) Short circuit to sensor or damaged ECM
connector: ECMB-K3 to TAS-B
GND pins.
(expected value: < 2 ohms).
Measure resistance from
connector: ECMB-E1 to TAS-C
(expected value: < 2 ohms).
Make sure sensor
connector is fully inserted.
Measure resistance from
connector: ECMB-K1 to TAS-A
First Throttle Damaged circuit wires,
(expected value: < 2 ohms).
Accelerator Sensor damaged throttle position
P0123 ECM Measure resistance from
(TAS) shorted to sensor or damaged ECM
connector: ECMB-K3 to TAS-B
battery + pins.
(expected value: < 2 ohms).
Measure resistance from
connector: ECMB-E1 to TAS-C
(expected value: < 2 ohms).

4 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)
PCODE MODULE DESCRIPTION CAUSE
DTC is set when air
temperature sensor
Intake manifold air reaches 176 F (80C)
P0127 ECM
temperature high Could happen during
extended idling at very
hot ambient temperatures
Deffective O2 sensor,
damaged circuit wires,
damaged connector or
damaged ECM output pins.
Canister purge
circuit deffective
HO2S signal not Canister purge valve leaking
P0130 ECM
plausible Canister purge valve installed
in wrong flow direction
Fuel pressure too
high or too low.
Note: P0131 may appear
also in case of low voltage
output (lean)
Defective O2 sensor,
damaged circuit wires,
HO2S signal too low damaged ECM output pins.
P0131 ECM
voltage Fuel pressure too low
Note: P0130 may appear
also for the same reason
Short circuit to battery
Defective O2 sensor,
HO2S signal too high
P0132 ECM damaged circuit wires,
voltage
damaged connector or
damaged ECM output pins.
tmr2013-077
ACTION
Check fuse.
Disconnect HO2S1.
Measure voltage between
harness connector HO2S1-C
and ground (expected
value = 11 to 13 volts).
Measure resistance between
HO2S1 pin C and D (expected
value = 7 to 12 ohms).
Disconnect ECM-B.
Measure resistance
between harness connector
HO2S1-D and ground
(expected value > open).
Measure resistance from harness
connector: HO2S1-D to ECMB-L2
(expected value: < 2 ohms).
Disconnect HO2S1.
Disconnect ECM-B.
Measure resistance between
harness connector HO2S1-B and
ground (expected value > open).
Measure resistance from harness
connector: HO2S1-B to ECMB-D2
(expected value: < 2 ohms).
Measure resistance
between harness connector
HO2S1-A and ground
(expected value > open).
Measure resistance from harness
connector: HO2S1-A to ECMB-J1
(expected value: < 2 ohms).
Disconnect HO2S1.
Disconnect ECM-B.
Measure resistance between
harness connector HO2S1-B and
ground (expected value > open).
Measure resistance from harness
connector: HO2S1-B to ECMB-D2
(expected value: < 2 ohms).
Measure resistance
between harness connector
HO2S1-A and ground
(expected value > open).
Measure resistance from harness
connector: HO2S1-A to ECMB-J1
(expected value: < 2 ohms).
5
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Replace lambda sensor
HO2S signal response Investigate possibility of lambda
P0133 ECM Defective lambda sensor
time is too slow sensor contamination (ex: type of
fuel used, gasket sealants used)
HO2S internal heater Defective internal heater in
P0135 ECM Replace lambda sensor
circuit defective lambda sensor
Any reason which
will cause a lean If ECM first initialization is
condition under load, ex: performed GBPS initialization
Fuel correction
Fuel pressure too low must be done as per Warranty
P0171 ECM reached the maximum
Clogged fuel filter Bulletin 2010-4 procedure
limit, multiplicative
Clogged fuel injector Check injector and fuel supply
Large quantity of ethanol system.
fuel mixed in the tank
Inspect evap canister
purge valve function.
Perform EVAP Purge Valve
Any reason which
Operational Test as described in
will cause a rich
the Fuel Tank and Fuel System
condition under load, ex:
section of the shop manual
Fuel correction Fuel pressure too high
If purge valve is replaced perform
P0172 ECM reached the minimum Oil entering the intake
ECM first initialization using
limit, multiplicative system through the
BUDS ECM/Setting screen
vacuum assist line
If ECM first initialization is
Canister purge valve stuck
performed GBPS initialization
open
must be done as per Warranty
Bulletin 2010-4 procedure
Check fuel pressure regulator.
Open ECM ACTIVATION
Disconnected injector
Injector circuit open, page in B.U.D.S.
P0201 ECM Blown fuse
LH side cylinder Activate injector and check if
Damaged circuit wires
injector is reacting as expected.
Open ECM ACTIVATION
Disconnected injector
Injector circuit open, page in B.U.D.S.
P0202 ECM Blown fuse
middle cylinder Activate injector and check if
Damaged circuit wires
injector is reacting as expected.
Open ECM ACTIVATION
Disconnected injector
Injector circuit open, page in B.U.D.S.
P0203 ECM Blown fuse
RH side cylinder Activate injector and check if
Damaged circuit wires
injector is reacting as expected.
DTC is set when coolant
temperature sensor reaches Check for coolant fluid leak
230 F (110C) with engine and coolant fluid level.
Engine coolant over
P0217 ECM running, or 253F (123C) Check radiator condition.
temperature condition
with engine stopped Check for other fault, check
Front radiators blocked thermostat.
with road debris or insects

6 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Make sure sensor
connector is fully inserted.
Measure resistance from
connector: ECMB-J3 to TAS-D
Damaged circuit wires,
2nd Throttle (expected value: < 2 ohms).
damaged throttle position
P0222 ECM Accelerator Sensor Measure resistance from
sensor, or damaged ECM
(TAS) shorted to GND connector: ECMB-B3 to TAS-E
pins.
(expected value: < 2 ohms).
Measure resistance from
connector: ECMB-A3 to TAS-F
(expected value: < 2 ohms).
Make sure sensor
connector is fully inserted.
Measure resistance from
connector: ECMB-J3 to TAS-D
2nd Throttle Damaged circuit wires,
(expected value: < 2 ohms).
Accelerator Sensor damaged throttle position
P0223 ECM Measure resistance from
(TAS) shorted to sensor, or damaged ECM
connector: ECMB-B3 to TAS-E
battery + pins.
(expected value: < 2 ohms).
Measure resistance from
connector: ECMB-A3 to TAS-F
(expected value: < 2 ohms).
Check fuse.
Measure voltage between
harness connector FP-B
and ground (expected
value: 11 to 13 volts).
Blown fuse, damaged or Measure resistance on
Fuel pump circuit disconnected fuel pump, the fuel pump connector
P0231 ECM shorted to ground, or damaged circuit wires, between terminals B and C
open circuit damaged connectors or (expected value: < 2 ohms).
damaged ECM output pins. Measure resistance from harness
connector: ECMB-M1 to FP-C
(expected value: < 2 ohms).
Measure voltage between
harness connector FP-C and
ground (expected value: 0 volts).
Check fuse.
Measure voltage between
harness connector FP-B
and ground (expected
value: 11 to 13 volts).
Measure resistance on
Damaged fuel pump,
the fuel pump connector
Fuel pump circuit damaged circuit wires,
P0232 ECM between terminals B and C
shorted to battery + damaged connectors or
(expected value: < 2 ohms).
damaged ECM output pins.
Measure resistance from harness
connector: ECMB-M1 to FP-C
(expected value: < 2 ohms).
Measure voltage between
harness connector FP-C and
ground (expected value: 0 volts).

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Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check fuse.
Disconnect injector 3.
Measure resistance between
injector pin 1 and 2 (expected
value = 14 to15 ohms).
Measure resistance from harness
Defective injector,
Injector short to connector: ECMA-J1 to INJ1-1
Damaged circuit wires.
P0261 ECM ground, LH side (expected value: < 2 ohms).
Damaged connector or
cylinder Measure voltage between
damaged ECM output pins.
harness connector INJ1-2
and ground (expected
value: 11 to 13 volts).
Check if HIC connector is
connecting the engine harness to
the vehicle harness.
Disconnect injector 3.
Measure resistance between
injector pin 1 and 2 (expected
value = 14 to15 ohms).
Measure resistance from
Defective injector,
Injector short to harness connector: INJ1-1 to
damaged circuit wires,
P0262 ECM battery voltage, LH INJ1-2 (expected value: > open).
Damaged connector or
side cylinder Measure voltage between
damaged ECM output pins.
harness connector ECMA-J1 and
ground (expected value: 0 volts).
Check if HIC connector is
connecting the engine harness to
the vehicle harness.
Check fuse.
Disconnect injector 2.
Measure resistance between
injector pin 1 and 2 (expected
value = 14 to15 ohms).
Measure resistance from harness
Defective injector,
Injector short to connector: ECMA-K1 to INJ2-1
Damaged circuit wires.
P0264 ECM ground, middle (expected value: < 2 ohms).
Damaged connector or
cylinder Measure voltage between
damaged ECM output pins.
harness connector INJ2-2
and ground (expected
value: 11 to 13 volts).
Check if HIC connector is
connecting the engine harness to
the vehicle harness.
Disconnect injector 2.
Measure resistance between
injector pin 1 and 2 (expected
value = 14 to15 ohms).
Measure resistance from
Defective injector,
Injector short to harness connector: INJ2-1 to
damaged circuit wires,
P0265 ECM battery voltage, middle INJ2-2 (expected value: > open).
Damaged connector or
cylinder Measure voltage between
damaged ECM output pins.
harness connector ECMA-K1 and
ground (expected value: 0 volts).
Check if HIC connector is
connecting the engine harness to
the vehicle harness.

8 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check fuse.
Disconnect injector 1.
Measure resistance between
injector pin 1 and 2 (expected
value = 14 to15 ohms).
Measure resistance from harness
Defective injector,
Injector short to connector: ECMA-B3 to INJ1-1
Damaged circuit wires.
P0267 ECM ground, RH side (expected value: < 2 ohms).
Damaged connector or
cylinder Measure voltage between
damaged ECM output pins.
harness connector INJ1-2
and ground (expected
value: 11 to 13 volts).
Check if HIC connector is
connecting the engine harness to
the vehicle harness.
Disconnect injector 1.
Measure resistance between
injector pin 1 and 2 (expected
value = 14 to15 ohms).
Measure resistance from
Defective injector,
Injector short to harness connector: INJ1-1 to
damaged circuit wires,
P0268 ECM battery voltage, RH INJ1-2 (expected value: > open).
Damaged connector or
side cylinder Measure voltage between
damaged ECM output pins.
harness connector ECMA-B3 and
ground (expected value: 0 volts).
Check if HIC connector is
connecting the engine harness to
the vehicle harness.
Damaged knock sensor,
Make sure sensor connector is
Knock sensor 1 damaged circuit wires,
P0327 ECM fully inserted and check knock
negative line damaged connector or
system.
damaged ECM output pins.
Damaged knock sensor,
Make sure sensor connector is
Knock sensor 1 damaged circuit wires,
P0328 ECM fully inserted and check knock
positive line damaged connector or
system.
damaged ECM output pins.
Knock sensor
electrically disconnected Make sure sensor connector is
Knock sensor signal
P032A ECM Knock sensor not properly fully inserted and check knock
fault
bolted to the engine system.
Knock sensor defective
Make sure sensor
Disconnected sensor
connector is fully inserted.
Defective CPS,
Measure resistance from
damaged circuit wires,
Error on crankshaft connector: ECMA-H1 to CPS-1
P0335 ECM damaged connector or
position sensor signal (expected value: < 2 ohms).
damaged ECM output pins.
Measure resistance from
Mechanical damage around
connector: ECMA-K2 to CPS-2
the CPS encoder wheel
(expected value: < 2 ohms).

tmr2013-077 9
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Make sure sensor
Disconnected sensor connector is fully inserted.
Blown fuse Measure voltage between
Defective CAPS, harness connector CAPS-3
damaged circuit wires, and ground (expected
Error on camshaft damaged connector or value: 11 to 13 volts).
P0340 ECM
position sensor signal damaged ECM output pins. Measure resistance from
Trigger wheel missing connector: ECMA-E2 to CAPS-2
or in incorrect position (expected value: < 2 ohms).
on intake camshaft Measure resistance from
connector: ECMA-D4 to CAPS-1
(expected value: < 2 ohms).
Internal open circuit in
P0357 ECM ignition powerstage, Defective ECU Replace ECU if fault is persisting
RH side cylinder
Open the ECM Activation
page in B.U.D.S.
Perform an ignition coil
activation and check if ignition
coil is reacting as expected.
Check fuse and HIC connector.
Defective ignition coil, Measure resistance from harness
damaged circuit wires, connector: ECMA-M4 to COIL-1
Ignition coil maximum damaged connector or (expected value: < 2 ohms).
P0358 ECM current exceeded, RH damaged ECM output pins. Measure voltage between
side cylinder Ignition coil harness connector COIL-1
resistance too low and ground (expected
Defective ECU value: 11 to 13 volts).
Check connector HIC that
connects to engine harness
to the vehicle harness.
Refer to the SERVICE MANUAL
for detailed IGNITION COIL
TESTING procedure.
Open the ECM Activation
page in B.U.D.S.
Perform an ignition coil
activation and check if ignition
coil is reacting as expected.
Check fuse and HIC connector.
Defective ignition coil, Measure resistance from harness
damaged circuit wires, connector: ECMA-M2 to COIL-2
Ignition coil maximum damaged connector or (expected value: < 2 ohms).
P0359 ECM current exceeded, damaged ECM output pins. Measure voltage between
middle cylinder Ignition coil harness connector COIL-2
resistance too low and ground (expected
Defective ECU value: 11 to 13 volts).
Check connector HIC that
connects to engine harness
to the vehicle harness.
Refer to the SERVICE MANUAL
for detailed IGNITION COIL
TESTING procedure.

10 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Open the ECM Activation
page in B.U.D.S.
Perform an ignition coil
activation and check if ignition
coil is reacting as expected.
Check fuse and HIC connector.
Defective ignition coil, Measure resistance from harness
damaged circuit wires, connector: ECMA-M1 to COIL-3
Ignition coil maximum damaged connector or (expected value: < 2 ohms).
P0360 ECM current exceeded, LH damaged ECM output pins. Measure voltage between
side cylinder Ignition coil harness connector COIL-3
resistance too low and ground (expected
Defective ECU value: 11 to 13 volts).
Check connector HIC that
connects to engine harness
to the vehicle harness.
Refer to the SERVICE MANUAL
for detailed IGNITION COIL
TESTING procedure.
Internal open circuit in
P0361 ECM ignition powerstage, Defective ECU Replace ECU if fault is persisting
middle cylinder
Internal open circuit in
P0362 ECM ignition powerstage, Defective ECU Replace ECU if fault is persisting
LH side cylinder
Check fuse.
Disconnect EVAP.
Measure resistance between
EVAP pin 1 and 2 (expected
Purge valve disconnected
value = 10 to 20 ohms).
Defective purge valve,
Canister purge valve Measure resistance from harness
P0443 ECM damaged circuit wires,
open circuit connector: ECMA-M3 to EVAP-1
damaged connector or
(expected value: < 2 ohms).
damaged ECM output pins.
Measure voltage between
harness connector EVAP-2 and
ground (expected value: 11 to 13
volts).
Check fuse.
Disconnect purge valve.
Measure voltage between
harness connector EVAP-1
and ground (expected
value: < 2 volts).
Blown fuse, defective purge Measure voltage between
Canister purge valve valve, damaged circuit wires, harness connector EVAP-2
P0458 ECM
shorted to ground damaged connectors or and ground (expected
damaged ECM output pins. value: 11 to 13 volts)
Measure resistance between
EVAP pin 1 and 2 (expected
value = 10 to 20 ohms).
Check if HIC connector is
connecting the engine harness to
the vehicle harness.

tmr2013-077 11
Subsection XX (DIAGNOSTIC AND FAULT CODES)
PCODE MODULE DESCRIPTION CAUSE
Defective purge valve,
Canister purge valve damaged circuit wires,
P0459 ECM
shorted to battery + damaged connector or
damaged ECM output pins.
Damaged or disconnected
relay, damaged circuit wires,
Main radiator fan relay damaged connectors or
P0481 ECM
open circuit damaged ECM output pins,
damaged headlamp overrun
switch.
Vehicle speed not Vehicle speed correlation
P0501 ECM
plausible check failed.
Brake signal vs
brake pressure
correlation check failed.
Driver may be activating the
Brake signal not
P0504 ECM BLS for more than 2.5 sec
plausible
without building more than
10psi of hydraulic pressure
in the brake system.
BLS may be always activated
Blown fuse, damaged
or disconnected relay,
damaged circuit wires,
P0512 ECM Starter control circuit damaged connectors or
damaged ECM output pins,
damaged headlamp overrun
switch.
P0513 ECM D.E.S.S. key invalid Invalid Access Key Detected
12
ACTION
Disconnect purge valve.
Measure voltage between
harness connector EVAP-1
and ground (expected
value: < 2 volts).
Measure voltage between
harness connector EVAP-2
and ground (expected
value: 11 to 13 volts).
Measure resistance between
EVAP pin 1 and 2 (expected value
= 10 to 20 ohms).
Check fuse.
Disconnect relay.
Measure resistance between
terminals 85 and 86 on relay
(expected value: 70 to 90 ohms).
Measure resistance between
harness connector FB-85 and
ground (expected value > open).
Measure resistance from harness
connector: ECMA-A4 to FB-85
(expected value: < 2 ohms).
Check for VCM fault.
Open the VCM Monitoring
page in B.U.D.S.
Verify that speed sensors
are working as expected.
Open the ECM Monitoring
page in B.U.D.S.
Press on brake pedal.
Ensure that brake switch light
comes on ECM Monitoring page.
Verify that brake pressure
sensor displays a valid value
on VCM Monitoring page.
Check fuse F5.
Check fuse.
Disconnect prestarting relay.
Measure resistance between
terminals 85 and 86 on relay
(expected value: 70 to 90 ohms).
Measure resistance between
harness connector FB-C4 and
ground (expected value > open).
Measure resistance from harness
connector: ECMB-C4 to FB-C4
(expected value: < 2 ohms).
A non stored access key was
detected when key switch was
turned to ON.
tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Measure resistance between
harness connector EOP and
ground when engine stopped
(expected value < 2 ohms).
Defective oil pressure
Measure resistance between
switch, damaged
harness connector EOP and
Engine oil pressure circuit wires,
ground when engine running
P0520 ECM sensor circuit damaged connector
(expected value = open).
malfunction or loose terminals,
Measure resistance from harness
damaged ECM pins.
connector: EOP to ECMA-E3
(expected value: < 2 ohms).
Check if HIC connector is properly
connected (engine harness to the
vehicle harness).
Measure resistance between
harness connector EOP and
ground when engine stopped
Disconnected oil (expected value < 2 ohms).
pressure switch Measure resistance between
Damaged oil pressure harness connector EOP and
Engine oil pressure switch, damaged ground when engine running
P0523 ECM
switch sticking circuit wires, (expected value = open).
damaged connector, Measure resistance from harness
damaged ECM pins. connector: EOP to ECMA-E3
(expected value: < 2 ohms).
Check if HIC connector is properly
connected (engine harness to the
vehicle harness).
Measure resistance between
harness connector EOP and
ground when engine stopped
Oil level too low (expected value < 2 ohms).
Engine mechanical problem Measure resistance between
Defective oil pressure harness connector EOP and
Engine oil pressure switch, damaged ground when engine running
P0524 ECM
too Low circuit wires, (expected value = open).
damaged connector, Measure resistance from harness
damaged ECM pins. connector: EOP to ECMA-E3
(expected value: < 2 ohms).
Check if HIC connector is properly
connected (engine harness to the
vehicle harness).
Open the ECM Monitoring
If no valid brake pressure on page in B.U.D.S.
CAN is available from VCM, Check fuse F5
a system check can not Press on brake pedal.
Brake Pressure on
P0556 ECM be realized. Therefore the Ensure that brake switch light
CAN not valid
condition for a non plausible comes on ECM Monitoring page.
brake signal is set after a Verify that brake pressure sensor
certain time. displays a valid value on VCM
Monitoring page.
Non-plausibility error ECU internal failure in reading
P0560 ECM Replace ECU if fault is persisting
on system voltage system voltage

tmr2013-077 13
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Measure battery voltage with
engine stopped (expected
Alternator defective value: 11 to 13 volts).
or not connected Measure battery voltage with
Battery failure; an engine running (expected
P0562 ECM System voltage Low external battery charger value: 13 to 14.7 volts).
may have been used. Check connections
Damaged circuit wires or on voltage regulator.
connection. Check ground and positive
connections on battery.
Check ground on vehicle frame.
Measure battery voltage with
engine stopped (expected
value: 11 to 13 volts).
Measure battery voltage with
Defective voltage regulator
engine running (expected
inside the alternator
P0563 ECM System voltage High value: 13 to 14.7 volts).
An external battery charger
Check connections
may have been used.
on voltage regulator.
Check ground and positive
connections on battery.
Check ground on vehicle frame.
Try updating the ECM calibration.
Faulty calibration. If the problem
Control module
P0606 ECM Faulty programming. persists, reflash ECM.
processor
Damaged ECM. If the problem persists, replace
the ECM.
Make sure sensor
connector is fully inserted.
Measure resistance from
connector: ECMB-K1 to TAS-A
(expected value: < 2 ohms).
Measure resistance from
connector: ECMB-K3 to TAS-B
(expected value: < 2 ohms).
Throttle Accelerator
Measure resistance from
Sensor (TAS)
Throttle Accelerator Sensors connector: ECMB-E1 to TAS-C
P060D ECM synchronistic error
(TAS) plausibility check error. (expected value: < 2 ohms).
between sensor 1 and
Measure resistance from
2
connector: ECMB-J3 to TAS-D
(expected value: < 2 ohms).
Measure resistance from
connector: ECMB-B3 to TAS-E
(expected value: < 2 ohms).
Measure resistance from
connector: ECMB-A3 to TAS-F
(expected value: < 2 ohms).

14 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Throttle position
P060E ECM TPS plausibility check error.
performance
Faulty variant coding.
Faulty programming.
P0610 ECM Variant coding error
Wrong ECM after
replacement.
Brake signals do not
give same information
when compared.
Brake switch,
damaged circuit wires,
brake signal states
P061E ECM damaged connectors or
Invalid
damaged ECM output pins.
Brale state calculated
by brake pressure
from CAN not valid
Disconnect TPS.
Measure voltage between
harness connector TPS-1
and TPS-3 (expected
value = 4.8 to 5.1 volt).
Measure resistance between
TPS pin 1 and 3 (expected
value = 3K to 5K ohms).
Disconnect ECMA.
Measure resistance from harness
connector: TPS-2 to ECMA-F3
(expected value: < 2 ohms).
Measure resistance from harness
connector: TPS-4 to ECMA-K3
(expected value: < 2 ohms).
Try updating the ECM
variant or calibration.
If the problem
persists, reflash ECM.
If the problem persists, replace
ECM.
Open the ECM Monitoring
page in B.U.D.S.
Press on brake pedal.
Ensure that brake switch light
comes on ECM Monitoring page.
Verify that brake pressure
sensor displays a valid value
on VCM Monitoring page.
Check fuse F5.

Check LFB F3 fuse

Check battery terminals
Alternator disconnected Check alternator terminals
Alternator feed back Damaged alternator Measure resistance from harness
P0625 ECM circuit shorted to Battery unplugged connector: LFB-B6 to ALT2
ground or open circuit Open sensing circuit or (expected value: < 2 ohms).
burnt LFB 10A F3 fuse Measure resistance from harness
connector: LFB-A6 to LFB-87
(expected value: < 2 ohms).
Check for VCM fault.
Vehicle speed Open the VCM Monitoring
Message counter plausibility
P062C ECM message on CAN page in B.U.D.S.
check of vehicle speed failed.
not plausible Verify that speed sensors
are working as expected.
Try updating the ECM
Faulty calibration or transmission variant or calibration.
Internal control
transmission variant. If the problem
P062F ECM module EEPROM
Faulty programming. persists, reflash ECM
error
Damaged ECM. If the problem persists, replace
ECM.

tmr2013-077 15
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check fuse.
Disconnect Main relay 2.
Measure voltage between
harness connector FB-D5
and ground (expected
value: 11 to 13 volts).
Measure voltage between
harness connector FB-C5
Blown fuse, damaged
and ground (expected
or disconnected relay,
value: 11 to 13 volts).
P0685 ECM Main relay 2 circuit damaged circuit wires,
Measure resistance from harness
damaged connectors or
connector: ECMB-J2 to FB-C6
damaged ECM output pins.
(expected value: < 2 ohms).
Measure resistance from harness
connector: ECMB-J2 to JMP1-C
(expected value: < 2 ohms).
Measure resistance between
terminals 85 and 86 on the 2
relays (expected value: 70 to 90
ohms).
Check fuse.
Disconnect main relay 2.
Measure voltage between
harness connector FB-D5
and ground (expected
value: 11 to 13 volts).
Measure voltage between
harness connector FB-C5
Blown fuse, damaged
and ground (expected
Main relay 2 circuit or disconnected relay,
value: 11 to 13 volts).
P0686 ECM shorted to ground or damaged circuit wires,
Measure resistance from harness
open circuit damaged connectors or
connector: ECMB-J2 to FB-C6
damaged ECM output pins.
(expected value: < 2 ohms).
Measure resistance from harness
connector: ECMB-J2 to JMP1-C
(expected value: < 2 ohms).
Measure resistance between
terminals 85 and 86 on the 2
relays (expected value: 70 to 90
ohms).

16 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check fuse.
Disconnect main relay 2.
Measure voltage between
harness connector FB-D5
and ground (expected
value: 11 to 13 volts).
Measure voltage between
harness connector FB-C5
Damaged relay, and ground (expected
Main relay 2 circuit damaged circuit wires, value: 11 to 13 volts).
P0687 ECM
shorted to battery + damaged connector or Measure resistance from harness
damaged ECM output pins. connector: ECMB-J2 to FB-C6
(expected value: < 2 ohms).
Measure resistance from harness
connector: ECMB-J2 to JMP1-C
(expected value: < 2 ohms).
Measure resistance between
terminals 85 and 86 on the 2
relays (expected value: 70 to 90
ohms).
Check fuse.
Disconnect radiator fan relay.
Measure voltage between
harness connector FB-86
and ground (expected
Blown fuse, value: 11 to 13 volts).
damaged fan relay, Measure resistance between
Main radiator fan relay
P0693 ECM damaged circuit wires, harness connector FB-85 and
shorted to ground
damaged connectors or ground (expected value: open).
damaged ECM output pins. Measure resistance from harness
connector: ECMA-A4 to FB-85
(expected value: < 2 ohms).
Measure resistance between
terminals 85 and 86 on relay
(expected value: 70 to 90 ohms).
Disconnect radiator fan relay.
Measure voltage between
Damaged fan relay,
harness connector FB-85 and
Main radiator fan relay damaged circuit wires,
P0694 ECM ground (expected value: 0 volts).
shorted to battery + damaged connector or
Measure resistance between
damaged ECM output pins.
terminals 85 and 86 on relay
(expected value: 70 to 90 ohms).
Check that vent line of vacuum
assist is not restricted
Check for proper hose
connection on the solenoid valve
Clutch slippage Clutch slippage was detected
P0811 ECM Check for short to
detected for more than 10 seconds
ground on solenoid wire
Inspect clutch for excessive wear
Check adjustment of clutch
adjuster

tmr2013-077 17
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Blown fuse, damaged
or disconnected relay,
damaged circuit wires,
Pre-starting relay short
P081A ECM damaged connectors or
circuit to ground
damaged ECM output pins,
damaged headlamp overrun
switch.
damaged or disconnected
Reverse lock actuator relay, damaged circuit wires,
P0924 ECM
relay circuit damaged connectors or
damaged ECM output pins.
Check fuse.
Disconnect prestarting relay.
Measure resistance between
terminals 85 and 86 on relay
(expected value: 70 to 90 ohms).
Measure resistance between
harness connector FB-C4 and
ground (expected value > open).
Measure resistance from harness
connector: ECMB-C4 to FB-C4
(expected value: < 2 ohms).
Check fuse.
Disconnect Reverse
lock actuator relay
Measure resistance between
terminals 85 and 86 on the relays
(expected value: 70 to 90 ohms).
Measure voltage between
harness connector LFB-A12
and ground (expected
value: 11 to 13 volts).
Measure voltage between
harness connector LFB-A11
and ground (expected
value: 11 to 13 volts).
Measure resistance from
harness connector: ECMB-G1
to LFB-B11 (expected
value: < 2 ohms).

Check fuse.
Disconnect Reverse
lock actuator relay
Measure resistance between
terminals 85 and 86 on the relays
(expected value: 70 to 90 ohms).
Measure voltage between
Blown fuse, damaged
harness connector LFB-A12
Reverse lock actuator or disconnected relay,
and ground (expected
P0926 ECM relay circuit shorted to damaged circuit wires,
value: 11 to 13 volts).
ground or open circuit damaged connectors or
Measure voltage between
damaged ECM output pins.
harness connector LFB-A11
and ground (expected
value: 11 to 13 volts).
Measure resistance from harness
connector: ECMB-G1 to LFB-B11
(expected value: < 2 ohms).

18 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check fuse.
Disconnect Reverse
lock actuator relay
Measure resistance between
terminals 85 and 86 on the relays
(expected value: 70 to 90 ohms).
Measure voltage between
harness connector LFB-A12
Damaged relay, and ground (expected
Reverse lock actuator
damaged circuit wires, value: 11 to 13 volts).
P0927 ECM relay circuit shorted to
damaged connector or Measure voltage between
battery +
damaged ECM output pins. harness connector LFB-A11
and ground (expected
value: 11 to 13 volts).
Measure resistance from
harness connector: ECMB-G1
to LFB-B11 (expected
value: < 2 ohms).

Check fuse.
Disconnect HO2S1.

Measure voltage
between harness connector
HO2S1-C and ground (expected
value = 11 to 13 volts).
Defective or
Measure resistance between
disconnected O2 sensor,
HO2S heater control HO2S1 pin C and D (expected
P1030 ECM damaged or disconnected
circuit open value = 7 to 12 ohms).
circuit wires, damaged ECM
Disconnect ECM-B.
output pins.
Measure resistance
between harness connector
HO2S1-D and ground
(expected value > open).
Measure resistance from harness
connector: HO2S1-D to ECMB-L2
(expected value: < 2 ohms).
Wrong Throttle
Wrong TPS sensor position.
P1120 ECM Position Sensor (TPS) Check TPS adjustment.
Both TPS position failed test.
position

tmr2013-077 19
Subsection XX (DIAGNOSTIC AND FAULT CODES)
PCODE MODULE DESCRIPTION CAUSE
Disconnected lambda sensor
Defective O2 sensor,
HO2S signal circuit
P1130 ECM damaged circuit wires,
open
damaged connector or
damaged ECM output pins.
Any reason which will cause
a lean condition at idle, ex:
Fuel pressure too low
Fuel correction
Clogged fuel injector
P1171 ECM reached the maximum
Defective fuel
limit, additive
injector (sticking)
Large quantity of ethanol
fuel mixed in the tank
Any reason which will cause
a rich condition at idle, ex:
Fuel pressure too high
Canister purge
valve stuck open
Fuel correction
Canister purge valve leaking
P1172 ECM reached the minimum
Canister purge valve installed
limit, additive
in wrong flow direction
Large amount of fuel vapor
coming out the crankcase
ventilation hose (fuel in
engine oil)
Damaged knock sensor,
Knock sensor 1 damaged circuit wires,
P1327 ECM
negative line damaged connector or
damaged ECM output pins.
Damaged knock sensor,
Knock sensor 1 damaged circuit wires,
P1328 ECM
positive line damaged connector or
damaged ECM output pins.
20
ACTION
Check fuse.
Disconnect HO2S1.
Measure voltage between
harness connector HO2S1-C
and ground (expected
value = 11 to 13 volts).
Measure resistance between
HO2S1 pin C and D (expected
value = 7 to 12 ohms).
Disconnect ECM-B.
Measure resistance
between harness connector
HO2S1-D and ground
(expected value > open).
Measure resistance from harness
connector: HO2S1-D to ECMB-L2
(expected value: < 2 ohms).
If ECM first initialization is
performed GBPS initialization
must be done as per Warranty
Bulletin 2010-4 procedure
Check injector and fuel supply
system.
Inspect evap canister
purge valve function.
Perform EVAP Purge Valve
Operational Test as described in
the Fuel Tank and Fuel System
section of the shop manual
If purge valve is replaced perform
ECM first initialization using
BUDS ECM/Setting screen
If ECM first initialization is
performed GBPS initialization
must be done as per Warranty
Bulletin 2010-4 procedure
Check fuel pressure regulator.
Check knock system.
Check knock system.
tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check fuse.
Disconnect relay.
Measure resistance between
Damaged or disconnected
terminals 85 and 86 on relay
relay, damaged circuit wires,
(expected value: 70 to 90 ohms).
Radiator fan direction damaged connectors or
P1480 ECM Measure resistance between
relays open circuit damaged ECM output pins,
harness connector FB-C8 and
damaged headlamp overrun
ground (expected value > open).
switch.
Measure resistance from harness
connector: ECMB-J4 to FB-C8
(expected value: < 2 ohms).
Open the ECM setting
Brake Pressure Brake Pressure Adaptation
page in B.U.D.S.
P1556 ECM adaptation Not is needed or was not
Perform the brake pressure
Initialized performed properly
adaptation reset
Check for ECM fault.
Control Module
P1606 ECM Internal ECM problem. External troubleshooting not
Processor
possible.
Disconnect ETA.
Measure resistance from
Damaged ETA,
Electrical Throttle connector: ECMA-L1 to ETA-3
damaged circuit wires,
P160E ECM Actuator (ETA) control (expected value: < 2 ohms).
damaged connector or
fault Measure resistance from
damaged ECM output pins.
connector: ECMA-L2 to ETA-4
(expected value: < 2 ohms).
Disconnect ETA.
Measure resistance from
Damaged ETA,
Electrical Throttle connector: ECMA-L1 to ETA-3
damaged circuit wires,
P1610 ECM Actuator (ETA) shorted (expected value: < 2 ohms).
damaged connector or
to V + Measure resistance from
damaged ECM output pins.
connector: ECMA-L2 to ETA-4
(expected value: < 2 ohms).
Disconnect ETA.
Measure resistance from
Damaged ETA,
Electrical Throttle connector: ECMA-L1 to ETA-3
damaged circuit wires,
P1611 ECM Actuator (ETA) shorted (expected value: < 2 ohms).
damaged connector or
to ground Measure resistance from
damaged ECM output pins.
connector: ECMA-L2 to ETA-4
(expected value: < 2 ohms).
Disconnect ETA.
Measure resistance from
Damaged ETA,
Electrical Throttle connector: ECMA-L1 to ETA-3
damaged circuit wires,
P1612 ECM Actuator (ETA) signal (expected value: < 2 ohms).
damaged connector or
not plausible Measure resistance from
damaged ECM output pins.
connector: ECMA-L2 to ETA-4
(expected value: < 2 ohms).
Disconnect ETA.
Measure resistance from
Damaged ETA,
connector: ECMA-L1 to ETA-3
Electrical Throttle damaged circuit wires,
P1613 ECM (expected value: < 2 ohms).
Actuator (ETA) damaged connector or
Measure resistance from
damaged ECM output pins.
connector: ECMA-L2 to ETA-4
(expected value: < 2 ohms).

tmr2013-077 21
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check throttle plate movement.
Check idle stop for wear.
Check throttle position
sensor angle at idle,
Throttle mechanical
expected value 2-3.5 degrees
Throttle idle position adjustment.
Perform THROTTLE
P1614 ECM failure on throttle No TPS reset
POSITION SENSOR RESET
release after throttle body/
in B.U.D.S. with throttle grip
ECM replacement.
accelerator not activated
since at least 30 seconds.
Refer to the SERVICE MANUAL
for more details.
Check throttle plate movement.
Check idle stop for wear.
Ensure throttle plate is
against throttle stop.
Check throttle position
Throttle mechanical
sensor angle at idle,
adjustment.
TPS position deviation expected value 2-3.5 degrees
P1615 ECM No TPS reset
fault Perform THROTTLE
after throttle body/
POSITION SENSOR RESET
ECM replacement.
in B.U.D.S. with throttle grip
accelerator not activated
since at least 30 seconds.
Refer to the SERVICE MANUAL
for more details.
Check throttle plate movement.
Check idle stop for wear.
Ensure throttle plate is
against throttle stop.
Check throttle position
Throttle mechanical stop. sensor angle at idle,
Throttle
No TPS reset expected value 2-3.5 degrees
P1616 ECM limp-home-position
after throttle body/ Perform THROTTLE
failed
ECM replacement. POSITION SENSOR RESET
in B.U.D.S. with throttle grip
accelerator not activated
since at least 30 seconds.
Refer to the SERVICE MANUAL
for more details.
Check idle stop for wear.
Wrong throttle body
Perform THROTTLE POSITION
mechanical position
SENSOR RESET in B.U.D.S.
P1619 ECM TPS adaptation failure during reset of closed TPS
with throttle grip accelerator
or no TPS reset after ECM
not activated since at least 30
replacement.
seconds.
Check idle stop for wear.
Wrong throttle body
Perform THROTTLE POSITION
mechanical position
SENSOR RESET in B.U.D.S.
P1620 ECM TPS adaptation failure during reset of closed TPS
with throttle grip accelerator
or no TPS reset after ECM
not activated since at least 30
replacement.
seconds.

22 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check idle stop for wear.
Ensure throttle plate is
against throttle stop.
Check throttle position
Throttle mechanical stop. sensor angle at idle.
TPS adaptation
No TPS reset Perform THROTTLE
P1621 ECM cancelled lower
after throttle body/ POSITION SENSOR RESET
mechanical stop failed
ECM replacement. in B.U.D.S. with throttle grip
accelerator not activated
since at least 30 seconds.
Refer to the SERVICE MANUAL
for more details.
Check idle stop for wear.
Check throttle position
sensor angle at idle.
Throttle mechanical stop. Perform THROTTLE
No TPS reset POSITION SENSOR RESET
P1622 ECM TPS adaptation failed
after throttle body/ in B.U.D.S. with throttle grip
ECM replacement. accelerator not activated
since at least 30 seconds.
Refer to the SERVICE MANUAL
for more details.
Check multi switch left.
Disconnect headlamp relays.
Measure voltage between
Damaged relay, damaged harness connector FB-C10 and
circuit wires, damaged ground (expected value: 0 volts).
Headlamp relay circuit
P1675 ECM multi switch left, Measure voltage between
shorted to battery +
damaged connector or harness connector FB-C12 and
damaged ECM output pins. ground (expected value: 0 volts).
Measure resistance between
terminals 85 and 86 on relays
(expected value: 70 to 90 ohms).
Check fuse and multi switch left.
Disconnect headlamp relays.
Blown fuse, damaged
Measure resistance between
or disconnected relay,
terminals 85 and 86 on relays
damaged circuit wires,
Headlamp relay circuit (expected value: 70 to 90 ohms).
damaged multi switch left
P1676 ECM shorted to ground or Measure resistance between
damaged connectors or
open circuit harness connector FB-C10 and
damaged ECM output pins,
ground (expected value > open).
damaged headlamp overrun
Measure resistance between
switch.
harness connector FB-C12 and
ground (expected value > open).
Check fuse and multi switch left.
Disconnect headlamp relays.
Blown fuse, damaged
Measure resistance between
or disconnected relay,
terminals 85 and 86 on relays
damaged circuit wires,
(expected value: 70 to 90 ohms).
damaged multi switch left
P1677 ECM Headlamp relay circuit Measure resistance between
damaged connectors or
harness connector FB-C10 and
damaged ECM output pins,
ground (expected value > open).
damaged headlamp overrun
Measure resistance between
switch.
harness connector FB-C12 and
ground (expected value > open).

tmr2013-077 23
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Blown fuse,
Radiator fan direction damaged fan relay,
P1691 ECM relays shorted to damaged circuit wires,
ground damaged connectors or
damaged ECM output pins.
Damaged fan relay,
Radiator fan direction
damaged circuit wires,
P1692 ECM relays shorted to
damaged connector or
battery +
damaged ECM output pins.
Blown fuse
Damaged clutch valve circuit,
damaged circuit wires,
damaged connector or
Clutch valve circuit
P1696 ECM damaged ECM output pins.
shorted to ground
Note: shorted to
ground solenoid may cause
slippage of the clutch
Damaged clutch valve circuit,
Clutch solenoid valve damaged circuit wires,
P1697 ECM circuit shorted to damaged connector,
battery + damaged ECM output pins,
circuit shorted to battery +.
Check fuse.
Disconnect radiator fan relay.
Measure voltage between
harness connector FB-D7
and ground (expected
value: 11 to 13 volts).
Measure resistance between
harness connector FB-C8 and
ground (expected value: open).
Measure resistance from harness
connector: ECM-J4 to FB-C8
(expected value: < 2 ohms).
Measure resistance between
terminals 85 and 86 on relay
(expected value: 70 to 90 ohms).
Disconnect radiator fan relay.
Measure voltage between
harness connector FB-C8 and
ground (expected value: 0 volts).
Measure resistance between
terminals 85 and 86 on relay
(expected value: 70 to 90 ohms).
Check fuse F2.
Disconnect clutch solenoid valve.
Measure voltage between
harness connector CSV-1 and
ground (expected value: 0 volts).
Measure voltage between
harness connector CSV-2
and ground (expected
value: 11 to 13 volts).
Measure resistance between
CSV pin 1 and 2 (expected
value = 20 to 30 ohms).
Measure resistance from harness
connector: CSV-1 to ECMA-L3
(expected value: < 2 ohms).
Disconnect clutch solenoid valve.
Measure voltage between
harness connector CSV-1 and
ground (expected value: 0 volts).
Measure voltage between
harness connector CSV-2
and ground (expected
value: 11 to 13 volts).
Measure resistance between
CSV pin 1 and 2 (expected
value = 20 to 30 ohms).
Measure resistance from harness
connector: CSV-1 to ECMA-L3
(expected value: < 2 ohms).

24 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check fuse F2.
Disconnect clutch solenoid valve.
Measure voltage between
harness connector 6-CSV-1 and
ground (expected value: 0 volts).
Disconnected solenoid valve Measure voltage between
Damaged clutch valve circuit, harness connector 6-CSV-2
Clutch valve open
P1698 ECM damaged circuit wires, and ground (expected
circuit
damaged connector or value: 11 to 13 volts).
damaged ECM output pins. Measure resistance between
CSV pin 1 and 2 (expected
value = 20 to 30 ohms).
Measure resistance from harness
connector: CSV-1 to ECMA-L3
(expected value: < 2 ohms).
ECU ADC plausibility Monitoring plausibility check
P16C0 ECM Check for ECM fault.
check failed.
Monitoring plausibility check
P16C1 ECM ECU ADC test failed Check for ECM fault.
failed.
Monitoring plausibility check
P16C2 ECM ECU monitoring error Check for ECM fault.
failed.
Throttle Accelerator
Sensors (TAS) Monitoring plausibility check
P16C3 ECM Check for ECM fault.
monitoring check failed.
fault
Engine speed
Monitoring plausibility check
P16C4 ECM monitoring check Check for ECM fault.
failed.
fault
Safety fuel cut-off
Monitoring plausibility check
P16C5 ECM activated monitoring Check for ECM fault.
failed.
check level 1
Safety fuel cut-off
Monitoring plausibility check
P16C6 ECM activated monitoring Check for ECM fault.
failed.
check level 2
Throttle valve
Monitoring plausibility check
P16C7 ECM plausibility check Check for ECM fault.
failed.
failed
Permitted throttle
valve position Monitoring plausibility check
P16C8 ECM Check for ECM fault.
monitoring check failed.
exceeded
Disconnect main relay.
Main relay Damaged circuit wires,
Measure resistance between
P20EB ECM de-energized too late damaged connectors or
terminals 85 and 86 on relay
or sticking damaged ECM output pins.
(expected value: 70 to 90 ohms).

tmr2013-077 25
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Ensure sensor connector
is fully inserted.
Measure resistance from
connector: ECMA-A2 to TPS-1
Damaged TPS,
(expected value: < 2 ohms).
2nd Throttle Position damaged circuit wires,
P212C ECM Measure resistance from
Sensors (TPS) low damaged connector or
connector: ECMA-K3 to TPS-4
damaged ECM output pins.
(expected value: < 2 ohms).
Measure resistance from
connector: ECMA-K4 to TPS-3
(expected value: < 2 ohms).
Ensure sensor connector
is fully inserted.
Measure resistance from
connector: ECMA-A2 to TPS-1
Damaged TPS,
(expected value: < 2 ohms).
2nd Throttle position damaged circuit wires,
P212D ECM Measure resistance from
Sensors (TPS) high damaged connector or
connector: ECMA-K3 to TPS-4
damaged ECM output pins.
(expected value: < 2 ohms).
Measure resistance from
connector: ECMA-K4 to TPS-3
(expected value: < 2 ohms).
Check for VCM fault.
Open VCM Monitoring
Vehicle speed not Vehicle speed correlation
P2159 ECM page in B.U.D.S.
plausible check failed.
Verify that speed sensors
are functioning as expected.
Ensure sensor connector
is fully inserted.
Measure voltage between
harness connector pins 1 and 3
(expected value: 4.8 to 5.1 volts).
Sensor disconnected or Measure resistance from
wire short to ground connector: ECMA-F2 to AAPTS-1
Defective sensor, (expected value: < 2 ohms).
Ambient pressure
P2228 ECM damaged circuit wires, Measure resistance from
sensor voltage too low
damaged connector or connector: ECMA-H4 to AAPTS-2
damaged ECM pins, ECM (expected value: < 2 ohms).
voltage supply low. Measure resistance from
connector: ECMA-G3 to AAPTS-4
(expected value: < 2 ohms).
Measure resistance from
connector: ECMA-B4 to AAPTS-3
(expected value: < 2 ohms).

26 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Ensure sensor connector
is fully inserted.
Measure voltage between
harness connector pins 1 and 3
(expected value: 4.8 to 5.1 volts).
Measure resistance from
connector: ECMA-F2 to AAPTS-1
Defective sensor, wire
Ambient pressure (expected value: < 2 ohms).
shorted to battery +,
P2229 ECM sensor voltage too Measure resistance from
ECM voltage supply too
high connector: ECMA-H4 to AAPTS-2
high.
(expected value: < 2 ohms).
Measure resistance from
connector: ECMA-G3 to AAPTS-4
(expected value: < 2 ohms).
Measure resistance from
connector: ECMA-B4 to AAPTS-3
(expected value: < 2 ohms).
Important leak in the Cracked plenum, loose Check for cracked plenum,
air intake system connection at flange to loose connection at flange to
P2279 ECM
causing engine cylinder head or throttle cylinder head or throttle body,
shutdown by ECU body, disconnected hoses disconnected hoses
Engine stop switch
Ignition switch state Check engine shut off switch
P2530 ECM connection or internal switch
not plausible function, replace if necessary
fault.
Throttle Position
P2620 ECM Wrong TPS sensor position. Check TPS adjustment.
Sensors (TPS) position
Ensure sensor connector
is fully inserted.
Measure resistance from
connector: ECMA-A2 to TPS-1
Damaged TPS,
(expected value: < 2 ohms).
First Throttle Position damaged circuit wires,
P2621 ECM Measure resistance from
Sensor (TPS) low damaged connector or
connector: ECMA-F3 to TPS-2
damaged ECM output pins.
(expected value: < 2 ohms).
Measure resistance from
connector: ECMA-K4 to TPS-3
(expected value: < 2 ohms).
Ensure sensor connector
is fully inserted.
Measure resistance from
connector: ECMA-A2 to TPS-1
Damaged TPS,
(expected value: < 2 ohms).
First Throttle Position damaged circuit wires,
P2622 ECM Measure resistance from
Sensors (TPS) high damaged connector or
connector: ECMA-F3 to TPS-2
damaged ECM output pins.
(expected value: < 2 ohms).
Measure resistance from
connector: ECMA-K4 to TPS-3
(expected value: < 2 ohms).

tmr2013-077 27
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Damaged circuit
wires, damaged
Gear position sensor
P2801 ECM gear position sensor,
invalid range
damaged ECM pins or
damaged transmission.
Bad GBPS learning
Bad GBPS
Selected gear number
P2805 ECM GBPS not connected
not plausible
to shift drum
Bad vehicle speed reading
Damaged circuit
Gear position sensor wires, damaged
P2806 ECM angle defined area vs gear position sensor,
position not plausible damaged ECM pins or
damaged transmission.
one or more gears are GBPS Initialization is needed
P280A ECM or was not performed
not learned properly
properly
Open ECM Monitoring
page in B.U.D.S.
Verify that gear position
information changes with gear
selection changes on vehicle.
Disconnect GBPS.
Measure voltage between
harness connector 5-GBPS-1
and 5-GBPS-3 (expected
value: 4.8 to 5.1 volts).
Measure resistance from
connector: 5-ECM-B13
to 5-GBPS-2 (expected
value: < 2 ohms).
Measure resistance from
connector: 5-ECM-B22 to
5-GBPS-3 (expected value: < 2
ohms).
Execute gear learning with BUDS
replace GBPS
replace transmission
Open ECM Monitoring
page in B.U.D.S.
Verify that gear position
information changes with gear
selection changes on vehicle.
Perform Gear Position
Sensor Reset in B.U.D.S.
ECM setting screen.
Disconnect GBPS.
Measure voltage between
harness connector 5-GBPS-1
and 5-GBPS-3 (expected
value: 4.8 to 5.1 volts).
Measure resistance from
connector: 5-ECM-B13
to 5-GBPS-2 (expected
value: < 2 ohms).
Measure resistance from
connector: 5-ECM-B22 to
5-GBPS-3 (expected value: < 2
ohms).
Open the ECM setting
page in B.U.D.S.
Perform Gear Position Sensor
Reset or ECM first initialization

28 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check for TCM fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID DLC-1 and ECMB-C1
Lost communication 220h from TCM. (expected value < 2 ohms).
U0101 ECM with TCM (lost of CAN Module internal error. Measure resistance between
ID’s) Damaged circuit wires or DLC-2 and ECMB-C2
damaged module pins. (expected value < 2 ohms).
Measure resistance
between DLC-1 and TCM-19
(expected value < 2 ohms).
Measure resistance
between DLC-2 and TCM-1
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between
harness connector TCM-4 and
ground (expected value = 11 to
13 volts).
Check for TCM fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID DLC-1 and ECMB-C1
Lost communication 220h from TCM. (expected value < 2 ohms).
U0101 ECM with TCM (lost of CAN Module internal error. Measure resistance between
ID’s) Damaged circuit wires or DLC-2 and ECMB-C2
damaged module pins. (expected value < 2 ohms).
Measure resistance
between DLC-1 and TCM-19
(expected value < 2 ohms).
Measure resistance
between DLC-2 and TCM-1
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between
harness connector TCM-4 and
ground (expected value = 11 to
13 volts).

tmr2013-077 29
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check for VCM fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID DLC-1 and ECMB-C1
Lost communication 020h from VCM. (expected value < 2 ohms).
U0122 ECM with VCM (lost of CAN Module internal error. Measure resistance between
ID’s) Damaged circuit wires or DLC-2 and ECMB-C2
damaged module pins. (expected value < 2 ohms).
Measure resistance
between DLC-1 and VCM-37
(expected value < 2 ohms).
Measure resistance
between DLC-2 and VCM-24
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between
harness connector VCM-32 and
ground (expected value = 11 to
13 volts).
Check for VCM fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID DLC-1 and ECMB-C1
Lost communication 230h from VCM. (expected value < 2 ohms).
U0122 ECM with VCM (lost of CAN Module internal error. Measure resistance between
ID’s) Damaged circuit wires or DLC-2 and ECMB-C2
damaged module pins. (expected value < 2 ohms).
Measure resistance
between DLC-1 and VCM-37
(expected value < 2 ohms).
Measure resistance
between DLC-2 and VCM-24
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between
harness connector VCM-32 and
ground (expected value = 11 to
13 volts).

30 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check for VCM fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID DLC-1 and ECMB-C1
Lost communication 430h from VCM. (expected value < 2 ohms).
U0122 ECM with VCM (lost of CAN Module internal error. Measure resistance between
ID’s) Damaged circuit wires or DLC-2 and ECMB-C2
damaged module pins. (expected value < 2 ohms).
Measure resistance
between DLC-1 and VCM-37
(expected value < 2 ohms).
Measure resistance
between DLC-2 and VCM-24
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between
harness connector VCM-32 and
ground (expected value = 11 to
13 volts).
Check for cluster
fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Missing CAN ID. Measure resistance between
Blown fuse DLC-1 and ECMB-C1
Lost communication
Module internal error. (expected value < 2 ohms).
U0155 ECM with CLUSTER (lost of
Damaged circuit wires or Measure resistance between
CAN ID’s)
damaged module pins. DLC-2 and ECMB-C2
(expected value < 2 ohms).
Measure resistance
between DLC-1 and CL-24
(expected value < 2 ohms).
Measure resistance
between DLC-2 and CL-23
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between
harness connector CL-8 and
ground (expected value = 11 to
13 volts).

tmr2013-077 31
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check for cluster
fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Missing CAN ID. Measure resistance between
Blown fuse DLC-1 and ECMB-C1
Lost communication
Module internal error. (expected value < 2 ohms).
U0155 ECM with CLUSTER (lost of
Damaged circuit wires or Measure resistance between
CAN ID’s)
damaged module pins. DLC-2 and ECMB-C2
(expected value < 2 ohms).
Measure resistance
between DLC-1 and CL-24
(expected value < 2 ohms).
Measure resistance
between DLC-2 and CL-23
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between
harness connector CL-8 and
ground (expected value = 11 to
13 volts).
Turn key on and measure
voltage between harness
connector DESS-A and ground
(expected value: 11 to 13 volts).
Turn key off and measure
voltage between harness
connector DESS-A and ground
Unable to Damaged key, damaged (expected value: < 1 volt).
U0167 ECM communicate with D.E.S.S key reader, damaged Measure resistance from harness
key ECU, damaged circuit wire connector: ECMB-F2 an ground
(expected value: < 2 ohms).
Measure resistance from harness
connector: ECMB-F2 an DESS-C
(expected value: < 2 ohms).
Measure resistance from harness
connector: ECMB-B2 an DESS-B
(expected value: < 2 ohms).

32 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
DLC-1 and ECMB-C1
(expected value < 2 ohms).
Measure resistance between
Missing CAN ID.
DLC-2 and ECMB-C2
Lost communication Blown fuse
(expected value < 2 ohms).
U0259 ECM with MSL-MSR (lost Module internal error.
Measure resistance
of CAN ID’s) Damaged circuit wires or
between DLC-1 and MSL3-2
damaged module pins.
(expected value < 2 ohms).
Measure resistance
between DLC-2 and MSL3-3
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between
harness connector MSL2-1
and ground (expected
value = 11 to 13 volts).
Measure voltage between
harness connector MSR2-6 and
ground (expected value = 11 to
13 volts).
Install the proper ECM
Invalid security Incorrect ECM or CLUSTER, or CLUSTER on vehicle.
U0300 ECM
exchange received Incorrect software version. Update security coding using
B.U.D.S.
Variant coding
Faulty calibration or Try updating the ECM.
manual transmission,
transmission variant. If the problem persists, make sure
U0302 ECM software
Faulty programming. the ECM part number is correct
incompatibility with
Damaged ECM. for the model it is installed on.
transmission
Invalid ECM Variant Faulty calibration or Try updating the ECM.
coding, software transmission variant. If the problem persists, make sure
U0303 ECM
incompatibility with Faulty programming. the ECM part number is correct
transmission type Damaged ECM. for the model it is installed on.
Try updating the ECM.
Variant coding
Faulty variant coding. If the problem persists, make sure
U0400 ECM failure software
Faulty programming. the ECM part number is correct
incompatibility
for the model it is installed on.

tmr2013-077 33
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Turn key on and measure
voltage between harness
connector DESS-A and ground
(expected value: 11 to 13 volts).
Turn key off and measure
voltage between harness
connector DESS-A and ground
Communication Damaged key, damaged (expected value: < 1 volt).
U0426 ECM problem with the D.E.S.S key reader, damaged Measure resistance from harness
key ECU, damaged circuit wire connector: ECMB-F2 an ground
(expected value: < 2 ohms).
Measure resistance from harness
connector: ECMB-F2 an DESS-C
(expected value: < 2 ohms).
Measure resistance from harness
connector: ECMB-B2 an DESS-B
(expected value: < 2 ohms).
External troubleshooting
Check sum error. is not possible.
Invalid check sum CAN message contains Check for communication
U220B ECM
from VCM message erroneous information or fault from VCM which may have
temporarily incorrect. contributed to the erroneous
information transmitted.
External troubleshooting
Check sum error. is not possible.
Invalid check sum CAN message contains Check for communication
U220B ECM
from VCM message erroneous information or fault from VCM which may have
temporarily incorrect. contributed to the erroneous
information transmitted.
External troubleshooting
Check sum error. is not possible.
Invalid check sum CAN message contains Check for communication
U220B ECM
from VCM message erroneous information or fault from VCM which may have
temporarily incorrect. contributed to the erroneous
information transmitted.
External troubleshooting
Check sum error. is not possible.
Invalid check sum CAN message contains Check for communication
U220C ECM
from TCM message erroneous information or fault from TCM which may have
temporarily incorrect. contributed to the erroneous
information transmitted.
External troubleshooting
Check sum error. is not possible.
Invalid check sum CAN message contains Check for communication
U220C ECM
from TCM message erroneous information or fault from TCM which may have
temporarily incorrect. contributed to the erroneous
information transmitted.

34 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

External troubleshooting
Check sum error. is not possible.
Invalid check sum
CAN message contains Check for communication
U220E ECM from CLUSTER
erroneous information or fault from CLUSTER which may
message
temporarily incorrect. have contributed to the erroneous
information transmitted.
External troubleshooting
Check sum error. is not possible.
Invalid check sum
CAN message contains Check for communication
U220E ECM from CLUSTER
erroneous information or fault from CLUSTER which may
message
temporarily incorrect. have contributed to the erroneous
information transmitted.
External troubleshooting
Check sum error. is not possible.
Invalid check sum
CAN message contains Check for communication
U220F ECM from MSL-MSR
erroneous information or fault from MSL-MSR which may
message
temporarily incorrect. have contributed to the erroneous
information transmitted.

tmr2013-077 35
Subsection XX (DIAGNOSTIC AND FAULT CODES)

TCM MODULE
PCODE MODULE DESCRIPTION CAUSE ACTION
Jump start conditions
exceeded max. Verify system behavior,
System voltage
TCM allowed time. especially actuators.
P0561 Invalid - jump start
BOSCH - due to customer misusage Replace faulty components.
detected
- due to defect in wiring, If system works fine clear fault.
battery or control unit.
Measure battery voltage with
engine stopped (expected
Blown fuse FC,
value: 11 to 13 volts).
battery failure, voltage
Measure battery voltage with
regulator failure,
engine running (expected
TCM damaged circuit wires
P0562 System voltage low value: 13 to 14.7 volts).
BOSCH or connection, damaged
Check connections
magneto generator.
on voltage regulator.
An external battery charger
Check ground and positive
may have been used.
connections on battery.
Check ground on vehicle frame.
Measure battery voltage with
engine stopped (expected
value: 11 to 13 volts).
Measure battery voltage with
Damaged regulator. engine running (expected
TCM
P0563 System voltage high An external battery charger value: 13 to 14.7 volts).
BOSCH
may have been used. Check connections
on voltage regulator.
Check ground and positive
connections on battery.
Check ground on vehicle frame.
Internal control Reset TCM unit and monitor
TCM
P062F module EEPROM Damaged TCM unit for TCM hardware failure
BOSCH
error Replace TCM unit
Measure resistance from
connector: OTS-1 to TCMA-B3
(expected value: < 2 ohms).
Damaged wiring harness
Transmission Fluid Measure resistance from
TCM Damaged
P0710 Temperature Sensor connector: OTS-2 to TCMA-H3
BOSCH temperature sensor
general fault (expected value: < 2 ohms).
Damaged TCM
Measure resistance from connector:
OTS-1 to OTS-2 (expected value:
between 30? and 230k?)
Measure resistance from
connector: OTS-1 to TCMA-H2
(expected value: < 2 ohms).
Measure resistance from
Damaged wiring harness connector: OTS-2 to TCMA-H3
Transmission Fluid
TCM Damaged (expected value: < 2 ohms).
P0712 Temperature Sensor
BOSCH temperature sensor Measure resistance from
short-to-ground
Damaged TCM connector: OTS-1 to GND
(expected value: < 2 ohms).
Measure resistance from connector:
OTS-1 to OTS-2 (expected value:
between 30? and 230k?)

36 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Measure resistance from
connector: OTS-1 to TCMA-B3
(expected value: < 2 ohms).
Damaged wiring harness
Transmission Fluid Measure resistance from
TCM Damaged
P0713 Temperature Sensor connector: OTS-2 to TCMA-H3
BOSCH temperature sensor
short-to-battery (expected value: < 2 ohms).
Damaged TCM
Measure resistance from connector:
OTS-1 to OTS-2 (expected value:
between 30? and 230k?)
Measure resistance from
connector: OTS-1 to TCMA-B3
(expected value: < 2 ohms).
Damaged wiring harness
Transmission Fluid Measure resistance from
TCM Damaged
P0714 Temperature Sensor connector: OTS-2 to TCMA-H3
BOSCH temperature sensor
open circuit (expected value: < 2 ohms).
Damaged TCM
Measure resistance from connector:
OTS-1 to OTS-2 (expected value:
between 30? and 230k?)
Actuator
Reverse interlock
TCM mechanically stuck Check reverse actuator
P072A actuator stuck to
BOSCH Interlock mechanically Check transmission
deployed position
stuck in transmission
Check fuse
Check Metallic wire
Check transmission
Check actuator
Check wiring and / or relay
Measure resistance from
connector: BA-1 and GND
Broken wire between (expected value: < 2 ohms).
solenoid actuator Measure resistance from
Reverse interlock and interlock lever connector: BA-2 and LFB-B12
TCM
P072D actuator stuck to Damaged (broken (expected value: < 2 ohms).
BOSCH
retracted position electrical wire, melted Measure resistance from
solenoid) solenoid actuator connector: ECMB-G2 and LFB-B11
Stuck interlock lever (expected value: < 2 ohms).
Turn key on
Measure voltage between
LFB-A12 and GND (expected
value: 11 to 13 volts).
Measure voltage between
LFB-A11 and GND (expected value:
11 to 13 volts).
Bad GBPS learning
Gearbox position Bad GBPS Execute gear learning with BUDS
TCM
P0730 received from ECM GBPS not connected replace GBPS
BOSCH
not plausible to shift drum replace transmission
Bad vehicle speed reading
Clutch coefficient
Change engine oil
of friction low
Replace clutch if friction coefficient
TCM clutch torque transfer clutch kisspoint
P0740 or offset out of service limits
BOSCH performance too low pressure high
Replace HCU if max clutch pressure
maximum clutch pressure
too low
low

tmr2013-077 37
Subsection XX (DIAGNOSTIC AND FAULT CODES)
PCODE MODULE DESCRIPTION CAUSE
Shift solenoid is broken
Shift spool valve is stuck
TCM Unable to Downshift Shift piston or linkage
P074D
BOSCH 3 time in a row is stuck or broken
Shift forks in transmission
are bent / stuck / broken
Dog on dog resolution does
not work (for missed shifts
when vehicle is stationary)
Transmission is
stuck in gear
TCM Unable to Upshift 3
P074E Shift linkage is
BOSCH time in a row
damaged / stuck
Line pressure is too low
to permit a shift (should
rise other low line pressure
DFCs)
A particle made the
valve to stick in its
close to line position.
TCM Clutch valve stuck
P07AF Pilot valve mechanically
BOSCH open on line side
broken, creating constant
5 bar pilot pressure no
matter solenoid current
A particle made the valve
to stick in its close
to tank position. No
TCM Clutch valve stuck pressure can be generated.
P07B1
BOSCH open on Tank Pilot valve mechanically
broken, creating constant
0 bar pilot pressure no
matter solenoid current
38
ACTION
Verify shift solenoid
Verify shift piston and linkage
Verify shift forks
1-put SM shifter on the shift shaft
protruding from the engine, left
side. Try to shift manually with
this added shifter. Does It works?
If yes, go to 2. if not, goto 3.
2- run TCTest_PCluLine and
TCTest_ShiftHyd. If there really
is a problem one of them
should fail. if so, replace HCU
3- Move by hand the reverse
interlock lever. if its not moving
freely, it can be the source
of the stuck transmission.
4- Start engine and press the
shift buttons. Put your hand on
the manual shifter while asking
for shifts. Do the manual shifter
on the shift shaft seems like if it
receives a force from the HCU? if
not, run step 2 again, replace HCU
5- Remove clutch cover then try
to shift the transmission manually.
Inspect the shift pawl and star
indexer for damage or foreign part
blocking movement. If it is possible
to shift the transmission once the
clutch cover is removed but it was
impossible with the clutch cover in
place, replace clutch cover with HCU
and shift linkage. If it still doesnt
shift, replace transmission.
Change engine oil, engine oil filter
and HCU oil filter
change engine oil, engine oil filter
and HCU oil filter
tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Is the vehicle behaviour ok?
too many error in Is engine oil level ok? Run cleaning cycle
TCM
P0810 clutch pressure error Is the right engine Replace engine oil
BOSCH
table oil grade used? Replace HCU

A clutch with
friction coefficient
that fell suddenly
Clutch valve with incorrect Verify clutch discs condition
TCM Clutch Slippage
P081E pressure response Verify maximum line pressure at idle
BOSCH during sychronisation
HCU with reduced The clutch could have overheated
maximum clutch pressure
(clogged filter, damaged
pump, damaged valve)
Defective TCM or connected
loose connection to battery components causing a deviation
TCM Power
TCM discharged battery between battery voltage and
P0881 Input voltage
BOSCH inoperative generator switched battery voltage due to high
Range/Performance
blown fuse current draw over switched battery
voltage.

TCM Clutch Pressure Valve Damaged TCM Reset TCM

P0901
BOSCH output fault Replace TCM

Disconnect Y2
Measure resistance
between TCMA-G2 and Y2-2
(expected value: < 2 ohms).
Clutch Pressure Valve Damaged wiring harness Measure resistance
TCM
P0902 short-to-ground or Damaged solenoid between TCMA-L4 and Y2-1
BOSCH
open pin fault Damaged TCM (expected value: < 2 ohms).
Turn key to ignition
Measure voltage between
Y2-1 and GND (expected value: 12
volts).
Disconnect Y2
Measure voltage between TCMA-G2
Damaged wiring harness
TCM Clutch Pressure Valve and GND (expected value: 0 volts).
P0903 Damaged solenoid
BOSCH short-to-battery Measure resistance between Y2-1
Damaged TCM
and Y2-2 from Y2 (expected value:
between 4 and 6 Ohms)

TCM Line Pressure Valve Reset TCM

P0911 Damaged TCM
BOSCH output fault Replace TCM

Disconnect Y1
Measure resistance
between TCMA-E2 and Y1-2
(expected value: < 2 ohms).
Line Pressure Valve Damaged wiring harness Measure resistance
TCM
P0912 short-to-ground or Damaged solenoid between TCMA-L4 and Y1-1
BOSCH
open pin fault Damaged TCM (expected value: < 2 ohms).
Turn key to ignition
Measure voltage between
Y1-1 and GND (expected value: 12
volts).

tmr2013-077 39
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Disconnect Y1
Measure voltage between TCMA-E2
Damaged wiring harness
TCM Line Pressure Valve and GND (expected value: 0 volts).
P0913 Damaged solenoid
BOSCH short-to-battery Measure resistance between Y1-1
Damaged TCM
and Y1-2 from Y1 (expected value:
between 4 and 6 Ohms)
Damaged wiring harness Verify wiring harness
TCM Clutch Pressure
P0932 Damaged sensor Replace sensor
BOSCH sensor circuit/open
Damaged TCM Replace TCM
Damaged wiring harness Verify wiring harness
TCM Clutch Pressure
P0933 Damaged sensor Replace sensor
BOSCH sensor Not alive
Damaged TCM Replace TCM
Measure resistance between
TCMA-B2 and OPS-2
(expected value: < 2 ohms).
Damaged wiring harness Measure resistance between
Unpowered sensor TCMA-J3 and OPS-1
TCM Clutch Pressure
P0934 Output of the sensor (expected value: < 2 ohms).
BOSCH sensor Circuit Low
shorted to GND Measure resistance between
Damaged TCM TCMA-M2 and OPS-3
(expected value: < 2 ohms).
Replace sensor
Replace TCM unit
Measure resistance between
TCMA-B2 and OPS-2
(expected value: < 2 ohms).
Measure resistance between
Damaged wiring harness
TCMA-J3 and OPS-1
TCM Clutch Pressure Output of the sensor
P0935 (expected value: < 2 ohms).
BOSCH sensor Circuit High shorted to Ignition or 5V
Measure resistance between
Damaged TCM
TCMA-M2 and OPS-3
(expected value: < 2 ohms).
Replace sensor
Replace TCM unit

TCM Down Shift Valve Damaged TCM Reset TCM

P0972
BOSCH output fault Replace TCM

Disconnect Y3
Measure resistance
between TCMA-J1 and Y3-2
(expected value: < 2 ohms).
Down Shift Valve Damaged wiring harness Measure resistance between
TCM
P0973 short-to-ground or Damaged solenoid TCMA-M1 and Y3-1
BOSCH
open pin fault Damaged TCM (expected value: < 2 ohms).
Turn key to ignition
Measure voltage between
Y3-1 and GND (expected value: 12
volts).
Disconnect Y3
Measure voltage between TCMA-J1
Damaged wiring harness
TCM Down Shift Valve and GND (expected value: 0 volts).
P0974 Damaged solenoid
BOSCH short-to-battery Measure resistance between Y3-1
Damaged TCM
and Y3-2 from Y3 (expected value:
between 10 and 12 Ohms)

40 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

TCM Up Shift Valve output Damaged TCM Reset TCM

P0975
BOSCH fault Replace TCM
Disconnect Y4
Measure resistance
between TCMA-H1 and Y4-2
(expected value: < 2 ohms).
Up Shift Valve Damaged wiring harness Measure resistance between
TCM
P0976 short-to-ground or Damaged solenoid TCMA-M1 and Y4-1
BOSCH
open pin fault Damaged TCM (expected value: < 2 ohms).
Turn key to ignition
Measure voltage between
Y4-1 and GND (expected value: 12
volts).
Disconnect Y4
Measure voltage between TCMA-H1
Damaged wiring harness
TCM Up Shift Valve and GND (expected value: 0 volts).
P0977 Damaged solenoid
BOSCH short-to-battery Measure resistance between Y4-1
Damaged TCM
and Y4-2 from Y4 (expected value:
between 10 and 12 Ohms)
Valve is worn out (high leak)
Clutch piston is leaking
Oil is of improper viscosity
Pump flow is too Replace oil and filters
TCM Time to reach clutch
P194A low (worn out) run dynamic and hysteresis
BOSCH pressure Too Long
Clutch valve can not tester service
travel its full stroke
Line pressure is too close
to clutch pressure
Drive the vehicle and put special
attention on the takeoff and
prelaunch behaviour. Is the takeoff
Clutch spool smooth and constant or it feels
valve is sticking like something is not right? While
Clutch solenoid is defective at a stop, gear engaged, is the
Clutch solenoid feed engine idle speed constant or
Clutch Pressure
TCM orifice is too large / erratic? Do you feel like the
P194C Hydraulic gain too
BOSCH transfer plate is leaking engine is loaded for no reason?
high
Pilot 5bar pressure Execute clutch pressure test:
regulator is defective TCTest_PCluLine, TCTest_PHys
Clutch spool valve spring is If any test fails Execute Clutch
defective cleaning and ventilation procedure
and go back to step 1 max 3 times.
If test passes, HCU is ok. If test fails
the 3rd time, replace HCU

tmr2013-077 41
Subsection XX (DIAGNOSTIC AND FAULT CODES)
PCODE MODULE DESCRIPTION CAUSE
Clutch spool
valve is sticking
Clutch spool valve is leaking
Clutch Pressure
TCM Clutch spool valve
P194D Hydraulic gain too
BOSCH spring is defective
low
Clutch circuit has
an unexpected leak
Clutch solenoid is defective
Clutch is worn out. Friction
TCM
P194E clutch is too thin pads are significantly
BOSCH
thinner than originally.
Clutch is defective.
Clutchpack thickness is
TCM higher than expected.
P194F clutch is too thick
BOSCH Foreign part can have been
wedged between two
disks
5Bar feed pilot pressure
regulator broken
Leak in the pilot circuit
TCM Line pressure too of the line pressure valve
P195A
BOSCH high Pilot solenoid feed
orifice enlarged
Broken / missing spool
spring
5Bar feed pilot pressure
regulator broken
Leak in the clutch circuit
TCM
P195B Line pressure too low Pilot solenoid feed
BOSCH
orifice clogged
Pilot feed screen clogged
Bent spool spring
TCM Line pressure valve Particle ingestion, valve
P195C
BOSCH stuck damage
42
ACTION
Drive the vehicle and put special
attention on the takeoff and
prelaunch behaviour. Is the takeoff
smooth and constant or it feels
like something is not right? While
at a stop, gear engaged, is the
engine idle speed constant or
erratic? Do you feel like the
engine is loaded for no reason?
Execute clutch pressure test:
TCTest_PCluLine, TCTest_PHys
If any test fails Execute Clutch
cleaning and ventilation procedure
and go back to step 1 max 3 times.
If test passes, HCU is ok. If test fails
the 3rd time, replace HCU
Inspect clutch and replace if
necessary
Clutch should be
disassembled and checked.
Look for :
- foreign parts between
2 disks of the clutch OR
- stuck clutch disks on clutch
drum/basket. Check for wear marks
on clutch drum. If wear marks are
evident, replace clutch drum and
basket
If the vehicle is driving
correctly, no action is required.
Verify for leaks in clutch circuit
Verify solenoid condition
Verify pressure valve condition
Verify pressure regulator
Check if it’s possible to
shift around neutral at idle
Verify for leaks in clutch circuit
Verify solenoid condition
Verify pressure valve condition
Verify pressure regulator
If no complaint from user, no
change required. If user complains
about missed shifts and clutch slip,
replace HCU
1- Run TCTest_PCluLine.
2- If it fails, run
TCTest_ClngVentnCyc
and got step 1.
After 3 tryouts, replace HCU
tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Measure resistance between
TCMA-B3 and OTS-2
(expected value: < 2 ohms).
Damaged transmission oil
Measure resistance between
temperature sensor
Oil temperature TCMA-H3 and OTS-1
TCM Damaged
P195D sensor alive check (expected value: < 2 ohms).
BOSCH temperature sensor
failed Verify for short between ignition
Damaged wiring harness
and TCMA-B3 or TCMA-H3
Damaged TCM
Verify for damaged
Temperature sensor
replace TCM unit
Measure resistance between
TCMA-B3 and OTS-2
(expected value: < 2 ohms).
Damaged transmission oil
Measure resistance between
temperature sensor
Oil temperature TCMA-H3 and OTS-1
TCM Damaged
P195E sensor alive check (expected value: < 2 ohms).
BOSCH temperature sensor
failed Verify for short between ignition
Damaged wiring harness
and TCMA-B3 or TCMA-H3
Damaged TCM
Verify for damaged
Temperature sensor
replace TCM unit
Measure resistance between
TCMA-B3 and OTS-2
(expected value: < 2 ohms).
Transmission oil
Measure resistance between
temperature out of range
Oil temperature TCMA-H3 and OTS-1
TCM Damaged
P195F sensor Correlation (expected value: < 2 ohms).
BOSCH temperature sensor
check failed Verify for short between ignition
Damaged wiring harness
and TCMA-B3 or TCMA-H3
Damaged TCM
Verify for damaged
Temperature sensor
replace TCM unit
Measure resistance between
TCMA-B3 and OTS-2
(expected value: < 2 ohms).
Transmission oil
Measure resistance between
temperature out of range
TCMA-H3 and OTS-1
TCM Oil temperature Damaged
P196A (expected value: < 2 ohms).
BOSCH sensor not alive temperature sensor
Verify for short between ignition
Damaged wiring harness
and TCMA-B3 or TCMA-H3
Damaged TCM
Verify for damaged
Temperature sensor
replace TCM unit
Is the vehicle able to shift
around Neutral (R, N, 1st)
Pump is worn out
without missed shift?
TCM line pressure valve
P196B System pressure low Is the user complaining
BOSCH is defective / stuck
about missed shifts and / or
Leak in HCU
clutch slipping while cruising?
if yes, replace HCU

tmr2013-077 43
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Sticky clutch valve
Too viscous oil grade
used in engine
broken/missing
Run cleaning cycle
TCM clutch valve spring
P196C Clutch pressure high Replace engine oil
BOSCH bent 5bar regulator spring
Replace HCU
sticky 5bar regulator
Enlarged pilot
valve feed orifice
Faulty pilot solenoid
HCU characteristic out
of range (worn out)
Sticky clutch valve
Too low oil viscosity oil
grade used in engine
bent clutch valve spring
Run cleaning cycle
TCM broken / missing
P196D Clutch pressure Low Replace engine oil
BOSCH 5bar regulator spring
Replace HCU
Leak in HCU
Clogged pilot
circuit feed sieve
Clogged pilot
valve feed orifice

Disconnect all four solenoid.

Measure voltage between TCMA-G2
and GND (expected value: 0 volts).
Measure voltage between TCMA-E2
and GND (expected value: 0 volts).
Measure voltage between TCMA-J1
and GND (expected value: 0 volts).
Damaged wiring on: Measure voltage between TCMA-H1
clutch pressure solenoid, and GND (expected value: 0 volts).
line pressure solenoid, Measure shift up solenoid resistance
shift down solenoid between Y4-1 and Y4-2 (expected
TCM low-side driver output or shift up solenoid value: between 10 and 12 Ohms)
P196E
BOSCH short-to-battery Damaged clutch pressure Measure shift down solenoid
solenoid, line pressure resistance between Y3-1
solenoid, shift down and Y3-2 (expected value:
solenoid or shift up between 10 and 12 Ohms)
solenoid Measure Line pressure solenoid
resistance between Y2-1
and Y2-2 (expected value:
between 4 and 6 Ohms)
Measure clutch pressure solenoid
resistance between Y1-1 and Y1-2
(expected value: between 4 and 6
Ohms)

44 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Disconnect all four solenoid.
Measure resistance
between TCMA-H1 and Y4-2
(expected value: 0 volts).
Measure resistance between
TCMA-M1 and Y4-1
(expected value: 0 volts).
Measure resistance between
TCMA-M1 and Y3-1
(expected value: 0 volts).
Measure resistance
between TCMA-J1 and Y3-2
(expected value: 0 volts).
Measure resistance
between TCMA-G2 and Y1-2
Damaged wiring on: (expected value: 0 volts).
clutch pressure solenoid, Measure resistance
line pressure solenoid, between TCMA-L4 and Y1-1
shift down solenoid (expected value: 0 volts).
low-side-driver output
TCM or shift up solenoid Measure resistance
P196F short-to-ground or
BOSCH Damaged clutch pressure between TCMA-L4 and Y2-1
open-circuit
solenoid, line pressure (expected value: 0 volts).
solenoid, shift down Measure resistance
solenoid or shift up between TCMA-E2 and Y2-2
solenoid blown fuse (expected value: 0 volts).
Measure shift up solenoid resistance
between Y4-1 and Y4-2 (expected
value: between 10 and 12 Ohms)
Measure shift down solenoid
resistance between Y3-1
and Y3-2 (expected value:
between 10 and 12 Ohms)
Measure Line pressure solenoid
resistance between Y2-1
and Y2-2 (expected value:
between 4 and 6 Ohms)
Measure clutch pressure solenoid
resistance between Y1-1 and Y1-2
(expected value: between 4 and 6
Ohms)
Fault check of Output Reset TCM unit and monitor
TCM
P1970 Safety System for Damaged TCM unit for TCM hardware failure
BOSCH
DN-line is active Replace TCM unit
Fault check of Output
Safety System Reset TCM unit and monitor
TCM
P1971 for Inhibit Path Damaged TCM unit for TCM hardware failure
BOSCH
Test No.1 failed Replace TCM unit
(test-preparation)
Fault check of Output
Safety System for Reset TCM unit and monitor
TCM
P1972 Inhibit Path Test No.2 Damaged TCM unit for TCM hardware failure
BOSCH
failed (DN sensing Replace TCM unit
test)

tmr2013-077 45
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Fault check of Output
Safety System for Reset TCM unit and monitor
TCM
P1973 Inhibit Path Test No.3 Damaged TCM unit for TCM hardware failure
BOSCH
failed (HSS pinline Replace TCM unit
test)
Fault check of Output
Safety System for Reset TCM unit and monitor
TCM
P1974 Inhibit Path Test No.4 Damaged TCM unit for TCM hardware failure
BOSCH
failed (HSS activation Replace TCM unit
prevention test)
Fault check of Output
Safety System for Reset TCM unit and monitor
TCM
P1975 Inhibit Path Test No.5 Damaged TCM unit for TCM hardware failure
BOSCH
failed (LSS activation Replace TCM unit
prevention test)
Fault check of output Reset TCM unit and monitor
TCM
P197A peripheral clock for Damaged TCM unit for TCM hardware failure
BOSCH
too low Replace TCM unit
Fault check of output Reset TCM unit and monitor
TCM
P197B peripheral clock for Damaged TCM unit for TCM hardware failure
BOSCH
on after off Replace TCM unit
Fault check of output Reset TCM unit and monitor
TCM
P1980 stage power supplies Damaged TCM unit for TCM hardware failure
BOSCH
for general fault Replace TCM unit
Fault check of output Reset TCM unit and monitor
TCM
P1981 stage power supplies Damaged TCM unit for TCM hardware failure
BOSCH
for general fault Replace TCM unit
Measure resistance from
connector: Y1-1 to TCMA-L4
Damaged wiring harness
(expected value: < 2 ohms).
Fault check of output Damaged TCM
TCM Measure resistance from
P1982 stage power supplies Damaged or removed
BOSCH connector: Y2-1 to TCMA-L4
for open-pin Line pressure or clutch
(expected value: < 2 ohms).
pressure solenoid
Verify Line pressure solenoid and
clutch pressure solenoid
Measure resistance from
connector: Y3-1 to TCMA-M1
Damaged wiring harness
(expected value: < 2 ohms).
Fault check of output Damaged TCM
TCM Measure resistance from
P1983 stage power supplies Damaged or removed
BOSCH connector: Y4-1 to TCMA-M1
for open-pin shift up solenoid or shift
(expected value: < 2 ohms).
down solenoid
Verify shift up solenoid and shift
down solenoid
Fault check of output
TCM Damaged wiring harness Verify for a short between power
P1984 stage power supplies
BOSCH Damaged TCM and Y1-1 or Y2-1 or TCMA-L4
for short-to-battery
Fault check of output
TCM Damaged wiring harness Verify for a short between power
P1985 stage power supplies
BOSCH Damaged TCM and Y3-1 or Y4-1 or TCMA-M1
for short-to-battery

46 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Damaged wiring harness
Fault check of output
TCM Shorted Line pressure or Verify for a short between GND and
P1986 stage power supplies
BOSCH clutch pressure solenoid Y1-1 or Y2-1 or TCMA-L4
for short-to-ground
Damaged TCM
Damaged wiring harness
Fault check of output
TCM Shorted shift up solenoid Verify for a short between GND and
P1987 stage power supplies
BOSCH or shift down solenoid Y3-1 or Y4-1 or TCMA-M1
for short-to-ground
Damaged TCM
Damaged wiring harness
Fault check of output Short between TCMA-L4
TCM Verify for a short between TCMA-L4
P1988 stage power supplies and the shift up or
BOSCH and Y3-1 or Y4-1
for short to neighbor shift down solenoid
Damaged TCM
Damaged wiring harness
Fault check of output Short between TCMAC-M1
TCM Verify for a short between TCMA-M1
P1989 stage power supplies and the clutch or line
BOSCH and Y1-1 or Y2-1
for short to neighbor pressure solenoid
Damaged TCM
Fault check of output
TCM Sensor supply 5V
P198B sensor supplies for Damaged wiring harness
BOSCH short-circuit-to-battery
short-to-battery
Fault check of output
TCM Sensor supply 5V
P198D sensor supplies for Damaged wiring harness
BOSCH short-circuit-to-ground
short-to-ground
Clutch Pressure Damaged wiring harness Verify wiring harness
TCM
P198E sensor circuit Damaged sensor Replace sensor
BOSCH
Intermittent/Erratic Damaged TCM Replace TCM
Verify that the right type of oil is used
Wrong oil is used in engine
Verify that the engine is
Clutch friction
TCM clutch slope high limit running on all cylinders
P2789 disks are damaged
BOSCH exceeded Relearn the clutch
Engine torque estimation
Replace engine oil and clutch
is faulty
pack
Verify that the right type of oil is used
Wrong oil is used in engine
Verify that the engine is
Clutch is worn out /
TCM clutch slope Low limit running on all cylinders
P278F overheated / glazed
BOSCH exceeded Relearn the clutch
Engine torque estimation
Replace engine oil and clutch
is faulty
pack
Problem with the hydraulic If the shift mechanism let the gears
system making shift pop out, replace transmission
pressure without current If shift pressure is created
TCM Not intended
P284D on the shift solenoid unwantedly, check proper
BOSCH Downshift detected
Problem with the shift seating of shift solenoids in HCU
linkage not holding the If solenoids are ok, replace entire
gear in place HCU
Problem with the hydraulic If the shift mechanism let the gears
system making shift pop out, replace transmission
pressure without current If shift pressure is created
TCM Not intended Upshift
P284E on the shift solenoid unwantedly, check proper
BOSCH detected
Problem with the shift seating of shift solenoids in HCU
linkage not holding the If solenoids are ok, replace entire
gear in place HCU

tmr2013-077 47
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

TCM Downshift detected Shift valves wrongly
P284F Exchange connections to shift valves
BOSCH on upshift request connected
TCM Upshift detected on Shift valves wrongly
P2850 Exchange connections to shift valves
BOSCH downshift request connected
Check for TCM fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID
DLC-1 and TCMB-C1
Lost communication 102h from ECM.
TCM (expected value < 2 ohms).
U0100 with ECM (lost of Module internal error.
BOSCH Measure resistance between
CAN ID’s) Damaged circuit wires or
DLC-2 and TCMB-C2
damaged module pins.
(expected value < 2 ohms).
Measure resistance between
DLC-1 and ECMB-C1
(expected value < 2 ohms).
Measure resistance between
DLC-2 and ECMB-C2
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between harness
connector ECMB-M4 and ground
(expected value = 11 to 13 volts).
Check for TCM fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID
DLC-1 and TCMB-C1
Lost communication 103h from ECM.
TCM (expected value < 2 ohms).
U0100 with ECM (lost of Module internal error.
BOSCH Measure resistance between
CAN ID’s) Damaged circuit wires or
DLC-2 and TCMB-C2
damaged module pins.
(expected value < 2 ohms).
Measure resistance between
DLC-1 and ECMB-C1
(expected value < 2 ohms).
Measure resistance between
DLC-2 and ECMB-C2
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between harness
connector ECMB-M4 and ground
(expected value = 11 to 13 volts).

48 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check for TCM fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID
DLC-1 and TCMB-C1
Lost communication 120h from ECM.
TCM (expected value < 2 ohms).
U0100 with ECM (lost of Module internal error.
BOSCH Measure resistance between
CAN ID’s) Damaged circuit wires or
DLC-2 and TCMB-C2
damaged module pins.
(expected value < 2 ohms).
Measure resistance between
DLC-1 and ECMB-C1
(expected value < 2 ohms).
Measure resistance between
DLC-2 and ECMB-C2
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between harness
connector ECMB-M4 and ground
(expected value = 11 to 13 volts).
Check for TCM fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID
DLC-1 and TCMB-C1
Lost communication 122h from ECM.
TCM (expected value < 2 ohms).
U0100 with ECM (lost of Module internal error.
BOSCH Measure resistance between
CAN ID’s) Damaged circuit wires or
DLC-2 and TCMB-C2
damaged module pins.
(expected value < 2 ohms).
Measure resistance between
DLC-1 and ECMB-C1
(expected value < 2 ohms).
Measure resistance between
DLC-2 and ECMB-C2
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between harness
connector ECMB-M4 and ground
(expected value = 11 to 13 volts).

tmr2013-077 49
Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check for TCM fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID
DLC-1 and TCMB-C1
Lost communication 300h from ECM.
TCM (expected value < 2 ohms).
U0100 with ECM (lost of Module internal error.
BOSCH Measure resistance between
CAN ID’s) Damaged circuit wires or
DLC-2 and TCMB-C2
damaged module pins.
(expected value < 2 ohms).
Measure resistance between
DLC-1 and ECMB-C1
(expected value < 2 ohms).
Measure resistance between
DLC-2 and ECMB-C2
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between harness
connector ECMB-M4 and ground
(expected value = 11 to 13 volts).
Check for TCM fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID
DLC-1 and TCMB-C1
Lost communication 308h from ECM.
TCM (expected value < 2 ohms).
U0100 with ECM (lost of Module internal error.
BOSCH Measure resistance between
CAN ID’s) Damaged circuit wires or
DLC-2 and TCMB-C2
damaged module pins.
(expected value < 2 ohms).
Measure resistance between
DLC-1 and ECMB-C1
(expected value < 2 ohms).
Measure resistance between
DLC-2 and ECMB-C2
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between harness
connector ECMB-M4 and ground
(expected value = 11 to 13 volts).

50 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check for TCM fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID
DLC-1 and TCMB-C1
Lost communication 310h from ECM.
TCM (expected value < 2 ohms).
U0100 with ECM (lost of Module internal error.
BOSCH Measure resistance between
CAN ID’s) Damaged circuit wires or
DLC-2 and TCMB-C2
damaged module pins.
(expected value < 2 ohms).
Measure resistance between
DLC-1 and ECMB-C1
(expected value < 2 ohms).
Measure resistance between
DLC-2 and ECMB-C2
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between harness
connector ECMB-M4 and ground
(expected value = 11 to 13 volts).
Check for TCM fault or ECM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID
DLC-1 and TCMB-C1
Lost communication 343h from ECM.
TCM (expected value < 2 ohms).
U0100 with ECM (lost of Module internal error.
BOSCH Measure resistance between
CAN ID’s) Damaged circuit wires or
DLC-2 and TCMB-C2
damaged module pins.
(expected value < 2 ohms).
Measure resistance between
DLC-1 and ECMB-C1
(expected value < 2 ohms).
Measure resistance between
DLC-2 and ECMB-C2
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between harness
connector ECMB-M4 and ground
(expected value = 11 to 13 volts).

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Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check for TCM fault or VCM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID DLC-1 and TCMB-C1
Lost communication 230h from VCM. (expected value < 2 ohms).
TCM
U0122 with VCM (lost of Module internal error. Measure resistance between
BOSCH
CAN ID’s) Damaged circuit wires or DLC-2 and TCMB-C2
damaged module pins. (expected value < 2 ohms).
Measure resistance
between DLC-1 and VCM-26
(expected value < 2 ohms).
Measure resistance
between DLC-2 and VCM-14
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between harness
connector VCM-1, VCM-25, VCM-28
and ground (expected value = 11 to
13 volts).
Check for TCM fault
or WPM/EPB fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Missing CAN ID 460h Measure resistance between
Lost communication from WPM/EPB. DLC-1 and TCMB-C1
TCM
U0128 with WPM/EPB (lost Module internal error. (expected value < 2 ohms).
BOSCH
of CAN ID’s) Damaged circuit wires or Measure resistance between
damaged module pins. DLC-2 and TCMB-C2
(expected value < 2 ohms).
Measure resistance
between DLC-1 and WPM-6
(expected value < 2 ohms).
Measure resistance
between DLC-2 and WPM-8
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between harness
connector WPM-5 and ground
(expected value = 11 to 13 volts).

52 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

Check for TCM fault
or CLUSTER fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Missing CAN ID Measure resistance between
Lost communication 400h from CLUSTER. DLC-1 and TCMB-C1
TCM
U0155 with CLUSTER (lost Module internal error. (expected value < 2 ohms).
BOSCH
of CAN ID’s) Damaged circuit wires or Measure resistance between
damaged module pins. DLC-2 and TCMB-C2
(expected value < 2 ohms).
Measure resistance
between DLC-1 and CL-24
(expected value < 2 ohms).
Measure resistance
between DLC-2 and CL-23
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between harness
connector CL-8, CL-9 and ground
(expected value = 11 to 13 volts).
Check for TCM fault or SWM fault.
With unit connected
to BUDS with MPI2,
Turn ignition switch OFF,
wait for cluster to turn off.
Disconnect MPI2
from DLC connector.
Measure resistance between
DLC-1 and DLC-2 (expected
value = 50 to 70 ohms).
Measure resistance between
Missing CAN ID
DLC-1 and TCMB-C1
Lost communication 340h from SWM.
TCM (expected value < 2 ohms).
U0259 with SWM (lost of Module internal error.
BOSCH Measure resistance between
CAN ID’s) Damaged circuit wires or
DLC-2 and TCMB-C2
damaged module pins.
(expected value < 2 ohms).
Measure resistance
between DLC-1 and MSL3-3
(expected value < 2 ohms).
Measure resistance
between DLC-2 and MSL3-2
(expected value < 2 ohms).
Turn ignition switch ON
Measure voltage between harness
connector MSR2-6 and ground
(expected value = 11 to 13 volts).

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Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

External troubleshooting
checksum error. is not possible.
TCM Invalid checksum CAN message contains Check for communication
U220A
BOSCH from ECM message erroneous information or fault from ECM which may have
temporarily incorrect. contributed to the erroneous
information transmitted.
External troubleshooting
checksum error. is not possible.
TCM Invalid checksum CAN message contains Check for communication
U220A
BOSCH from ECM message erroneous information or fault from ECM which may have
temporarily incorrect. contributed to the erroneous
information transmitted.
External troubleshooting
checksum error. is not possible.
TCM Invalid checksum CAN message contains Check for communication
U220A
BOSCH from ECM message erroneous information or fault from ECM which may have
temporarily incorrect. contributed to the erroneous
information transmitted.
External troubleshooting
checksum error. is not possible.
TCM Invalid checksum CAN message contains Check for communication
U220A
BOSCH from ECM message erroneous information or fault from ECM which may have
temporarily incorrect. contributed to the erroneous
information transmitted.
External troubleshooting
checksum error. is not possible.
TCM Invalid checksum CAN message contains Check for communication
U220A
BOSCH from ECM message erroneous information or fault from ECM which may have
temporarily incorrect. contributed to the erroneous
information transmitted.
External troubleshooting
checksum error. is not possible.
TCM Invalid checksum CAN message contains Check for communication
U220A
BOSCH from ECM message erroneous information or fault from ECM which may have
temporarily incorrect. contributed to the erroneous
information transmitted.
External troubleshooting
checksum error. is not possible.
TCM Invalid checksum CAN message contains Check for communication
U220B
BOSCH from VCM message erroneous information or fault from VCM which may have
temporarily incorrect. contributed to the erroneous
information transmitted.
External troubleshooting
checksum error. is not possible.
Invalid checksum
TCM CAN message contains Check for communication
U220E from CLUSTER
BOSCH erroneous information or fault from CLUSTER which may
message
temporarily incorrect. have contributed to the erroneous
information transmitted.
External troubleshooting
checksum error. is not possible.
TCM Invalid checksum CAN message contains Check for communication
U220F
BOSCH from SWM message erroneous information or fault from SWM which may have
temporarily incorrect. contributed to the erroneous
information transmitted.

54 tmr2013-077
 Subsection XX (DIAGNOSTIC AND FAULT CODES)

PCODE MODULE DESCRIPTION CAUSE ACTION

External troubleshooting
checksum error. is not possible.
Invalid checksum
TCM CAN message contains Check for communication
U221B from WPM/EPB
BOSCH erroneous information or fault from WPM/EPB which may
message
temporarily incorrect. have contributed to the erroneous
information transmitted.
Put vehicle at normal
Extreme ambient room temperature
TCM Chip temperature for
U3E00 temperature Reset TCM unit and monitor
BOSCH signal too high
Damaged TCM unit for TCM hardware failure
Replace TCM unit
Put vehicle at normal
Extreme ambient room temperature
TCM Chip temperature for
U3E01 temperature Reset TCM unit and monitor
BOSCH signal too low
Damaged TCM unit for TCM hardware failure
Replace TCM unit
Reset TCM unit and monitor
TCM Chip temperature for
U3E02 Damaged TCM unit for TCM hardware failure
BOSCH plausibility fault
Replace TCM unit
Fault check of Rom Reset TCM unit and monitor
TCM
U3E03 Checksum Cyclic for Damaged TCM unit for TCM hardware failure
BOSCH
general fault Replace TCM unit
Fault check of Rom Reset TCM unit and monitor
TCM
U3E04 Checksum Cyclic for Damaged TCM unit for TCM hardware failure
BOSCH
general fault Replace TCM unit
Fault check of Rom Reset TCM unit and monitor
TCM
U3E05 Checksum Cyclic for Damaged TCM unit for TCM hardware failure
BOSCH
general fault Replace TCM unit
Reset TCM unit and monitor
TCM HW related watchdog
U3E06 Damaged TCM unit for TCM hardware failure
BOSCH fault
Replace TCM unit
Reset TCM unit and monitor
TCM HW related watchdog
U3E07 Damaged TCM unit for TCM hardware failure
BOSCH fault (DFE)
Replace TCM unit
Reset TCM unit and monitor
TCM SW related watchdog
U3E08 Damaged TCM unit for TCM hardware failure
BOSCH fault
Replace TCM unit
Reset TCM unit and monitor
TCM Fault check of MCore
U3E09 Damaged TCM unit for TCM hardware failure
BOSCH Monitoring faults
Replace TCM unit
General fault of the Safety System: safety
TCM
U3E0A Safety Reaction reaction manager general Damaged TCM
BOSCH
Manager fault
Fault check of reset Different TCU internal
TCM Software Reset has
U3E0C recognition - Bosch software malfunctions
BOSCH occurred
function Assumed under voltage

tmr2013-077 55
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

ELECTRONIC FUEL INJECTION (EFI)

SERVICE TOOLS
Description Part Number Page
DIGITAL INDUCTION TACHOMETER ........................................... 529 014 500 ............................................. 4
ECM ADAPTER TOOL................................................................... 529 036 166 ...... 12, 14, 17, 20, 22, 26–27,
31, 33, 36, 38, 42–44
FLUKE 115 MULTIMETER ............................................................ 529 035 868 .. 9, 12–14, 17, 20, 22–24, 26,
30–33, 35–36, 38, 40, 42–44
FUEL HOSE DISCONNECT TOOL ................................................ 529 036 037 ............................................. 7
MPI-2 DIAGNOSTIC CABLE.......................................................... 710 000 851 ........................................... 11

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
FLUKE AUTOMOTIVE BACK PROBE PIN..................................... TP40 ........................................... 40

SERVICE PRODUCTS
Description Part Number Page
DIELECTRIC GREASE ................................................................... 293 550 004 ........................................... 28
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 23
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ..................................... 36–37

GENERAL To release fuel pressure prior to removing a hose,

WARNING
Fuel is flammable and explosive under cer-
tain conditions. Ensure work area is well ven-
tilated. Do not smoke or allow open flames or
sparks in the vicinity.
WARNING
Always disconnect battery prior to working
on the fuel system. Always disconnect bat-
tery exactly in the specified order, BLACK (-)
cable first. It is recommended to disconnect
electrical connections prior to disconnecting
fuel lines.
WARNING
Fuel lines remain under pressure at all times.
Always proceed with care and use appro-
priate safety equipment when working on a
pressurized fuel system. Wear safety glasses.
Proceed with care when removing/installing
pressure test equipment or disconnecting
fuel line connections.
refer to FUEL TANK AND FUEL PUMP subsection.
Cover the fuel line connection with an absorbent
shop rag before disconnecting it. Slowly discon-
nect the fuel hose to minimize spillage.
WARNING
Do not allow fuel to spill on hot engine parts
and/or on electrical connectors. Wipe off any
fuel spillage in the engine compartment.
NOTICE Never use a hose pincher on injec-
tion system high pressure hoses. Replace any
damaged or deteriorated fuel line.
When the repair or test is completed, ensure that
all hoses are connected and secured. Perform the
FUEL SYSTEM PRESSURE TEST and the FUEL
SYSTEM LEAK TEST as explained in FUEL TANK
AND FUEL PUMP subsection.

rmr2014-024 1
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))
WARNING
Always perform the fuel pressure test if any
fuel line has been disconnected from a com-
ponent, or the fuel component has been re-
moved. A pressure test must be carried out
before turning the ignition key to ON. The fuel
pump is activated each time the ignition key
is turned ON.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory stan-
dards.
SYSTEM DESCRIPTION
ECM
smr2009-027-005
TYPICAL - ECM
The ECM reads input signals from various sensors
that provide it with an indication of the engine op-
erating conditions at micro-second intervals.
The ECM calculates the appropriate amount of air,
fuel, and ignition timing required, and activates
the outputs to the injectors, ignition coils and
electric throttle actuator (ETA).
EFI Sensors
The TAS (Throttle Accelerator Sensor), CPS
(Crankshaft Position Sensor), the MAPTS (Mani-
fold Absolute Pressure and Temperature Sensor),
CAPS (Camshaft Position Sensor), CTS (Coolant
Temperature Sensor) and the TPS (Throttle Po-
sition Sensor), are the primary sensors used to
control the injection. Other sensors such as tem-
perature sensors are used as secondary inputs.
The AAPTS (Ambient Air Pressure and Temper-
ature Sensor) functions in conjunction with the
MAPTS. The AAPTS reading is compared with
the MAPTS reading. The ECM uses the compar-
ative results to improve engine operation in high
altitude areas.
The injection system is a closed loop type. This is
achieved by the addition of a heated oxygen sen-
sor (HO2S).
2 rmr2014-024
Closed loop system operation (also called a feed-
back system) regulates the air/fuel ratio based
on predetermined values stored within the ECM.
The stored values are used in relation to the infor-
mation received from the input sensors and the
residual amount of oxygen in the exhaust-gas,
which is measured by the heated oxygen sensor
(or Lambda sensor).
The engine will begin to operate in open loop
when first started, and switch to closed loop
operation when the oxygen sensor reaches its
operating temperature. At high engine loads, the
engine reverts again to the open loop.
Throttle Body (ETC (Electronic Throttle
Control))
A 54 mm (2.13 in) single draft throttle body (ETC)
is mounted directly on the air intake manifold.
The throttle position sensor (TPS) and the electric
throttle actuator (ETA) are part of the throttle body
assembly.
rmr2014-024-009 _a
TYPICAL
1. Throttle body
2. Air intake manifold
The ETA is used to control air delivery by open-
ing or closing the throttle plate. It allows the ECM
to electrically control the position of the throttle
plate throughout the full range of engine opera-
tion. There is no idle air control valve (IACV).
The TPS provides the ECM with a signal of the ac-
tual angular position of the throttle plate. When
the ETA changes the position of the throttle plate,
the ECM uses the TPS signal to monitor the throt-
tle plate position, and modulate the ETA through
pulse width modulation to move the throttle plate
until the targeted position is achieved.
The use of an ETA controlled by the ECM also al-
lows for an electronic cruise control function.
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

If there is a system malfunction and the ETA is

not powered by the ECM, return springs move
the throttle plate back to the LIMP HOME posi-
tion against a mechanical stop, not the idle posi-
tion. The throttle plate is electrically driven to the
idle position by the ETA when commanded by the
ECM.

Throttle Accelerator Sensor (TAS)

TAS Description
This vehicle is designed with an electronic throt-
tle accelerator sensor (TAS) that is used to deter-
mine the driver requested torque. There are no rmr2014-024-003_a

mechanical cables between the throttle grip and 1. Fuel rail

the throttle body. This is often referred to as a
"throttle by wire" system. Fuel Injectors
The TAS sensor is composed of two magnets and Three fuel injectors are used to inject fuel into the
a double output hall effect sensor that are incorpo- intake ports of the cylinder head. One injector is
rated within the throttle grip assembly. used per cylinder.
The double hall effect sensor TAS is used for
redundancy. If one sensor is inoperative, throttle
control will be maintained, but a check engine
light and a check engine message will appear in
the gauge cluster, and a relevant fault code will
be recorded in the ECM.
TAS Operation
The ECM provides a supply voltage and a ground
to each hall effect sensor. The hall effect sensors
in the TAS each produce a command signal volt-
age that is proportional to the throttle position.
Turning the throttle grip varies the two command
signal voltages produced by the TAS accordingly.
The ECM will then power the ETA to open or close rmr2014-024-004_a

the throttle plates in the throttle body according to
the torque commanded by the operator, or other
inputs such as cruise control or transmission con-
trol module (SE6 model).
If the brake pedal is depressed and the throttle
is not released, engine torque will be reduced
to idle. Normal engine control will resume when
braking action is ceased.
Fuel System
Fuel Rail
A fuel rail is mounted on the intake manifold. The
fuel rail, which is used to secure the injectors to
the manifold, also provides to the injectors the
fuel pressure that it receives from the fuel pump.
The fuel pressure applied to the fuel rail is regu-
lated by the fuel pressure regulator located in the
fuel pump module.
1. Fuel injectors
Fuel is injected in accordance with injection sig-
nals received from the ECM.
Fuel Pump
An electric fuel pump with an integrated pressure
regulator and an external in line fuel system filter
is used. For more details on the fuel pump mod-
ule, refer to FUEL TANK AND FUEL PUMP sub-
section.
ADJUSTMENT
IDLE SPEED
Idle speed is not adjustable. The EMS (Engine
Management System) controls the idle speed of
the engine by controlling throttle plate opening
using the ETA (electric throttle actuator).

rmr2014-024 3
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))
With the engine running, engine RPM may be
verified using the applicable B.U.D.S. software
version, refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection.
In B.U.D.S., select the following:
rmr2014-024-010_a
TYPICAL - VERIFYING ENGINE RPM USING B.U.D.S.
Step 1: Click on the Read Data button
Step 2: Select the Monitoring page tab
Step 3: Read the engine RPM indication
As an alternate method, the engine RPM can be
measured using the following procedure:
REQUIRED TOOL
DIGITAL INDUCTION TACHOMETER
(P/N 529 014 500)
529014500
1. Wrap the tachometer's wire a few times
around the protruding part of the ignition coil.
4 rmr2014-024
A32CCIA
TYPICAL
2. Start engine.
3. Read the engine RPM on the induction
tachometer.
NOTE: If idle speed is not within specifications,
check if there is any occurred or active fault
code(s) using B.U.D.S.. Follow recommend ser-
vice actions.
IDLE SPEED
900 ± 50 RPM
THROTTLE POSITION SENSOR
RESET
General Information
This operation performs a reset of the values
stored in the ECM for the TPS when it is at the
closed position and at the limp home position.
The TPS position is used to determine the basic
parameters for all fuel mapping and several ECM
calculations.
A reset must be carried out each time any of the
following situations has occurred:
– Throttle body has been replaced.
– ECM has been replaced.
NOTE: The TPS is not adjustable. The ECM must
learn the TPS values when carrying out the Throt-
tle position sensor initialization reset procedure
in B.U.D.S. An improperly set TPS may lead to
poor engine performance. Emission compliance
could possibly be affected.
TPS initialization
1. Connect vehicle to the latest applicable
B.U.D.S. version.
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))
2. Turn the ignition key to ON. Do not start the
engine.
3. In B.U.D.S., click on the Read Data button.
4. Follow the steps shown in the following illustra-
tions.
rmr2014-024-011_a
Step 1: Click on Setting tab
Step 2: Select the ECM tab
Step 3: Ensure the TPS Learned LED is OFF
rmr2014-024-011_b
THROTTLE POSITION SENSOR INITIALIZATION
Step 1: Click on Reset button.
rmr2014-024
rmr2014-024-011_c
THROTTLE POSITION SENSOR INITIALIZATION
Step 1: Ensure the TPS Learned LED is ON
5. Start engine and make sure it operates nor-
mally throughout its full engine RPM range.
If a fault code appears, refer to DIAGNOSTIC
AND FAULT CODES subsection for more infor-
mation.
TROUBLESHOOTING
DIAGNOSTIC TIPS
The first step in troubleshooting the EFI system
is to check for fault codes using B.U.D.S.; refer
to DIAGNOSTIC AND FAULT CODES subsection.
Also check for fuel trim changes as indicated in
B.U.D.S.. Fuel trim levels can be used for diag-
nosis of fuel system problems. However, engine
problems are not necessarily related to the elec-
tronic fuel injection system.
It is important to ensure that the engine, fuel de-
livery system and electrical system are operating
normally.
WARNING
Electrical actuators and electronic modules
may be powered up as soon as the ignition
key is set to ON. Always disconnect the bat-
tery prior to disconnecting any electrical or
electronic parts.
Never use a battery charger to temporarily substi-
tute the battery as it may cause the ECM to func-
tion erratically, or not at all.
Check related-circuit fuse solidity and condition
with an ohmmeter. A visual inspection could lead
to a false diagnosis.
5
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))
Poor Idling
If poor idling is experienced, check the following:
– Poor quality fuel or water in the fuel
– Fault codes using B.U.D.S.
– Throttle body cleanliness
– Engine leaks or other mechanical problem.
Engine Related Problems
The following items should not be overlooked:
– Inappropriate engine valve timing or valve lifter
damage
– Poor or unequal engine compression.
Fuel Delivery System Related
Problems
The following items may affect the fuel injection
system:
– Faulty fuel pump
– Faulty fuel pressure regulator
– Dirty or clogged fuel filter
– Faulty purge valve
– Leaking, kinked, or obstructed fuel line
– An air leak that is not metered
– A faulty heated oxygen sensor (HO2S).
Electrical Related Problems
It is important to check that the following items in
the electrical system are functioning properly:
– Battery
– Fuses
– Relay(s)
– Ignition (misfiring spark plug or faulty ignition
coil)
– Ground connections
– Wiring connectors.
Pay particular attention to ensure that pins are not
out of their connectors or out of shape.
When probing terminals, pay attention to the
condition of terminal pins and sockets. Be sure
not to bend the terminal pins. Multimeter probes
should never be inserted in terminal sockets as
this could deform the socket and create a loose
connection that would be difficult to troubleshoot.
Always use special tools (such as an ECM adapter
tool) when carrying out electrical tests. Refer to
WIRING HARNESS AND CONNECTORS subsec-
tion for more details on electrical connectors.
Never use a battery charger to temporarily substi-
tute the battery, as it may cause the ECM (engine
control module) to function erratically, or not at all.
6 rmr2014-024
WARNING
Some EMS components are continuously
powered when the ignition key is turned on.
The ECM switches the circuit to the ground
to complete the electrical circuits it controls.
Take this into account when troubleshoot-
ing. Always disconnect the battery prior to
disconnecting any electric or electronic com-
ponent.
Ensure that all electronic components are genuine
OEM parts (original equipment manufacturer) rec-
ommended by BRP. Any modification to a circuit
may generate fault codes or result in bad system
operation.
NOTE: For diagnostics purposes, use the latest
applicable B.U.D.S. software version. See DIAG-
NOSTIC AND FAULT CODES subsection.
After a problem has been solved, always clear the
fault(s) in the ECM (and other ECUs as applicable)
using the B.U.D.S. software.
Check related circuit fuse solidity and condition
with an ohmmeter. A visual inspection may lead
to a false conclusion.
Temperature Sensors
When measuring the resistance with an ohmme-
ter, all values are given for a temperature of 20°C
(68°F). The resistance value of a resistance varies
with the temperature. The resistance value for
commonly used resistors or windings (such as in-
jectors) increases as the temperature increases.
However, temperature sensors normally used in
this vehicle are NTC types (Negative Temperature
Coefficient), which means that the resistance
value decreases as their temperature increases.
This must be taken into account when measuring
them at temperatures other than 20°C (68°F).
The resistance value of a temperature sensor may
test good at a certain temperature but may not be
within acceptable limits at other temperatures. If
in doubt, try a new sensor.
Also remember that this validates the operation
of the sensor at room temperature. It does not
validate the functionality of the sensor at higher
(or normal) operating temperatures. To test it, the
sensor could be removed from the engine and
heated with a heat gun while it is still connected
to the harness to see if the ECM will detect the
high temperature condition and generate a fault
code.
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

Fuel Injection Related Problems REQUIRED TOOL

Also check for the following items: FUEL HOSE DISCONNECT TOOL (P/N 529 036 037)
– Leaking, faulty or dirty fuel injector(s).
– Fuel injector connector problem.
– Faulty fuel pump (inadequate pressure).
– Clogged fuel filter.
– MAPTS sensor port obstruction, leakage, dam-
age or proper electrical connection. Refer to 529036037

MAPTS SENSOR in this subsection.

– Throttle body TPS or ETA faults.
– Intake flange leakage.

PROCEDURES
FUEL RAIL
Fuel Rail Access
Refer to BODY subsection and remove the follow-
ing:
– LH and RH top side panels
– LH and RH middle side panels
– LH and RH acoustic panels.
Remove primary air intake silencer (air filter hous-
ing), refer to AIR INTAKE SYSTEM subsection. lmr2006-008-010

Fuel Rail Removal NOTE: It may be necessary to rotate fuel hose fit-
ting to align the tool ends with the openings of the
Disconnect battery, refer to POWER DISTRIBU-
locking mechanism.
TION AND GROUNDS.
Remove parts required for access to fuel rail. Re- Fuel Rail Removal
fer to FUEL RAIL ACCESS in this subsection. 1. Disconnect all injector electrical connectors.
Release fuel pressure from fuel system, refer to 2. Remove screws retaining fuel rail.
FUEL TANK AND FUEL PUMP subsection. 3. Remove locking ties securing engine harness to
Fuel Rail Hose Disconnection fuel rail.
NOTICE Do not disconnect fuel pressure
hose fitting from fuel rail unless necessary. If
fuel pressure hose is disconnected from fuel
rail, the quick disconnect fitting must be re-
placed.
1. Place an absorbent shop rag around the fuel
supply hose fitting at the fuel rail to catch any
fuel leakage.
2. Disconnect fuel hose from fuel rail.
2.1 Lightly push quick disconnect fitting
against fuel rail to relieve pressure from
locking mechanism.
2.2 Gently unlock quick disconnect fitting us- rmr2014-024-004_b

ing recommended tool. 1. Fuel injector connectors

2. Locking ties
2.3 Remove quick disconnect fitting from fuel
rail. 4. Remove fuel rail retaining screws.

rmr2014-024 7
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

IMPORTANT: Push fuel hose fitting on fuel rail un-

til you hear a "click". Try pulling fuel hose off fuel
rail to ensure fitting is properly locked.
2. Pressurize the fuel system and check for a fuel
leak. Refer to FUEL SYSTEM HIGH PRESSURE
LEAK TEST in FUEL TANK AND FUEL PUMP
subsection.
WARNING
Failure to pressurize the fuel system to check
for fuel leaks may result in severe injury or a
life threatening situation should a leak occur.
rmr2014-024-012_b

1. Fuel rail retaining screws

3. Reinstall all remaining removed parts.

5. Gently wiggle fuel rail side to side as you pull FUEL INJECTOR
the fuel rail out with fuel injectors.
Fuel Injector Connector Access
Fuel Rail Installation Remove primary air intake silencer (air filter hous-
Reverse the removal procedure. However, pay at- ing). Refer to AIR INTAKE SYSTEM subsection.
tention to the following.
Fuel Injector Functional Test with
FUEL RAIL INSTALLATION B.U.D.S. (Dynamic)
INJECTOR SERVICE PRODUCT 1. Connect vehicle to latest applicable B.U.D.S.
O-RINGS APPLY ENGINE OIL ON O-RING version. Refer to COMMUNICATION TOOLS
AND B.U.D.S.
TORQUE
RETAINING 2. Start engine.
SCREWS 11 N•m ± 1 N•m
(97 lbf•in ± 9 lbf•in) 3. In B.U.D.S., click the following:
– Read Data button
Fuel Rail Hose Connection – Monitoring tab.
FUEL RAIL HOSE CONNECTION 4. Using the latest applicable B.U.D.S. version,
shut down each engine cylinder one at a time
FUEL HOSE SERVICE PRODUCT by clicking on the button under the applicable
O-RINGS ENGINE OIL cylinder.

rmr2014-024-001_a

MONITORING AND ECM TABS

mmr2009-121-022_a 1. Click on cylinder number to be tested
1. Apply oil on O-rings
If the engine RPM drops when clicking on a cylin-
1. Connect fuel hose to fuel rail. der, the injector and the ignition of the cylinder are
functioning normally.
8 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

If the engine RPM does not drop when clicking on 3. In B.U.D.S., select:
a cylinder, the cylinder is not functioning properly. – Read Data button
Check the following: – Activation tab.
– Fuel injector operation. Refer to FUEL IN-
4. Use the FLUKE 115 MULTIMETER (P/N 529 035
JECTOR FUNCTIONAL TEST WITH B.U.D.S.
868) and set it to Vdc.
(STATIC).
– Spark plug and ignition coil. Refer to IGNITION NOTE: Make sure multimeter is in the Auto
SYSTEM. Range mode.
– Engine condition.
Turn engine OFF.

Fuel Injector Functional Test with

B.U.D.S. (Static)
1. Turn ignition key to ON.
2. Using the latest applicable B.U.D.S. version, en-
ergize the fuel injector(s).
2.1 In B.U.D.S., click on the Read Data button.
2.2 Click on the Activation tab.
2.3 Select the ECM tab.
2.4 Click on the fuel injector to be tested to
activate it.

mmr2009-120-020_a

5. Press the Hz button so that the display shows

Hz.

rmr2014-024-044_a

TYPICAL - FUEL INJECTOR ACTIVATION

You should hear the injector working.

This will validate the injector mechanical and elec-
trical operation.
If the injector does not function, carry out a FUEL
INJECTOR SIGNAL TEST.
Fuel Injector Signal Test mmr2009-120-020_b

1. Connect vehicle to the latest applicable 6. Connect the multimeter probes as indicated in
B.U.D.S. version. Refer to COMMUNICA- the following table and using the B.U.D.S. soft-
TION TOOLS AND B.U.D.S. subsection. ware, activate each injector and read the fre-
2. Turn ignition key to ON. quency on the multimeter.

rmr2014-024 9
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

2. Connect vehicle to B.U.D.S. software. Refer to

COMMUNICATION TOOLS AND B.U.D.S.
3. Turn ignition key to ON.
4. In B.U.D.S., click the following:
– Read Data button
– Activation tab
– ECM page.
5. In B.U.D.S., click the Fuel Pump button to ac-
tivate fuel pump. Record fuel system pressure
once the fuel pump has stopped, and just be-
fore you carry out the following step.

rmr2014-024-048_a

INJECTOR ACTIVATION IN B.U.D.S.

1. Click on no. 1 injector to activate
2. Click on no. 2 injector to activate
3. Click on no. 3 injector to activate

NOTE: The multimeter counts the pulses per sec-

onds (Hertz) of current the ECM sends to the in-
jector.
INJECTOR
INJECTOR CONNECTOR BATTERY MEASUREMENT
CONTACT
No. 1 VIOLET/BLUE rmr2014-024-047_a

(clutch side) wire ACTIVATION AND ECM PAGE TABS

1. Fuel Pump activation button
No. 2 VIOLET/GREEN Battery Approximately
(center) wire ground 40 Hz 6. In B.U.D.S., energize fuel injector no. 1.
No. 3 VIOLET/ORANGE
(belt side) wire

If there is a frequency reading, the control circuit

is functional. Carry out a INJECTOR INPUT VOLT-
AGE TEST in this subsection.
If there is no reading, check continuity of control
circuit (ECM to injectors). Refer to INJECTOR RE-
SISTANCE TEST (ECM TO FUSE BOX) in this sub-
section.

Fuel Injector Balance Test with

B.U.D.S.
NOTICE After fuel injector activation using
B.U.D.S., always crank engine in drowned
mode to ventilate engine and prevent a po-
tential backfire due to fuel accumulation in rmr2014-024-048_a

ACTIVATION AND ECM PAGE TABS

engine. 1. Injector number 1
2. Injector number 2
1. Install a fuel pressure gauge as described in 3. Injector number 3
FUEL SYSTEM PRESSURE TEST . Refer to
FUEL TANK AND FUEL PUMP subsection. 7. Record the fuel pressure drop for injector
no. 1 immediately after the injector cycle has
stopped.

10 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

8. Repeat previous 3 steps for fuel injectors no. 2 4. Set emergency engine stop switch to STOP.
and no. 3 and record the pressure drop for each 5. Disconnect vehicle from B.U.D.S. by discon-
injector. necting the MPI-2 DIAGNOSTIC CABLE (P/N 710
9. The maximum difference in fuel pressure drop 000 851) from the vehicle diagnostic connector.
between injectors should not exceed the fol-
lowing specification:
MAXIMUM DIFFERENCE IN FUEL PRESSURE
DROP ALLOWED BETWEEN FUEL INJECTORS
13.8 kPa (2 PSI)

10. Turn ignition key OFF.

If all injector electrical tests are all good, then the
injector that is out of tolerance should be replaced, 710000851
and the balance test repeated.
FUEL INJECTOR BALANCE TEST
6. Wait for vehicle electrical power to shut off; the
multifunction gauge will turn off.
POSSIBLE
RESULT
CAUSE
ACTION 7. Remove fuel rail with injectors from engine
however, do not disconnect fuel pump pres-
Fuel pressure sure hose from fuel rail. Refer to FUEL RAIL
drop of an Fuel injector Clean the REMOVAL in this subsection.
injector is lower may be dirty or injectors and
than other 2 clogged. repeat the test. 8. Position fuel rail so that an appropriate con-
injectors. tainer may be placed under the injectors to
collect any fuel leakage.
Fuel pressure
drop of an
Clean the
injector is Injector may be
injectors and
greater than sticking open.
repeat the test.
other 2
injectors.
Carry out
all injector
Cleaning
electrical
injectors does Faulty wiring
tests in this
not reestablish and connectors
subsection.
fuel injector Faulty injector.
Replace
balance.
injector.
Repeat the test.

11. Using the valve on the fuel pressure gauge,

release the pressure in the system (if so
rmr2014-024-046
equipped).
TYPICAL - INJECTOR LEAKAGE TEST SETUP
12. Remove fuel pressure gauge and reinstall re-
moved parts. 9. Connect vehicle to B.U.D.S. Refer to COMMU-
NICATION TOOLS AND B.U.D.S. subsection
Fuel Injector Leak Test Injector Leak Test
Injector Leak Test Setup 1. In B.U.D.S., select the following:
1. Ensure there is enough fuel in fuel tank. – Activation page tab
2. Ensure fuel pressure from fuel pump is within – ECM page.
specification. Refer to FUEL TANK AND FUEL 2. Click on the Fuel Pump button to activate fuel
PUMP subsection. pump for a few seconds.
NOTE: Keep the pressure gauge installed for the
leak test.
3. Remove key from ignition switch.
rmr2014-024 11
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

REQUIRED TOOLS
FLUKE 115
ECM ADAPTER TOOL
MULTIMETER
(P/N 529 036 166)
(P/N 529 035 868)

FUSE
ECM RESISTANCE
INJECTOR BOX
ADAPTER @ 20°C (68°F)
CONTACT
rmr2014-024-047_a No. 1
B3
ACTIVATION AND ECM TABS (clutch side)
1. Click here
No. 2
K1 B3 11.4 - 12.6
3. Check for fuel leakage from the injector noz- (center)
zles. No. 3
J1
4. Monitor fuel pressure at fuel pressure gauge. (belt side)
If pressure drops below 372 kPa (54 PSI) during
the test, re-activate fuel pump as necessary. If resistance value is as specified, the injector and
its circuits from the fuse contact are good. Refer
FUEL INJECTOR LEAKAGE to INJECTOR INPUT VOLTAGE TEST in this sub-
TEST DURATION SPECIFICATION section.
1 drop per minute If resistance value is NOT as specified, refer to
2 minutes INJECTOR RESISTANCE TEST (AT INJECTOR) in
maximum
this subsection.
If test is not within specification, replace the faulty
fuel injector. Injector Resistance Test
5. Properly reinstall fuel rail. Refer to FUEL RAIL (at Injector)
in this subsection. 1. Disconnect injector electrical connector.
6. Reinstall remaining removed components. 2. Check resistance value between injector pins
as follows.
WARNING
RESISTANCE @ 20°C
Wipe up any spilled fuel. INJECTOR PIN
(68°F)
1 2 11.4 - 12.6
Injector Resistance Test
(ECM to Fuse Box)
1. Remove IGNITION COILS AND INJECTORS
fuse (F6) in LH fuse box. Refer to POWER
DISTRIBUTION AND GROUNDS subsection.
2. Disconnect ECM-A connector and install it on
the ECM adapter tool; refer to ECM CONNEC-
TOR ACCESS in ENGINE CONTROL MODULE
(ECM) in this subsection.
3. Check injector resistance as follows.

rmr2014-024-005_a

If reading is not as specified, replace injector.

12 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

If reading is as specified, carry out a:

– CONTINUITY TEST OF INJECTOR POWER
CIRCUIT
– CONTINUITY TEST OF INJECTOR CONTROL
CIRCUIT in this subsection.
Injector Input Voltage Test
1. Turn ignition key OFF.
2. Ensure IGNITION COILS AND INJECTOR fuse
(F6) is in good condition and installed in LH fuse
box.
3. Ensure ECM is properly connected.
4. Disconnect the electrical connector from the in- rmr2014-024-013_a

jector(s).
If the injector input voltage is good, the injector
problem may be mechanical.
If the injector input voltage is not good, check fuse
F6 in the LH fuse box. If the fuse is good, the
problem may be in the power distribution system
before the fuse, or in the ECM (does not provide
a ground signal).

Continuity Test of Injector Power

Circuit
1. Referto POWER DISTRIBUTION AND
GROUNDS subsection and remove from the
LH fuse box:
smr2009-030-028_a – Main power relay (R3)
PRESS HERE TO UNLOCK – Fuse F6
5. Turn ignition key to ON. 2. Using a multimeter set to " ", test for continu-
ity of the injector power circuit as per following
6. Using a multimeter set to Vdc, measure the in-
table.
jector input voltage as per following table.
REQUIRED TOOLS
REQUIRED TOOL
FLUKE 115
FLUKE 115 MULTIMETER
MULTIMETER (P/N 529 035 868)
(P/N 529 035 868)

INJECTOR CONNECTOR
CYLINDER WIRE MEASUREMENT
No. 1 VIOLET/
(clutch side) BLUE
No. 2 VIOLET Battery
Battery voltage
(center) /GREEN ground
No. 3 VIOLET/
(belt side) ORANGE

rmr2014-024 13
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

INJECTOR CIRCUIT 3. Test the injector ground circuit continuity be-

tween the injector and ECM adapter as per fol-
LH lowing table.
CYLINDER MEASUREMENT
INJECTOR FUSE
WIRE BOX INJECTOR ECM “A”
PIN CYLINDER CONNECTOR CONNECTOR MEASUREMENT
No. 1 WIRE PIN
VIOLET/
(clutch No. 1
BLUE BROWN/
side) (clutch B3
Close to 0 RED
No. 2 VIOLET/ B3 side)
(continuity) Close to 0
(center) GREEN No. 2 BROWN/
K-1 (continuity)
No. 3 VIOLET/ (center) BLUE
(belt side) ORANGE No. 3 BROWN/
J-1
(belt side) GRAY

If control circuit is faulty, repair wiring or connec-

tor.

Injector Replacement
Injector Removal
1. Remove fuel rail and injectors as an assembly.
Refer to FUEL RAIL in this subsection.
2. Remove the injector retaining clip.

rmr2013-024-300_a

LH FUSE BOX PIN-OUT

If continuity is good, carry out the CONTINUITY

TEST OF INJECTOR CONTROL CIRCUIT in this
subsection.
If continuity is faulty, repair wiring or connector be-
tween fuse box and injector.

Continuity Test of Injector Control

Circuit rmr2014-024-037_a

FUEL RAIL ASSEMBLY

1. Remove main power relay (R3) in LH fuse 1. Fuel injector
box. Refer to POWER DISTRIBUTION AND 2. O-rings
3. Injector retaining clip
GROUNDS subsection.
2. Disconnect ECM-A connector and install it on 3. Pull the fuel injector out of the fuel rail and dis-
the ECM adapter tool. Refer to ECM CONNEC- card the O-rings.
TOR ACCESS in ENGINE CONTROL MODULE Injector Installation
(ECM) in this subsection.
For the installation, reverse the removal proce-
FLUKE 115
ECM ADAPTER TOOL dure however, pay attention to the following
MULTIMETER details.
(P/N 529 036 166)
(P/N 529 035 868)
NOTICE If installing the removed injector(s),
always install NEW O-rings.
1. Apply a thin film of engine oil on O-rings to pre-
vent possible damage and ease insertion in rail.

14 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

rmr2014-024-039_a
rmr2014-024-038_a
1. Fuel injector
1. Oil on O-rings here 2. O-rings
3. Alignment keys
2. Install fuel injector with your hand. Do not use
any tool. 5. Tighten fuel rail to specification.
FUEL INJECTOR INSTALLATION SPECIFIED TORQUE
O-RINGS New Lubricate with engine oil 11 N•m ± 1 N•m
Fuel rail retaining screws
(97 lbf•in ± 9 lbf•in)
3. Carefully insert injectors in fuel rail and install
injector retaining clips. 6. Apply engine oil on O-rings of fuel pressure
hose fitting.

rmr2014-024-037_a

FUEL RAIL ASSEMBLY

1. Fuel injector
2. O-rings
3. Injector retaining clip
mmr2009-121-022_a
4. Gently push the fuel rail together with injectors
FUEL PRESSURE HOSE FITTING
in the air intake manifold. 1. Apply oil on O-rings

NOTICE Pay attention to not damage the
O-rings and engage injector alignment keys
with intake manifold alignment keys.
7. Connect fuel pressure hose to fuel rail.
IMPORTANT: Push fuel hose fitting on fuel rail un-
til you hear a "click". Try pulling on fuel hose fitting
to ensure it is properly locked.
8. Pressurize the fuel system and check for fuel
leaks. Refer to FUEL SYSTEM PRESSURIZA-
TION in FUEL TANK AND FUEL PUMP subsec-
tion.

rmr2014-024 15
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

WARNING ECM ENGINE THROTTLE BODY

Failure to pressurize the fuel system and Throttle actuator: Off.
checking for fuel leaks may result in severe OFF Stopped
Throttle plate: Rest position, maintained
injury or a life threatening situation should a opened at approximately 7-8° (1). This is
leak occur. also the limp home position.
Throttle actuator: On.
9. Reinstall all remaining removed parts. Throttle plate: Quickly moves through a
Not routine commanded by the ECM to check
ON
THROTTLE BODY (ETC started ETA and throttle mechanism integrity. If
ETA and throttle mechanism parameters
(ELECTRONIC THROTTLE are out of range, a fault code is initiated.
CONTROL)) Started. Throttle actuator: On.
Throttle Body (ETC) Description Normal Throttle plate: Opened and closed
ON
operation as necessary to control the idle speed as
at idle commanded by the ECM.
Started.
Throttle actuator: On.
Normal
Throttle plate: Opens and closes
ON operation
according to ECM torque management
at various
priorities.
RPM
(1) Degree values are given from the fully closed position.

Throttle-Body (ETC) Faults and Effects

NOTE: Among other things, a weak or broken
spring and a sticky throttle plate are validated by
the throttle body diagnostic mode.
FAULT EFFECT
rmr2014-024-040_a Limp home mode.
1. Throttle body ECM will use the remaining TAS sensor.
2. Throttle plate Partial failure
Fault code set and beeper
3. Throttle actuator (electric motor inside) of TAS sensor
4. Throttle position sensor (TPS) (inside) activated to emit warning signals.
(one internal
Check engine light will flash ON on and OFF.
sensor only)
Electric Throttle Actuator (ETA) Driveability will be normal and throttle will
decrease to idle when brake pedal pressed.
The electric throttle actuator (ETA) is a DC mo-
tor on the throttle body that regulates the throttle Complete Limp home mode. Engine idle
plate via a drive gear. It receives its control signal failure of speed increased to 1400 RPM.
from the ECM. Pulse width modulation (PWM) is TAS sensor Fault code set and beeper
(both internal activated to emit warning signals.
used to control the motor.
sensors) Check engine light will flash ON on and OFF.
Throttle Plate Operating Positions Limp home mode. Engine speed
limited according to TAS position.
Two torsional springs are connected to the throttle Any throttle
Fault code set and beeper
plate. A main spring and another one in a plunger body failure
activated to emit warning signals.
mechanism. Check engine light will flash ON on and OFF.
When there is no power to the throttle actuator
(ETA), the plunger mechanism maintains the throt- Throttle Body (ETC) Access
tle plate at a rest position. This also serves as the
limp home position. Refer to BODY subsection and remove the follow-
ing:
When the throttle plate is opened by the ETA as
– RH top side panel
commanded by the ECM, it acts against the main
spring. If the ETA failed, the return spring would – RH acoustic panel.
bring the throttle plate back to the limp home po-
sition.

16 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))
Electric Throttle Actuator (ETA) Test
Electric Throttle Actuator (ETA) Test with
B.U.D.S.
1. Connect vehicle to the latest B.U.D.S. version.
Refer to COMMUNICATION TOOLS AND
B.U.D.S. subsection.
2. Turn ignition key to ON.
3. In B.U.D.S., select:
– Read Data button
– Setting page tab.
NOTE: Use the Setting page to confirm ETA
movement. The B.U.D.S. indication may lag the
actual ETA movement.
4. Slowly rotate the throttle from the idle to WOT.
The ETA should move from approximately 7%
to 60% if ECO mode is selected, and 100% if
ECO mode is not selected.
rmr2014-024-011_d
TYPICAL
1. ETA position
If result is out of specification, carry out a THROT-
TLE POSITION SENSOR RESET. Refer to AD-
JUSTMENT in this subsection.
NOTE: The ETA is reset at the same time as the
TPS.
After the reset, test ETA again.
If the result is still out of specification, check wire
continuity between ECM and throttle body before
assuming the ETA is at fault.
ETA Resistance Test
1. Remove main power relay (R3) in LH fuse
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
rmr2014-024
2. Disconnect ECM-A connector and connect it to
the ECM adapter tool. Refer to ECM CONNEC-
TOR ACCESS in ENGINE CONTROL MODULE
(ECM) in this subsection.
3. Set multimeter to " " selection and measure
the ETA motor coil resistance as per following
table.
FLUKE 115
ECM ADAPTER TOOL
MULTIMETER
(P/N 529 036 166)
(P/N 529 035 868)
ETA RESISTANCE TEST
ECM ADAPTER PINS RESISTANCE
L1 L2 1.6
If resistance measured is not close to specifica-
tion, repeat test at the ETA connector. If resis-
tance is still not to specification, replace the throt-
tle body.
If resistance is as specified at ETA, carry out a con-
tinuity test of the wiring from ECM connector to
ETA connector. Refer to applicable WIRING DIA-
GRAM for details. Repair or replace wiring and
connectors as required.
If the wiring and ETA test good, inspect the throt-
tle body. Refer to THROTTLE BODY (ETC) ME-
CHANICAL INSPECTION and THROTTLE BODY
(ETC) CLEANING.
If the throttle body checks good, refer to ENGINE
CONTROL MODULE (ECM) in this subsection.
The problem may be related to the ECM.
NOTE: ECM requires proper signals from the TAS
(throttle accelerator sensor) and the TPS (throttle
position sensor) for proper control of the ETA.
Throttle Body (ETC) Inspection
Always check for corroded terminals or damaged
wiring when diagnosing throttle body problems.
Throttle Body (ETC) Dynamic Tests
1. Remove the parts required to access the throt-
tle body, refer to THROTTLE BODY (ETC) RE-
MOVAL.
2. Remove the air inlet hose from the throttle
body.
3. Observe the throttle plate with the engine
stopped.
17
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))
NOTE: The throttle plate should be in the rest po-
sition (slightly opened).
WARNING
Keep your fingers out of the throttle plate
area while the ECM turns on. The throttle
actuator will cycle. This could cause serious
injuries as the throttle plate moves quickly.
4. As you observe the throttle plate, turn the igni-
tion key to ON.
NOTE: The throttle plate should cycle quickly
from the rest position to a partially open position),
then back to the rest position.
5. As you observe the throttle plate, have some-
one gradually and evenly rotate the throttle,
then release it in the same way.
NOTE: The throttle plate should open then close
smoothly according to throttle grip position how-
ever, the movement of the throttle plate may not
be linear with the displacement of the throttle
grip.
If any test failed, proceed with the THROTTLE
BODY (ETC) STATIC TESTS.
Throttle Body (ETC) Static Tests
WARNING
First ensure the ECM is off. Do not move the
throttle plate using your fingers. Otherwise,
should the ignition key be set to On, the ECM
would turn on and quickly cycle the throttle
plate which could cause serious injury.
1. Using a blunt tool, push in on the throttle plate
and ensure it opens smoothly within the throt-
tle body.
rmr2014-024-015_b
TYPICAL
1. Push here to open
18
NOTE: The throttle plate must open fully and
return freely to the limp home position (slightly
opened) when released.
2. Push throttle plate closed as indicated in follow-
ing illustration. It must close completely and re-
turn freely to the limp home position (slightly
opened) when released.
rmr2014-024-015_c
TYPICAL
1. Push here to close
If the throttle plate does not move smoothly or
does not return freely to the limp home position,
the problem is mechanical. Check for a sticking
throttle plate shaft. The problem may also be an
actuator or gear problem. Replace throttle body if
necessary.
If throttle plate operates normally, the problem is
electrical. Check electric throttle actuator (ETA)
wiring continuity, throttle position sensor (TPS)
and throttle accelerator sensor (TAS).
WARNING
If the throttle plate does not properly return to
its rest position after proper cleaning, replace
the throttle body.
Throttle Body (ETC) Lubrication
No lubrication is required.
Throttle Body (ETC) Cleaning
Remove the parts required to access the throttle
body, refer to THROTTLE BODY (ETC) REMOVAL.
Check throttle body cleanliness using a flashlight.
Fully open throttle plate and verify:
– Throttle body bore
– Throttle plate edge.
Clean throttle body to remove any visible de-
posits.
rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

NOTICE Only use an appropriate throttle

body cleaner that will not damage O-rings and
EFI sensors.
WARNING
Use the product in well ventilated area. Refer
to product manufacturer's warnings. Wipe
off any excess product.

To avoid getting dirt into engine, spray cleaner on

a clean rag, then rub rag against throttle plate and
bore. A toothbrush works well too.
WARNING
rmr2014-024-007_a
First ensure ECM is off. Otherwise, if ECM TYPICAL
should suddenly turn off, it would quickly 1. Throttle body
2. Throttle body connector
close the throttle plate which could cause 3. Inlet hose
serious injury. 4. Inlet hose clamp

5. Remove retaining screws from throttle body.

Manually open throttle and hold fully open to
reach all surfaces.
WARNING
Ensure nobody sets the ignition key to ON.
The ECM would turn on and the throttle actu-
ator (ETA) would cycle. This could cause seri-
ous injury as the throttle plate moves quickly.

To remove residual dirt, spray cleaner on throttle

plate and on bore.
Reinstall removed parts.

Throttle Body (ETC) Replacement

Throttle Body (ETC) Removal
rmr2014-024-006_a
1. Release fuel pressure in the system, refer to 1. Throttle body connector
FUEL TANK AND FUEL PUMP subsection. 2. Throttle body screws
2. Remove main power relay (R3) in LH fuse 6. Pull throttle body off air intake manifold.
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection. Throttle Body (ETC) Installation
3. Remove air inlet hose from throttle body. Installation of the new throttle body is the reverse
4. Disconnect throttle body connector. of the removal procedure. However, pay attention
to the following.
1. Tighten retaining screws to specification as per
following sequence.
RETAINING SCREW TIGHTENING SEQUENCE
3 N•m ± 0.3 N•m
Step 1 and 2
(27 lbf•in ± 3 lbf•in)
11 N•m ± 1 N•m
Step 3 through 6
(97 lbf•in ± 9 lbf•in)

rmr2014-024 19
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

TPS Resistance Test

1. Remove the parts required to access the throt-
tle body, refer to THROTTLE BODY REMOVAL
in this subsection.
2. Ensure the throttle body connector is properly
connected.
3. Disconnect ECM-A connector and install it on
the ECM adapter tool. Refer to ECM CONNEC-
TOR ACCESS in this subsection.
4. Set multimeter to selection.
FLUKE 115
ECM ADAPTER TOOL
MULTIMETER
(P/N 529 036 166)
(P/N 529 035 868)
rmr2014-024-006_b

2. Perform the THROTTLE POSITION SENSOR

RESET. See procedure in ADJUSTMENTS.

THROTTLE POSITION SENSOR

(TPS) 5. Probe circuit as per following table while using
a blunt tool to manually move throttle plate.
General
FULLY CLOSED FULLY OPEN
The throttle position sensor (TPS) is a twin poten- ECM THROTTLE THROTTLE
tiometer that sends two signals to the ECM, that ADAPTER PLATE (1) PLATE
are proportional to the throttle shaft angle.
RESISTANCE ( )
IMPORTANT: Prior to testing the TPS, ensure
throttle body components are properly installed PIN MIN. MAX. MIN. MAX.
and connected. A-A2 A-K4 625 3000 625 3000
Use the latest applicable B.U.D.S. version to A-A2 A-K3 681 3750 163 1260
check for related fault codes the EMS may have
A-A2 A-F3 181 1350 700 3840
generated. Refer to DIAGNOSTIC AND FAULT
CODES subsection for more information. A-K3 A-K4 163 1260 681 3750
A-K3 A-F3 925 4800 925 4800
TPS Location
The TPS is an integral part of the throttle body. A-K4 A-F3 700 3840 181 1350
(1) To obtain the fully closed position, it is necessary
TPS Access to push against the throttle plate in the throttle body
Refer to BODY subsection and remove: using a blunt tool, and hold it in this position for the
measurement.
– RH middle side panel
– RH top side panel
– RH acoustic panels.

TPS Faults
The TPS is a redundant sensor with two opposite
outputs.
If a TPS fault occurs, the ECM will trigger a fault
and the vehicle will be in limp home mode. Use
B.U.D.S. to read the fault codes(s) and carry
out service actions. Refer to DIAGNOSTIC AND
FAULT CODES subsection. vmr2008-022-005_a

20 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

If any resistance value is incorrect, check wire
continuity between ECM and throttle body before
assuming the TPS is at fault. Refer to WIRING
DIAGRAM subsection.
If voltage test is good, test for continuity of
the signal wires and the neutral wire between
the throttle body and ECM. Refer to applicable
WIRING DIAGRAM.
TPS Replacement
Replace throttle body.

TPS Adjustment
NOTE: There is no adjustment that can be car-
ried out on the TPS, however a THROTTLE POSI-
TION SENSOR RESET must be carried out when
the throttle body has been replaced. Refer to AD-
JUSTMENTS in the beginning of this subsection.
If the ECM was replaced, then an ECM FIRST INI-
rmr2014-024-017_a
TIALIZATION will need to be carried out.
TPS CONNECTOR PIN-OUT
While using B.U.D.S., check for and reset fault
If the TPS resistance values are correct, try a new codes. Refer to DIAGNOSTIC AND FAULT
ECM. Refer to ENGINE CONTROL MODULE CODES subsection.
(ECM) in this subsection.
TPS Input Voltage Test
CRANKSHAFT POSITION
SENSOR (CPS)
1. Ensure main power relay (R3) is installed in LH
fuse box. CPS Location
2. Disconnect throttle body connector . The CPS is located on the lower engine crankcase
3. Turn ignition key ON. half, on the LH side of the engine.
4. Measure for voltage at TPS harness connector
as follows.
CONNECTION VOLTAGE
Pin 3 with battery ground 3.3 V

rmr2014-024-008_a

TYPICAL - CPS LOCATION

1. CPS
2. CPS connector

rmr2014-024-018_a CPS Access

TPS INPUT VOLTAGE TEST
Refer to BODY subsection and remove the follow-
If voltage test is not good, test and repair the ing:
wiring from ECM to the throttle body as required. – LH middle side panel
Refer to applicable WIRING DIAGRAM. – LH top side panel
If wiring is good, refer to ECM REPLACEMENT in – LH bottom side panel
this subsection. – LH acoustic panels (as applicable).

rmr2014-024 21
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

CPS Troubleshooting If resistance is not within specifications, replace

When troubleshooting a CPS fault, take into ac- the CPS.
count that a CPS fault can be triggered by bent or If the CPS resistance tests good, reconnect the
missing encoder wheel teeth. CPS connector and carry out the CPS CIRCUIT
First check for applicable fault codes, refer to DI- CONTINUITY TEST.
AGNOSTIC AND FAULT CODES subsection.
CPS Circuit Continuity Test
If there is a fault code and the CPS and its circuit
test good, check the encoder wheel teeth condi- 1. Remove main power relay (R3) in LH fuse
tion, refer to CRANKSHAFT subsection. box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
NOTE: After servicing the engine, if the CPS and
knock sensor connectors to the main harness are 2. Disconnect ECM-A connector and install it on
swapped, the engine will not start. The RPM indi- the ECM adapter tool. Refer to ECM CONNEC-
cation on the monitoring page will remain at zero TOR ACCESS in ENGINE CONTROL MODULE
when cranking the engine. (ECM) in this subsection.
3. Using a multimeter set to selection, recheck
CPS Resistance Test resistance as per following table.
1. Remove main power relay (R3) in LH fuse REQUIRED TOOLS
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection. FLUKE 115
ECM ADAPTER TOOL
MULTIMETER
2. Disconnect CPS connector. (P/N 529 036 166)
(P/N 529 035 868)

ECM ADAPTER MEASUREMENT

RESISTANCE
PIN
@ 20°C (68°F)
H1 K2 774 - 946

If resistance value is incorrect, repair or replace

wiring harness between the ECM and CPS con-
nectors.
rmr2014-024-019_a

1. ECM CPS Replacement

2. CPS connector
3. Knock sensor connector 1. Disconnect the CPS connector.
4. Engine interconnect (HIC)
2. Cut locking ties and remove clamp that secure
3. Set multimeter to " " selection and probe CPS CPS wire harness to the engine.
terminals as per following table. 3. Remove the CPS.
REQUIRED TOOL

FLUKE 115
MULTIMETER
(P/N 529 035 868)

CPS CONNECTOR MEASUREMENT

RESISTANCE
PIN
@ 20°C (68°F)
1 2 774 - 946

22 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

6. Secure CPS wire harness as per factory instal-

lation.

CAMSHAFT POSITION SENSOR

(CAPS)
CAPS Location
CAPS sensor is located on the back of the cylinder
head, RH side of engine.

rmr2014-024-020_a

TYPICAL
1. CPS connector
2. Locking ties (3)
3. Clamp location
4. CPS retaining screw

4. Install new CPS as per following table.

CPS INSTALLATION
CPS O-RING
Service product Engine oil rmr2014-024-002 _b

CAPS LOCATION, RH OF SIDE ENGINE

RETAINING SCREW 1. CAPS
2. CAPS connector
LOCTITE 243 (BLUE)
Service product
(P/N 293 800 060)
CAPS Access
11 N•m ± 1 N•m Refer to BODY subsection and remove:
Tightening torque
(97 lbf•in ± 9 lbf•in)
– RH middle side panel
5. Reconnect CPS. – RH top side panel
NOTE: Wiring harness connector is marked with – RH acoustic panel (if applicable).
"CPS". Do not reconnect with "KS" connector.
CAPS Input Voltage Test
1. Disconnect CAPS connector.
2. Turn ignition key ON.
3. Set multimeter to Vdc and probe CAPS connec-
tor as per following table.
REQUIRED TOOL

FLUKE 115
MULTIMETER
(P/N 529 035 868)

CAPS CONNECTOR VOLTAGE

Battery
ORANGE/GREEN BLACK/GREEN
voltage
rmr2014-024-042_a

1. CPS connector If input voltage is good, carry out the CAPS OUT-
PUT VOLTAGE TEST.

rmr2014-024 23
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

If input voltage is not good, repeat test as per fol- CAPS

lowing table. CAPS CONNECTOR VOLTAGE
CONDITION
PROBE VOLTAGE Metallic
Battery
object on OG/GN YE/GN
CAPS CONNECTOR voltage
Vehicle Battery sensor
ORANGE/GREEN
ground voltage
wire

If input voltage is not good, repair or replace

wiring/connectors between CAPS and fuse LFB
F18. Refer to applicable WIRING DIAGRAM.

CAPS Output Voltage Test

NOTICE This test should only be used as a
last resort if a known good CAPS is not avail-
able for testing in place of the original CAPS in-
stalled on the engine. Back probing the CAPS
connector may damage connector seals.
1. Remove CAPS sensor from engine. Refer to
CAPS REPLACEMENT further in subsection.
2. Make sure CAPS connector is properly con-
nected. rmr2008-021-079_a

3. Using a multimeter set to Vdc, back-probe con- TYPICAL - CAPS MOVED ACROSS METAL FRAME MEMBER
nector as per following tables.
If voltage signal does not change as CAPS is
REQUIRED TOOL moved across metal frame member, check conti-
nuity of YE/GN wire from CAPS to ECM. If it tests
FLUKE 115 good, try a new CAPS.
MULTIMETER
(P/N 529 035 868) CAPS Replacement
1. Remove main power relay (R3) in LH fuse
CAPS box. Refer to POWER DISTRIBUTION AND
CAPS CONNECTOR VOLTAGE
CONDITION GROUNDS subsection.
Close to 2. Disconnect connector from CAPS.
Free OG/GN YE/GN
0 Vdc 3. Remove the CAPS retaining screw and replace
the CAPS..

rmr2008-021-078_a
rmr2014-024-021_a
TYPICAL - CAPS AWAY FROM METAL
1. CAPS connector
2. Retaining screw

24 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

CAPS INSTALLATION MAPTS Quick Test (Pressure Function)

PRODUCT ON O-RING SCREW TORQUE 1. Connect vehicle to latest applicable B.U.D.S.
version. Refer to COMMUNICATION TOOLS
11 N•m to 1 N•m AND B.U.D.S. subsection.
Engine oil
(97 lbf•in to 9 lbf•in)
2. In B.U.D.S., select the following:
4. Reinstall removed parts. – Read Data
– Monitoring page tab
MANIFOLD ABSOLUTE – ECM page.
PRESSURE AND TEMPERATURE
SENSOR (MAPTS)
NOTE: This sensor is a multifunction device. It
measures manifold absolute pressure and intake
air temperature for air flow calculations.

MAPTS Access
Refer to BODY subsection and remove the follow-
ing:
– LH top side panel
– Acoustic panel.

rmr2014-024-049

TYPICAL - MAPTS PRESSURE READING IN B.U.D.S.

3. Look for and take note of the MAPTS pressure

reading while the engine is stopped.
NOTE: The indicated intake air pressure in
B.U.D.S. must be within 3.4 kPa (.5 PSI) of lo-
cal atmospheric pressure when the engine is
stopped.
MAPTS PRESSURE FUNCTION QUICK TEST
RESULT SERVICE ACTION
Circuit
rmr2014-024-022_a Continuity MAPTS
Repair or
MAPTS LOCATION NO Test of Input
1. Manifold air pressure and temperature sensor (MAPTS) replace
READING MAPTS Voltage
wiring
Pressure Test
MAPTS Pressure Function Function
Before the engine is started, the sensor measures VALUE IS
the ambient atmospheric air pressure. Once the OUT OF Replace MAPTS
engine is started, it measures the air pressure in RANGE
the intake manifold at operating RPMs.
The sensor must be correctly installed on the in- 4. Perform the same test with a new MAPTS and
take manifold, and no leaks should be present in compare both readings.
the system. Otherwise, the MAPTS could gener- MAPTS Input Voltage Test
ate a fault code for an unexpected sensor range
when it reads an erroneous intake manifold pres- 1. Remove parts required to access the MAPTS,
sure. refer to MAPTS ACCESS.
2. Remove electrical connector from MAPTS.

rmr2014-024 25
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

MAPTS Circuit Continuity Test (Pressure

Function)
1. Remove parts required to access ECM connec-
tors, refer to ECM CONNECTOR ACCESS in
this subsection.
2. Disconnect the ECM-A connector from the
ECM and connect it to the ECM adapter tool.
3. Using the multimeter set to and check conti-
nuity of the following circuits.
REQUIRED TOOLS
FLUKE 115
ECM ADAPTER TOOL
MULTIMETER
(P/N 529 036 166)
(P/N 529 035 868)
rmr2014-024-023_a

1. MAPTS connector

3. Turn ignition key to ON.

4. Using a multimeter set to Vdc, measure for
MAPTS input voltage as per following table.
MAPTS CIRCUIT CONTINUITY TEST
REQUIRED TOOL (PRESSURE FUNCTION)
MAPTS RESISTANCE
FLUKE 115 ECM-A
CONNECTOR VALUE
MULTIMETER
(P/N 529 035 868) Pin B4 Pin 3
Pin G4 Pin 4 Close to 0
MAPTS CONNECTOR MEASUREMENT Pin H2 Pin 1
PIN VOLTAGE
If resistance is not within specification, repair or
1 3 5 Vdc
replace the wiring harness between ECM connec-
tor and the MAPTS. Refer to WIRING DIAGRAM.

MAPTS Temperature Function

The MAPTS also monitors the temperature of the
air in the intake manifold.
MAPTS Resistance Test (Temperature
Function)
1. Disconnect the MAPTS connector.
2. Using the multimeter set to , test MAPTS re-
sistance at the sensor as per following tables.
REQUIRED TOOLS

FLUKE 115
MULTIMETER
rmr2014-024-024_a (P/N 529 035 868)

If voltage test is good, replace the MAPTS.

MAPTS MEASUREMENT
If voltage test is not good, carry out the MAPTS
CIRCUIT CONTINUITY TEST (PRESSURE FUNC- PIN Refer to MAPTS
TION). 1 2 TEMPERATURE SENSOR TABLE

26 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

REQUIRED TOOL

ECM ADAPTER TOOL

(P/N 529 036 166)

5. Using a multimeter, recheck resistance value as

per following table.
ECM
MEASUREMENT
ADAPTER
PIN Refer to MAPTS TEMPERATURE
H2 H3 SENSOR TABLE

MAPTS TEMPERATURE SENSOR TEST RESULTS

rmr2014-024-024_b

RESULT SERVICE ACTION

MAPTS TEMPERATURE SENSOR TABLE
Circuit
RESISTANCE Continuity MAPTS
TEMPERATURE Repair or
(ohms ±10 %) NO Test of Input
replace
°C °F AAPTS READING MAPTS Voltage
wiring
Temperature Test
- 30 - 22 26860 Function
- 20 - 4 15614 INCORRECT
Check condition of connector
RESISTANCE
- 10 14 9425 pins, replace MAPTS
VALUE
0 32 6350
CORRECT
20 68 2510 RESISTANCE Try a new ECM
VALUE
30 86 1715
40 104 1200 MAPTS Circuit Continuity Test (Temperature
Function)
50 122 850
60 140 610 MAPTS CIRCUIT CONTINUITY TEST
(TEMPERATURE FUNCTION)
70 158 445
ECM MAPTS RESISTANCE
80 176 330 ADAPTER CONNECTOR VALUE
90 194 245 Pin H2 Pin 1
Close to 0
100 212 185 Pin H3 Pin 2
110 230 140
Repair or replace wiring as required.
120 248 110
130 266 85

If resistance is not within specification, replace

the MAPTS.
If resistance tests good, reconnect the MAPTS
and proceed with the following steps.
3. Disconnect the ECM-A connector.
4. Install ECM-A connector on the ECM adapter
tool.

rmr2014-024 27
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

MAPTS Replacement AMBIENT AIR PRESSURE

AND TEMPERATURE SENSOR
(AAPTS)
AAPTS Location

rmr2014-024-023_b

Step 1: MAPTS connector

Step 2: Retaining screw

1. Disconnect MAPTS connector and remove the

MAPTS from the intake manifold. rmr2008-021-040_a

TYPICAL - AAPTS LOCATION

2. Install new MAPTS as per following table.
The sensor continuously measures the atmo-
MAPTS INSTALLATION
spheric air pressure and temperature.
TORQUE
Retaining screw 6 N•m ± 1 N•m
PTS Connector Location
(53 lbf•in ± 9 lbf•in) The PTS connector is attached to a connector
holder just above the RH front suspension. It
SERVICE PRODUCT
connects the AAPTS sensor to the ECM connec-
Connector DIELECTRIC GREASE tor.
(P/N 293 550 004)
To access the PTS connector:
– Open the front cargo compartment
– Remove the RH service cover.

rmr2014-024-025_a

PTS CONNECTOR LOCATION

1. PTS connector

28 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

AAPTS Connector and AAPTS Access

Remove the RH air duct panel. Refer to BODY
subsection.
NOTE: On models equipped with fog lights, or
low beams, located on the cargo module, remove
the RH fog light, or RH low beam light assembly
(as applicable).

AAPTS Test Using B.U.D.S.

AAPTS Pressure Function Test
1. Connect vehicle to the latest applicable
B.U.D.S. software version, refer to COMMU-
NICATION TOOLS AND B.U.D.S. subsection.
2. Turn ignition key ON.
rmr2008-021-082_a

3. In B.U.D.S., select the following: TYPICAL

– Read Data button
If there is no reading or if it does not change, carry
– Monitoring tab
out the AAPTS INPUT VOLTAGE TEST.
– Cluster tab.
If you doubt the AAPTS reading, compare it to an
4. Read the atmospheric pressure indication. atmospheric pressure gauge (barometer), or try a
NOTE: The atmospheric pressure indication is vis- new AAPTS.
ible near the center of the page. When comparing the readings, values must be
within specification.
AAPTS ALLOWED DISCREPANCY
PRESSURE VALUE
± 3.4 kPa (.5 PSI)

If the vehicle AAPTS value is out of this range, re-

place it.
AAPTS Temperature Function Test
1. As in the previous AAPTS PRESSURE FUNC-
TION TEST, read the ambient air temperature
indication.

rmr2014-024-050_a

TYPICAL - ATMOSPHERIC PRESSURE INDICATION IN B.U.D.S.

5. Blow some compressed air in the sensor area

as you observe the atmospheric pressure indi-
cation. The reading should change.

rmr2014-024-050_b

TYPICAL - AMBIENT TEMPERATURE INDICATION IN B.U.D.S.

rmr2014-024 29
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

2. Using a heat gun, carefully heat the sensor as AAPTS CONNECTOR MEASUREMENT
you observe the ambient temperature indica-
tion. The reading should change. PIN VOLTAGE
1 3 5 Vdc

rmr2008-021-084
rmr2008-021-083_a
TYPICAL
TYPICAL
If there is no reading or if it does not change, carry
out an AAPTS INPUT VOLTAGE TEST. If voltage test is not good, carry out the AAPTS
CIRCUIT CONTINUITY TEST.
If you doubt the temperature reading, compare
it with a known good thermometer, or try a new If voltage test is good and the problem is related to
AAPTS. the temperature indication, carry out the AAPTS
RESISTANCE TEST. If the problem is related to
When comparing, readings must be within speci- the pressure function of the AAPTS, carry out the
fication. AAPTS CIRCUIT CONTINUITY TEST.
AAPTS ALLOWED DISCREPANCY
TEMPERATURE VALUE AAPTS Circuit Continuity Test
± 2°C (3°F) 1. Remove main power relay (R3) in LH fuse
box. Refer to POWER DISTRIBUTION AND
If the vehicle AAPTS value is out of this range, re- GROUNDS subsection.
place it. 2. Disconnect ECM-A connector and install it on
the ECM adapter tool. Refer to ECM CONNEC-
AAPTS Input Voltage Test TOR ACCESS in ENGINE CONTROL MODULE
1. With the ignition key turned to OFF, disconnect (ECM) in this subsection.
AAPTS connector. 3. Using a multimeter set to " ", test wiring har-
2. Turn ignition key ON. ness continuity between ECM and AAPTS as
per following table.
3. Using a multimeter set to Vdc, test the voltage
output from the ECM to the pressure sensor as
per following table.
NOTE: This test may first be carried out at the
PTS connector. If test is good there, then repeat
test at AAPTS connector.
REQUIRED TOOLS

FLUKE 115
MULTIMETER
(P/N 529 035 868)

30 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

REQUIRED TOOLS
FLUKE 115
ECM ADAPTER TOOL
MULTIMETER
(P/N 529 036 166)
(P/N 529 035 868)

AAPTS CIRCUIT CONTINUITY TEST

ECM AAPTS
RESISTANCE
ADAPTER CONNECTOR
F2 Pin 1 rmr2008-021-085_a

H4 Pin 2 Close to 0 AAPTS SENSOR TEMPERATURE TABLE

G3 Pin 4 (continuity)
RESISTANCE
B4 Pin 3 TEMPERATURE
(ohms ± 10 %)

If continuity test is good and the problem is re- °C °F AAPTS

lated to the pressure function, replace the AAPTS. - 30 - 22 26860
If the problem is related to the temperature func-
- 20 - 4 15614
tion, carry out the AAPTS RESISTANCE TEST.
If continuity is not good, repair or replace - 10 14 9425
wiring/connectors between ECM and AAPTS 0 32 6350
connector.
20 68 2510
AAPTS Resistance Test 30 86 1715
1. Disconnect PTS connector. 40 104 1200
2. Using a multimeter set to " ", test the resis- 50 122 850
tance of the sensor as illustrated. Compare re-
sult with the sensor temperature table. 60 140 610
70 158 445
REQUIRED TOOLS
80 176 330
FLUKE 115 90 194 245
MULTIMETER
(P/N 529 035 868) 100 212 185
110 230 140
AAPTS 120 248 110
Pin 1 Pin 2 130 266 85
If an open circuit or an abnormal resistance value If resistance value measured is not close to spec-
is measured, repeat the test at the AAPTS sensor. ification, replace the AAPTS.
If resistance tests good, carry out the AAPTS CIR-
CUIT CONTINUITY TEST.
AAPTS Replacement
1. Loosen AAPTS retaining screw.
2. Slide AAPTS out.
3. When installing sensor, be sure to position
foam around sensor tip.

rmr2014-024 31
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

– Monitoring tab
– ECM tab.

rmr2008-021-086_a

4. Reinstall removed parts.

rmr2011-071-001_a

1. Engine temperature (analog readout)

COOLANT TEMPERATURE 2. Engine temperature (digital readout)

SENSOR (CTS) If engine temperature indicated in B.U.D.S. is cor-

CTS Location rect for actual engine temperature, the CTS and
it's circuit is functioning normally.
If there is no temperature reading, or if reading
does not reflect actual engine temperature, pro-
ceed with CTS RESISTANCE TEST.

CTS Resistance Test at Component

1. Remove main power relay (R3) in LH fuse
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.

CAUTION Do not disconnect CTS when

vehicle is powered. If CTS is disconnected
while vehicle is powered, the ECM will cause
the cooling fans to come on, possibly resulting
rmr2014-024-026_a
in injury.
TYPICAL - LH SIDE OF ENGINE 2. Disconnect CTS connector.
1. Coolant temperature sensor
3. Using a multimeter set to " ", measure the re-
CTS Access sistance through the CTS resistance and com-
pare the resistance value obtained to the sen-
Refer to BODY subsection and remove: sor temperature table.
– LH middle side panel
REQUIRED TOOLS
– LH top side panel
– LH acoustic panel. FLUKE 115
MULTIMETER
CTS Test Using B.U.D.S. (P/N 529 035 868)
1. Connect vehicle to latest applicable B.U.D.S.
version, refer to COMMUNICATION TOOLS
CTS SENSOR
AND B.U.D.S. subsection.
2. In B.U.D.S., select the following: Pin 1 Pin 2
– Read Data button

32 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

REQUIRED TOOLS
FLUKE 115
ECM ADAPTER TOOL
MULTIMETER
(P/N 529 036 166)
(P/N 529 035 868)

ECM CONNECTOR MEASUREMENT

RESISTANCE
PIN
@ 20°C (68°F)
Refer to TEMPERATURE
A1 J2
rmr2014-024-027_a SENSOR TABLE above
TYPICAL
If resistance value is incorrect, repair the connec-
SENSOR TEMPERATURE TABLE
tors or replace the wiring harness between ECM
RESISTANCE connector and the CTS.
TEMPERATURE
(ohms)
°C °F CTS
CTS Replacement
1. Remove main power relay (R3) in LH fuse
- 40 - 40 38457 to 52630
box. Refer to POWER DISTRIBUTION AND
- 10 14 8208 to 10656 GROUNDS subsection.
20 68 2233 to 2780 2. Disconnect CTS connector.
80 176 297 to 349 3. Remove CTS from engine.
120 248 105 to 122 4. Install new CTS and tighten as specified.
CTS TORQUE
If resistance measured is out of specification, re-
place the CTS. 17 N•m ± 1 N•m (150 lbf•in ± 9 lbf•in)
If resistance measured is within specification, re- 5. Reinstall remaining removed parts.
connect the CTS and carry out the CTS RESIS-
TANCE TEST AT ECM. 6. Refill and bleed the cooling system, refer to
COOLING SYSTEM subsection.
CTS Resistance Test at ECM 7. Use the latest applicable B.U.D.S. version to
1. Remove main power relay (R3) in LH fuse check for and reset fault codes. Refer to DIAG-
box. Refer to POWER DISTRIBUTION AND NOSTIC AND FAULT CODES subsection.
GROUNDS subsection.
2. Disconnect ECM-A connector and install it on HEATED OXYGEN SENSOR
the ECM adapter tool. Refer to ECM CONNEC- (HO2S)
TOR ACCESS in ENGINE CONTROL MODULE
(ECM) in this subsection. Oxygen Sensor Location
3. Using a multimeter, recheck resistance at the This vehicle is equipped with 1 heated oxygen
ECM adapter as per following table. sensor (HO2S): The sensor is located on the ex-
haust pipe, near the exhaust manifold.

rmr2014-024 33
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

– Do not allow sensor or wire to touch exhaust

system or any other hot component.
– Do not route sensor wires to create tension in
the wires. This could cause faults or sensor
malfunction.

Oxygen Sensor Troubleshooting

Always use B.U.D.S. to check for fault codes.
Carry out service actions.
In B.U.D.S., also check oxygen sensor voltage and
refer to following table.
OXYGEN SENSOR VOLTAGE IN B.U.D.S.
rmr2014-024-029_a VOLTAGE READING CONDITION
HEATED OXYGEN SENSORS
Normal oxygen sensor
Varies 0.1 to 0.8 Volts
Oxygen Sensor and Connector Access operation in closed loop

The oxygen sensor and its connector are accessi- Oxygen sensor circuit
Constant 0.45 Volts
ble through an opening in the bottom pan. open
Indicates fuel
mixture too lean,
possible oxygen
Constant low voltage sensor fault,
possible fuel
system fault,
possible air leak
Indicates fuel
mixture too rich,
possible fuel
Constant high voltage
system fault,
possible fuel canister
problem

Oxygen Sensor Test Using B.U.D.S.

rmr2014-024-030_a

RH SIDE VIEW— SOME PARTS REMOVED FOR CLARITY

1. Using the latest applicable B.U.D.S. version,
PURPOSE monitor the oxygen sensor.
1. Oxygen sensor
2. Oxygen sensor connector 2. Click on Monitoring tab, then on ECM tab.
3. Opening in bottom pan
3. Start engine.
Oxygen Sensor General Precautions 4. Observe the O2 sensor V and Oxygen Sensor
Take the following precautions to avoid sensor Status indications in B.U.D.S.
malfunction:
– Do not use any product on sensor probe.
– Do not expose sensor to water, oil, windshield
cleaner, anticorrosion oil, grease, terminal
cleaner, etc.
– Do not drop or use an oxygen sensor that has
been dropped.
– Do not use any compound on sensor threads
unless labeled as compatible with oxygen sen-
sor.
– Do not use impact wrench or conventional
socket type wrench to install sensor.

34 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

rmr2014-024-051_a

OXYGEN SENSOR VOLTAGE AND STATUS INDICATIONS

rmr2014-024-052_a

If a fault code related to an oxygen sensor is ac-

tive, the oxygen sensor indicator will not turn on.
The fault code(s) need(s) to be solved first.
When a properly functioning oxygen sensor cir-
cuit is first initiated, the oxygen sensor heats up
and the ECM is operating in a closed loop control
mode. The status of the oxygen sensor circuit will
change from “Init” to “Active” as it progresses
through a series of steps. These steps may be
viewed on the ECM Monitoring page of B.U.D.S.
in the Oxygen Sensor Status window.
NOTE: The steps listed in the following sensor
status table may not all be displayed, and may
vary from one time to the next. The steps dis-
played will depend on the engine operating status
and oxygen sensor operating status.
LIST OF OXYGEN SENSOR STATUS
INDICATIONS
Init
Heating Active
Control Active
Error
When the oxygen sensor reaches the “Active”
state, it becomes operational and its indicator will
turn on in B.U.D.S.
NOTE: At room temperature (approximately 21°C
(70°F)), the engine needs to run for approximately
15 seconds before the oxygen sensor becomes
CONTROL ACTIVE and its indicator light turns on
in B.U.D.S.
If a sensor status does not change or does not
reach the CONTROL ACTIVE state, or the oxygen
sensor indicator light does not come on, try a new
oxygen sensor.
NOTE: Before replacing a sensor, check wiring,
terminals and sensor condition.
Oxygen Sensor Input Voltage Test
NOTE: This test validates the heater element cir-
cuit.
1. Ensure main power relay (R3) in installed in LH
fuse box.
2. Disconnect the oxygen sensor connector.
3. Turn ignition switch ON.
4. Using a multimeter set to Vdc, read the input
voltage provided to the sensor heater.
REQUIRED TOOLS
FLUKE 115
MULTIMETER
(P/N 529 035 868)

OXYGEN SENSOR
CONNECTOR
(HARNESS SIDE) MEASUREMENT
PIN
C Battery ground Battery voltage

rmr2014-024 35
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

If Input voltage is good, carry out an OXYGEN OXYGEN SENSOR CIRCUIT CONTINUITY TEST
SENSOR RESISTANCE TEST and an OXYGEN
SENSOR CIRCUIT CONTINUITY TEST. ECM
OXYGEN RESISTANCE
CONNECTOR
If input voltage is not good, test the continuity of SENSOR PIN @ 20°C (68°F)
“B”
the power circuit from fuse F8 in LH fuse box.
A J1
Refer to the applicable WIRING DIAGRAM for de-
tails. B D2 Close to 0
If input voltage wire continuity is at fault, repair or D L2
replace wiring or connector.
If a resistance value is NOT as specified, repair or
Oxygen Sensor Resistance Test
replace the wiring and connectors.
Test the resistance value of the oxygen sensor be-
tween the sensor pins as follows. Oxygen Sensor Removal
OXYGEN RESISTANCE 1. Remove main power relay (R3) in LH fuse
SENSOR PIN @ 20°C (68°F) box. Refer to POWER DISTRIBUTION AND
Approximately
GROUNDS subsection.
C D
7 - 11
CAUTION Exhaust system and oxygen
If reading is not within specification, replace the sensor may be hot. To avoid possible injury,
oxygen sensor. allow exhaust system components time to
cool before proceeding.
Oxygen Sensor Circuit Continuity Test 2. Disconnect oxygen sensor connector.
NOTE: This test validates the heater element cir- 3. Cut locking tie securing oxygen sensor harness.
cuit and the sensor circuits.
4. Unscrew oxygen sensor from exhaust pipe.
1. Remove main power relay (R3) in LH fuse
box. Refer to POWER DISTRIBUTION AND NOTICE Handle oxygen sensor with clean
GROUNDS subsection. hands. Oxygen sensor probe must remain free
of oil, grease, antiseize lubricant and any other
2. Disconnect ECM-B connector and install it on
foreign matter that could affect its operation.
the ECM adapter tool. Refer to ECM CONNEC-
TOR ACCESS in ENGINE CONTROL MODULE
(ECM) in this subsection.
3. Using a multimeter set to " ", test for continuity
between the oxygen sensor harness connector
and the ECM adaptor as per following tables.
REQUIRED TOOLS
FLUKE 115
ECM ADAPTER TOOL
MULTIMETER
(P/N 529 036 166)
(P/N 529 035 868)

rmr2014-024-030_b

1. Oxygen sensor
2. Connector
3. Locking tie

Oxygen Sensor Installation (Same

Sensor)
If the same oxygen sensor is installed, apply LOC-
TITE 767 (ANTISEIZE LUBRICANT) (P/N 293 800 070)
on its first two threads.

36 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

NOTICE Always use a product that is oxygen engine noise level below a calibrated threshold, it
sensor safe. perceives this as a knock sensor fault and sets a
knock sensor fault code.

Knock Sensor Location

rmr2008-048-003_a

TYPICAL
1. Apply antiseize lubricant first two threads
2. Must be free of any product

NOTICE Do not apply any antiseize lubricant

to the sensor probe as it could affect its opera-
tion.
Screw sensor in exhaust pipe.
rmr2014-024-031_a

OXYGEN SENSOR INSTALLATION FRONT OF ENGINE (LH SIDE VIEW)

SERVICE PRODUCT TIGHTENING TORQUE

Knock Sensor Connector Location
LOCTITE 767 Refer to BODY subsection and remove the follow-
(ANTISEIZE 50 N•m ± 10 N•m
ing:
LUBRICANT) (37 lbf•ft ± 7 lbf•ft)
(P/N 293 800 070) – LH middle side panel
– LH top side panel
Install all other removed parts. – LH acoustic side panel.
Oxygen Sensor Installation (New
Sensor)
If a new oxygen sensor is installed, threads are
already coated with an anti-seize product. Sensor
is ready for installation.
Install sensor in the applicable exhaust pipe and
tighten to specification.
OXYGEN SENSOR TORQUE
50 N•m ± 10 N•m (37 lbf•ft ± 7 lbf•ft)

Install all other removed parts.

KNOCK SENSOR (KS) rmr2014-024-019_a

KNOCK SENSOR CONNECTOR LOCATION (LH SIDE)

This engine is equipped with one knock sensor 1. ECM
(KS1) that measures the amount of noise gener- 2. CPS sensor connector
3. Knock sensor connector
ated by the engine. 4. Engine harness interconnect (HIC)
If an abnormally high amount of noise is mea-
sured, the ECM perceives this as a KNOCK Knock Sensor Troubleshooting
condition and adjusts ignition timing by retarding Always use B.U.D.S. to check for a knock sensor
it to correct the situation. related fault code and carry out service actions.
If, with the engine running under load above 4000
RPM, the ECM receives no knock sensor signal,
or receives a knock sensor signal representing an
rmr2014-024 37
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))
Knock sensor problems may be related to, but not
limited to any of the following items:
– Loose or improperly torqued knock sensor
– Dirty or corroded mounting surface
– Cracked knock sensor from over torquing
– Bad wiring and connections
– An induced knock (or vibration) due to a loose
part external to the engine.
– Knock sensor and CPS sensor harness connec-
tors swapped (mixed up).
KS Dynamic Test
1. Using the latest applicable B.U.D.S. version,
check for a knock sensor fault. If an occurred
knock sensor fault is present, reset the fault.
2. Disconnect vehicle from B.U.D.S. and make ve-
hicle ready for a test ride.
3. During test ride, perform several accelerations
under load and ensure engine RPM exceeds
4000 RPM.
4. After test ride, reconnect vehicle to
B.U.D.S..and look for a knock sensor fault code
in B.U.D.S.
If no fault code occurs, the knock sensor is good.
If a fault occurs, do the following:
– Refer to KNOCK SENSOR TROUBLESHOOT-
ING and check for any of the problems listed.
Repair as required.
– Carry out a knock sensor resistance test.
KS Resistance Test at ECM
1. Disconnect ECM-A connector and install it on
the ECM adapter tool. Refer to ECM CONNEC-
TOR ACCESS in ENGINE CONTROL MODULE
(ECM) in this subsection.
2. Using a multimeter set to " ", measure the
knock sensor circuit resistance as per follow-
ing table.
REQUIRED TOOLS
FLUKE 115
ECM ADAPTER TOOL
MULTIMETER
(P/N 529 036 166)
(P/N 529 035 868)
38
ECM ADAPTER MEASUREMENT
RESISTANCE
SENSOR PINS
@ 20°C (68°F)
KS1 C3 G2
5 M
vmr2008-022-005_a
If knock sensor circuit resistance is as specified,
wiring harness and sensor are good.
If resistance measured at ECM connector is not
close to specification, carry out the KS RESIS-
TANCE TEST AT COMPONENT CONNECTOR.
KS Resistance Test at Component
Connector
1. Remove the required body parts to access the
knock sensor connector.
2. Disconnect the knock sensor connector.
3. Using a multimeter, measure the resistance be-
tween both terminals on the knock sensor and
compare the measurement with the preceding
table.
If resistance is not as specified, replace knock
sensor.
If resistance is good at the knock sensor, carry
out a continuity check of the wiring between the
knock sensor connector and ECM connector "A".
Refer to applicable WIRING DIAGRAM for details.
NOTE: Although the knock sensor resistance is
as specified, it may still be at fault as it may not
be producing a signal within its design specifica-
tion.
Repair or replace wiring and connectors between
the ECM and knock sensor.
KS Replacement
1. Disconnect KS sensor connector
2. Cut locking ties and remove clamp securing
wire harness.
3. Remove knock sensor mounting screw.
rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

4. Clean knock sensor contact surface on cylinder. 8. Reinstall all remaining removed parts.
Also clean threaded hole. 9. Install harness clamp and tighten to specifica-
5. Install new knock sensor and tighten as speci- tion. Tightening torque: 11 +/- 1 Nm.
fied.
SPECIFIED TORQUE
KNOCK SENSOR INSTALLATION
11 N•m to 1 N•m
Harness clamp screw
SPECIFIED TORQUE (97 lbf•in to 9 lbf•in)
20 N•m ± 2 N•m (15 lbf•ft ± 1 lbf•ft)
THROTTLE ACCELERATOR
NOTICE Improper torque may prevent sen- SENSOR (TAS)
sor from functioning properly and lead to
severe damage of internal engine compo- TAS Location
nents. The TAS is part of the throttle grip assembly.
6. Ensure knock sensor connector is clean and
corrosion free before connecting it.
NOTE: Wiring harness connector is marked with
"KNOCK". Do not reconnect with "CPS" connector.

rmr2013-022-159_a

TYPICAL

TAS Connector Location and Access

Refer to BODY subsection and remove the follow-
ing:
rmr2014-024-042_b
– RH middle side panel
1. Knock sensor harness connector
– RH top side panel
7. Install new locking ties as per factory specifica- – RH acoustic side panels.
tion.

rmr2014-024-041_a

1. Knock sensor
rmr2014-024-032_a
2. Harness clamp
TAS CONNECTOR ON RH SIDE

rmr2014-024 39
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

TAS Troubleshooting
When troubleshooting a throttle related problem,
proceed in this order:
– Check for an applicable fault code using the lat-
est applicable B.U.D.S. software version.
– Carry out recommended service actions.
– Carry out the TAS VOLTAGE TEST.

TAS Resistance Test

The throttle accelerator sensor is a double hall ef-
fect sensor. A resistance test cannot be carried
out.
rmr2014-024-033_a
TAS Voltage Test TAS VOLTAGE TEST
1. Turn ignition key to ON.
If voltage readings are as specified, the TAS and
2. Set emergency engine stop switch to RUN. its wiring are in good working order.
3. Using a multimeter set to Vdc, back-probe the If no voltage is measured between any of the pin
TAS connector pins as per following table. combinations in the table, test for continuity of the
NOTE: To safely probe wire terminals through the applicable wiring between the TAS harness con-
back of the connector, use the following tool or nector and the ECM connector before concluding
an equivalent. Care must be taken not to damage that the problem is related to the TAS, or to the
connector seals. ECM. Refer to the WIRING DIAGRAM for details.
REQUIRED TOOLS TAS Replacement
FLUKE 115 FLUKE AUTOMOTIVE If one or both sensors are not functioning nor-
MULTIMETER BACK PROBE PIN mally, the entire throttle grip assembly must be
(P/N 529 035 868) (P/N TP40) replaced. Refer to the STEERING AND FRONT
WHEELS subsection.

FLUKE AUTOMOTIVE BACK

PROBE PIN P/N TP40
ENGINE CONTROL MODULE
(ECM)
TAS VOLTAGE TEST ECM Location
VDC AT
TAS CONNECTOR VDC AT IDLE
WIDE OPEN
PINS POSITION
POSITION
Pin A (RD) Engine
4.5 - 5.5
Pin D (VT) ground

Pin B
Pin A (RD)
(BK)
4.5 - 5.5
Pin E
Pin D (VT)
(BN)
Pin B
Pin C (GN) 0.495 - 0.597 2.87 - 2.97
(BK)
Pin E
Pin F (BU) 0.248 - 0.348 1.385 - 1.485
(BN) rmr2014-024-034_a

LH SIDE VIEW

40 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

ECM Connector Access

Refet to BODY subsection and remove the follow-
ing:
– LH top side panel
– LH middle side panel
– LH bottom side panel
– LH acoustic panels. smr2009-027-005

ECM CONNECTORS

ECM Troubleshooting
Turn the ignition key to ON and look for the items
in the following two lists to come ON.
NOTE: The following listed items provide a visual
or audible indication that the ECM is initialized.
Other electronic modules and engine electrical
components not listed will be powered when
these relays close.
Main power relay LFB R3 will provide power to
the:
– ECM (main power)
– Cluster
rmr2014-024-035_a – Fuel pump
1. ECM – WPM
A. Connector "A"
B. Connector "B" – Light in parking brake switch
– Light in front heated grip switch
Power Supply to ECM – Light in fog light switch (optional)
When the ignition switch is turned to ON, the – Light in compressor suspension switch (op-
ECM receives 12 Vdc initialization voltage to tional)
wake up the ECM. – Analog fuel gauge (optional)
The ECM then provides a ground to the main – Analog coolant temp gauge (optional).
power relay (LFB R3) which closes its contacts If none of the items previously listed come on, the
and provides power to a large portion of the elec- ECM may not be initialized, or the main power re-
trical system. lay may not have closed. Carry out the following:
The main power relay also provides the main – ECM INPUT VOLTAGE TEST (IGNITION
12 Vdc battery power to the ECM. SWITCH)
ECM Power Supply and Ground Pinout – ECM GROUND CIRCUIT TEST
– Ignition switch test (refer to IGNITION SYS-
FUNCTION CONNECTOR PIN
TEM) subsection
Initialization 12 Vdc ECMB-A2 – MAIN POWER RELAY CONTROL CIRCUIT
R3 ground ECMB-H2 TEST (LFB R3).
Main 12 Vdc power ECMB-M4 If the fuel pump does not cycle on for a few sec-
onds when the ignition switch is first turned on,
ECM grounds ECMB Pins L1, M2, M3 and the engine will not crank, the ECM may not
receive its main 12 Vdc or is at fault. Test the fol-
lowing:
– ECM fuse (F5) in LH fuse box
– ECM main 12 Vdc input (refer to ECM INPUT
VOLTAGE TEST (BATTERY).

rmr2014-024 41
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

If these items test good, connect vehicle to the

latest applicable B.U.D.S. software version and
look for relevant fault codes before replacing an
ECM.
Also ensure the ignition key D.E.S.S. code is
recorded in the ECM. If not, the key will not be
recognized by the ECM at key on and a "BAD KEY"
message will scroll in the multifunction gauge.

ECM Fault (U0300)

smr2009-030-010_d
If a fault code indicating wrong engine control
module (ECM) is generated, the installed ECM is If there is no voltage, check the following:
not appropriate for the vehicle. Engine will not – Main power relay operation (LFB R3), refer to
crank. Refer to PARTS CATALOG for appropriate POWER DISTRIBUTION AND GROUNDS sub-
ECM part number according to vehicle. section.
– Circuit continuity from LFB contact B5 to
ECM Input Voltage Test (Ignition ECMB-H2, refer to WIRING DIAGRAM.
Switch)
If voltage is adequate, the main power relay coil
Refer to IGNITION SWITCH OUTPUT VOLTAGE and its control circuit to the ECM is good.
TEST
(TO ECM) in the IGNITION SYSTEM subsection. NOTE: Use B.U.D.S. to reset fault codes gener-
ated when voltage check was carried out with
Main Power Relay Control Circuit Test ECM adapter.
(LFB R3)
ECM Input Voltage Test (Battery)
1. Disconnect ECM-B connector and install it on
the ECM adapter tool. 1. Ensure ignition switch is set to OFF.
2. Set multimeter to Vdc. 2. Temporarily remove main power relay (R3) in
LH fuse box. Refer to POWER DISTRIBUTION
REQUIRED TOOLS AND GROUNDS subsection.
FLUKE 115 3. Disconnect ECM-B connector from the ECM
ECM ADAPTER TOOL
MULTIMETER and install it on the ECM adapter tool.
(P/N 529 036 166)
(P/N 529 035 868)
REQUIRED TOOLS
FLUKE 115
ECM ADAPTER TOOL
MULTIMETER
(P/N 529 036 166)
(P/N 529 035 868)

3. Turn ignition switch ON.

4. Measure voltage as per table.
NOTE: Because of lights and accessories current
consumption, a slight battery voltage drop is nor- 4. Reinstall main power relay (R3) in LH fuse box.
mal.
5. Install an appropriate insulated jumper wire as
IGNITION SWITCH OUTPUT VOLTAGE per table.
TEST (TO ECM)
JUMPER WIRE
TEST PROBES VOLTAGE
ECM adapter pin H2 Chassis ground
ECM-B pin H2 Ground Battery voltage
NOTE: This provides a ground to energize the
main power relay (R3), which provides the main
12 Vdc to the ECM.
6. Set multimeter to Vdc.
7. Read voltage as per following table.

42 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

ECM CONNECTOR “B” MEASUREMENT To check the CAN resistor within the ECM, carry
out the following steps.
PIN VOLTAGE
1. Turn ignition switch to OFF.
M-4 Battery ground Battery voltage
2. Remove main power relay (R3) in LH fuse
If battery voltage is not measured, test the follow- box. Refer to POWER DISTRIBUTION AND
ing: GROUNDS subsection.
– Fuse J4 in LH fuse box. 3. Remove diagnostic link connector (DLC) from
– Main power relay (R3), refer to POWER DIS- its holder.
TRIBUTION AND GROUNDS subsection. 4. Ensure the ECM connectors are properly con-
– Continuity of wiring and connectors from ECM nected.
to R3, refer to WIRING DIAGRAM subsection. 5. Reach in under the lower LH suspension arm
If battery voltage is measured, carry out an ECM and disconnect the VCM connector, refer to VE-
GROUND CIRCUIT TEST as follows. HICLE STABILITY SYSTEM (VSS) subsection.
6. Measure ECM CAN resistor through DLC con-
ECM Ground Circuit Test nector as follows.
1. Remove main power relay (R3) in LH fuse REQUIRED TOOLS
box. Refer to POWER DISTRIBUTION AND
GROUNDS subsection.
FLUKE 115
2. Disconnect connector “B” from the ECM. Re- MULTIMETER
fer to ECM CONNECTOR ACCESS in ENGINE (P/N 529 035 868)
CONTROL MODULE (ECM) in this subsection.
3. Install connector on the ECM adapter tool. NOTICE To avoid damaging the connector,
REQUIRED TOOL probe only the terminal tip.
ECM CAN RESISTOR TEST
ECM ADAPTER TOOL
(P/N 529 036 166) PROBE DLC CONNECTOR MEASUREMENT
Pin 1 Pin 2 110 - 130
4. Connect the alligator clip of a 12 Vdc test light
to the battery positive terminal.
5. Connect the probe of the test light to each
ground circuit as per following table to test
ECM ground circuit.
ECM GROUND CIRCUIT TEST
BATTERY ECM “B” CONNECTOR
Pin L-1
Positive terminal (+) Pin M-2
Pin M-3

If the test light does not come ON (or is dim) when

testing any of the ground circuits, check wiring
and connector pins for corrosion, loose pins, cut rmr2013-022-162_a

ECM CAN RESISTOR TEST

wire or broken wire at a connector pin. Repair or
replace as applicable.
ECM CAN Resistor Test
The ECM contains a CAN line termination resistor.
If the resistor value is not correct, or the resistor
is open circuit, the ECM will not be able to com-
municate with the other modules.
rmr2014-024
If the resistance value is NOT as specified, carry
out the ECM CAN LINE CONTINUITY TEST in this
subsection.
If the ECM is not communicating through CAN
and the resistance value measured is as specified,
ECM CAN resistor and CAN lines are good. Re-
place ECM.
43
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

7. Reconnect VCM connector and diagnostic con- ECM Removal

nector. NOTE: If a new ECM is to be installed, first read
the procedures in ECM REPLACEMENT further in
ECM CAN Line Continuity Test this subsection.
1. Remove main power relay (R3); refer to 1. Remove the J4 fuse in LH fuse box.
POWER DISTRIBUTION AND GROUNDS sub-
section. 2. Remove parts required for access to ECM. Re-
fer to ECM CONNECTOR ACCESS in this sub-
2. Remove diagnostic connector from its holder. section.
3. Disconnect ECM-B connector and install it on 3. Disconnect ECM connectors.
the ECM adapter tool. Refer to ECM CONNEC-
TOR ACCESS in this subsection. 4. Remove ECM mounting screws.
REQUIRED TOOLS
FLUKE 115
ECM ADAPTER TOOL
MULTIMETER
(P/N 529 036 166)
(P/N 529 035 868)

4. Test for circuit continuity between diagnostic

link connector (DLC) and ECM as per following
table.
NOTE: Refer to ECM POWER SUPPLY, GROUND
AND CAN PINOUT in this subsection for pin iden-
tification. rmr2014-024-035_b

1. ECM connectors
NOTICE To avoid damaging the connector, 2. ECM mounting screws
probe only the terminal tip.
ECM Installation
ECM CONNECTOR
1. Reconnect ECM connectors.
CAN* PROBES RESULT 2. Install the ECM in vehicle.
Diagnostic 3. If a new ECM is installed, enter data and
ECM-B
High link connector perform the required resets using the latest
pin C1
pin 1 Close to 0 applicable B.U.D.S. version. Refer to ECM
Diagnostic (continuity) REPLACEMENT further in this subsection.
ECM-B
Low link connector 4. Reinstall the J4 fuse in LH fuse box.
pin C2
pin 2
5. Reinstall all removed body parts, refer to BODY
* CAN: Serial data communication subsection.
If continuity is not good, check wiring and con- ECM Replacement
nectors from diagnostic link connector (DLC) to
ECM connector. Refer to applicable WIRING DI- 1. Prior to replacing a possibly faulty ECM, ensure
AGRAM. the following:
– Check for an applicable fault code using the
If everything tested good and ECM does not work,
latest applicable B.U.D.S. software version.
try a new ECM.
Carry out service actions and clear fault
5. Reconnect DLC and ECM connectors. codes.
– ECM power supply and all grounds have
been checked for proper contact/cleanli-
ness, tightness and continuity.

44 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

– Make sure terminals are free of corrosion

or moisture, properly crimped on wires and
locked in connector housing.
– Check wiring harness for any signs of scor-
ing, cuts, bare or pinched wires that may
cause short or open circuits.
– All the other recommended tests have been
carried out.
NOTE: If the ECM must be replaced, be sure to
obtain all vehicle keys. They will all need to be
programmed into the new ECM using B.U.D.S.
2. Collect the following data and settings required rmr2014-024-053_a

for entry into new ECM:

Double click on the AutoSave folder.
There are 2 possible methods to collect the re-
quired information. The 1st being the easiest.
– Use B.U.D.S. software and retrieve the data
from a saved .mpem file on your PC computer.
Refer to 1ST COLLECTING METHOD: RETRIEV-
ING DATA FROM A SAVED .MPEM FILE.
– Collect the information from the vehicle
and BOSSWeb. Refer to 2ND COLLECTING
METHOD: COLLECT THE INFORMATION
FROM THE VEHICLE AND BOSSWEB.
3. Replace the ECM.
4. Carry out an ECM INITIALIZATION RESET in
B.U.D.S.
mmr2009-023-082_a
1st Collecting Method: Retrieving Data from a TYPICAL
Saved .mpem File
1. Connect vehicle to the latest applicable NOTE: You may have to go to another AutoSave
B.U.D.S. software version. folder from a previous version of B.U.D.S.
2. Turn the ignition key to ON. Choose the latest file saved for this specific vehi-
cle.
3. In B.U.D.S., click on the Open button.

mmr2009-023-080

OPEN
smr2009-030-006

Click once on the Folder Up button in the Open TYPICAL

box. IMPORTANT: Ensure to use the file that specifi-
cally matches the vehicle you are servicing.

rmr2014-024 45
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

The file name structure is as follows:

BUDS version_VIN_date read (yyyymmdd)_hour read
(hhmmss).mpem

Example:

P2.3.22.12_2BPSBK8C68V000168_20090206_111640.mpem
Therefore:
B.U.D.S. version: P2.3.22.12
VIN: 2BPSBK8C68V000168
Date: 2009 02 06
Hour: 11h 16m 40s

On the Vehicle page, collect the following infor-

mation. rmr2014-024-036_a

1. Customer name ENGINE IDENTIFICATION TAG

2. VIN (Vehicle Identification Number)
2. Record the following numbers from BOSSWeb.
3. Engine serial number (without the leading
Look in Sales menu and choose Unit history.
“M”)
1. Vehicle serial number
4. Vehicle model number
2. Vehicle model number
5. Total hours.
3. Customer name.

rmr2014-024-054_a

DATA TO RETRIEVE
1. Customer (name) smr2014-026-004_a
2. Vehicle (VIN) SERVICE, UNIT HISTORY
3. Engine (serial number) 1. Click on SALES menu
4. Model 2. Select Unit History
5. Total hours

Enter recorded data in ECM as detailed in ENTER-

ING THE COLLECTED DATA IN THE ECM.
2nd Collecting Method: Collect the
Information from the Vehicle and BOSSWeb
1. Record engine serial number.
NOTE: The engine serial number may be obtained
from 2 locations on the LH rear side of engine,
near the drive belt pulley:
– A bar code identification sticker
– Etched on the engine crankcase.

46 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

smr2014-026-005_a
rmr2014-024-055_a
1. Vehicle Serial Number here
DATA TO ENTER IN VEHICLE PAGE OF B.U.D.S.
1. Customer (name)
3. Enter the recorded data in ECM as detailed 2. Vehicle (VIN)
in ENTERING THE COLLECTED DATA IN THE 3. Engine (serial number)
4. Model
ECM.
Entering Collected Data in the ECM 4. Click on Setting tab.
1. After the ECM is replaced, connect vehicle to 5. Click on the Vehicle Configuration tab at the
the latest applicable B.U.D.S. version. Refer to bottom of the page.
COMMUNICATION TOOLS AND B.U.D.S. sub-
section.
2. In B.U.D.S., click the Read Data button.

vmr2006-012-100_aen
rmr2014-024-056_a

3. On the Vehicle page of B.U.D.S., enter cus- 1. Setting tab

2. Vehicle Configuration tab
tomer and vehicle data in ECM.
6. In the Vehicle Configuration page:
6.1 Ensure the drop boxes reflect the vehicle
connected to B.U.D.S. in the Vehicle Con-
figuration area.

rmr2014-024 47
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

rmr2014-024-056_b
rmr2010-022-027_a
1. Vehicle Configuration area
2. Drop boxes 1. ECM selection
2. Enter ECM serial number here
6.2 In the Vehicle Option area, select the ACS 11. Click OK to save the ECM serial number and
box if the vehicle is equipped with an air exit the window.
controlled suspension.
12. Program all vehicle keys into the new ECM, re-
fer to DIGITALLY ENCODED SECURITY SYS-
TEM (D.E.S.S.) subsection.
Click the Write Data button to save the informa-
tion into the ECM.

rmr2014-024-056 _c

1. Vehicle Option area

2. ACS box vmr2006-012-100_ben

7. Click on History tab. NOTE: A message box will confirm a successful

8. Click on Part Replacement tab.
9. Click on Add Part in History tab.
operation.
13. Carry out the ECM FIRST INITIALIZATION pro-
cedure in this subsection.
Security Exchange
If the warning message in the following illustra-
tion appears when B.U.D.S. is connected to the
vehicle, the installed ECM is not the appropriate
ECM for the vehicle, or its calibration has been
changed.

rmr2008-021-021_a

10. In the Part Type area, choose ECM and add

the ECM serial number.
48 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

2. When the following message will appear, make

sure that:
2.1 The throttle grip is completely released.
2.2 The transmission in set to neutral.
2.3 The brake pedal is released.
2.4 The engine temperature and intake air
vmr2006-020-058_a temperature are above 5°C (41°F).
If it occurred just after replacing the ECM, refer 2.5 Click the "OK" button.
to the PARTS CATALOG to obtain the appropriate
ECM required for the vehicle type.
If this message appears after the ECM calibration
has been purposely changed, click Yes to update
the system, and to allow engine starting.
NOTICE It is not recommended to start an en-
gine with the wrong calibration.

ECM First Initialization

When the ECM First Initialization will be started, rmr2014-024-057_a

the ECM will automatically initiate a:

3. When the following message appears:
– Throttle position sensor initialization
3.1 Turn ignition key OFF.
– Brake pressure adaptation.
3.2 Wait 3 seconds.
Ensure transmission is set to NEUTRAL.
3.3 Turn ignition key ON.
NOTE: On SE6 models, the engine may need to
be started to set transmission to N. When done, 3.4 Click the "OK" button.
stop engine.
IMPORTANT: Do not activate anything on the ve-
hicle while performing a module reset.
1. In B.U.D.S., click the items in the illustrated or-
der.

rbg2012-006-115

4. When the following message appears, click the

"OK" button.

rbg2012-006-116
rmr2014-024-011_e

Step 1: Setting tab

Step 2: ECM tab 5. When the following message appears:
Step 3: Reset (ECM First Initialization)
5.1 Turn ignition key to OFF.
5.2 Wait until the message vanishes.

rmr2014-024 49
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

rmr2014-024-058

6. When the following message appears:

6.1 Turn ignition key to ON.
6.2 Click the "OK" button.

rbg2012-006-051

GBPS Learning
rmr2014-024-011_f
1. In B.U.D.S., press the gear position sensor GEAR POSITION SENSOR LEDS
button. 1. All the gear LEDs OFF

WARNING
Ensure the rear tire is well off the ground and
cannot come into contact with any obstacle
(ground, jack stand, etc.). Ensure the wheel
and tire assembly is free of particles that
could be thrown outward while rotating.

4. Lift and secure rear of vehicle off the ground so

rear wheel may turn freely.
4.1 Place vehicle on a level surface.
4.2 Ensure transmission is set to NEUTRAL.
4.3 Position a floor jack under the lower por-
tion of the rear shock absorber and lift the
rear of vehicle until the rear wheel is off
the ground.
rmr2014-024-011_i

1. GBPS RESET BUTTON NOTICE The floor jack must be posi-

tioned so that it cups the lower portion of
2. When the following message appears, click the the rear shock absorber.
"OK" button.

rbg2012-006-208

3. Ensure all the gear LEDs are OFF in B.U.D.S.

50 rmr2014-024
 Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

CAUTION Apply only sufficient throttle to

allow upshifting of forward gears. Do not ex-
ceed 3800 RPM.
7. Ensure all the gear LEDs are OFF in B.U.D.S.

rbg2010-004-002_a

TYPICAL
1. Lower portion of shock absorber

NOTE: It is highly recommended to install 4

wheel chocks at front wheels (in front and rear of
wheels).

rmr2014-024-011_g

GEAR POSITION SENSOR LEARNING LEDS

1. Wait until the gear LED turns green (learned) before shifting

8. All gear position sensor LEDs must be green in

B.U.D.S. to confirm the GBPS learning is com-
pleted.
9. Ensure all the gear LEDs are OFF in B.U.D.S.

rbg2010-004-001_a

WHEEL CHOCK INSTALLATION, EACH FRONT WHEEL

WARNING
Before starting engine, ensure the rear tire
is well off the ground and cannot come into
contact with any obstacle (ground, jack stand,
etc.). Keep hands, tools, feet and clothing
clear of rotating parts (rear wheel assembly,
drive belt). Ensure no one is standing in
close proximity to the vehicle.

5. Start engine.
rmr2014-024-011_h

6. Run transmission through all gears (N, R, 1. All LEDs must be green
1-2-3-4-5-6 and back to N) waiting until its LED
turns green (in B.U.D.S.) before changing gear. NOTE: During the GBPS learning procedure, the
cluster may show an orange screen and numer-
NOTICE Apply brake to stop wheel before ous indicator lights may come on (CHECK ENG,
shifting from reverse to forward. VSS, ABS, LIMP HOME, etc).
10. Turn ignition key OFF.
11. Wait 3 seconds.

rmr2014-024 51
Subsection 01 (ELECTRONIC FUEL INJECTION (EFI))

12. Turn the ignition key ON. 7. Exit B.U.D.S.

Clearing Faults
1. In B.U.D.S., click on Read Data.
vmr2006-012-100_aen
2. Click the items in the illustrated order.
3. Ensure there are no active faults. If so, carry
out service actions accordingly.
NOTICE To avoid potential vehicle damage,
it is very important to turn ignition key off BE-
FORE exiting B.U.D.S. or unplugging the MPI-2
diagnostic cable from the vehicle.
8. Unplug MPI-2 diagnostic cable from vehicle.
Road Test
1. Test drive vehicle. Ensure its proper operation
and that every gear position is correctly indi-
cated in the multifunction gauge.
On SE6 models, it is extremely important to en-
sure the transmission can be shifted into each
gear.

rbg2010-003-033_b

CLEARING FAULTS
Step 1: Faults
Step 2: Click "Clear Occurred Faults" button

4. When the following message appears, click the

"Yes" button.

rbg2012-006-119

5. Ensure no occurred fault remain.

NOTE: To clear all occurred faults, it may be nec-
essary to activate the Clear Occurred Faults but-
ton more than once.
6. Turn ignition key OFF.

52 rmr2014-024
 Subsection 02 (FUEL TANK AND FUEL PUMP)

FUEL TANK AND FUEL PUMP

SERVICE TOOLS
Description Part Number Page
ECM ADAPTER TOOL................................................................... 529 036 166 ..................................... 12, 18
FUEL HOSE ADAPTER.................................................................. 529 036 023 ............................................. 7
OETIKER PLIERS........................................................................... 295 000 070 ............................................. 6
PRESSURE GAUGE....................................................................... 529 035 709 ............................................. 7
VACUUM/PRESSURE PUMP ........................................................ 529 021 800 ............................... 17, 19–20

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
SNAP-ON SMOKE MACHINE ....................................................... EELD100 ............................................. 6

rmr2014-025 1
Subsection 02 (FUEL TANK AND FUEL PUMP)

NEW

7.5 ± 1 N•m
(66 ± 9 lbf•in)
NEW

NEW NEW

NEW

NEW
7.5 ± 1 N•m NEW
(66 ± 9 lbf•in)

10 ± 2 N•m 5 ± 1 N•m
(89 ± 18 lbf•in) (44 ± 9 lbf•in)

NEW = Component must be replaced when removed.

rmr2014-025-499_a

2 rmr2014-025
 Subsection 02 (FUEL TANK AND FUEL PUMP)

rmr2014-025-299_a

rmr2014-025 3
Subsection 02 (FUEL TANK AND FUEL PUMP)

GENERAL
WARNING
Torque wrench tightening specifications
must be strictly adhered to. Locking devices
must be replaced when removed (e.g.: lock-
ing tabs, elastic stop nuts, cotter pins, etc.).

WARNING
Always disconnect battery prior to working
on the fuel system.

WARNING
Fuel is flammable and explosive under cer-
tain conditions. Always work in a well venti-
lated area.

WARNING
Do not allow fuel to spill on hot engine parts
and/or on electrical connectors.

WARNING
Always proceed with care and use appropri-
ate safety equipment when working on pres-
surized fuel system. Wear safety glasses.

When replacing a fuel line, be sure to use BRP

approved fuel hoses as available from the BRP
parts department. This will ensure continued
proper and safe operation.
Fuel lines remain under pressure at all times.
Proceed with care when removing/installing high
pressure test equipment.
Disconnect fuel pump electrical connector to dis-
able fuel pump and crank engine to release fuel
pressure prior to disconnecting any fuel hose.
Cover the fuel hose connections with an ab-
sorbent shop rag and carefully disconnect them
to minimize spilling.
Wipe off any fuel spillage.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory stan-
dards.
WARNING
Replace any damaged, leaking or deterio-
rated fuel line. Use of damaged fuel lines, or
fuel lines not approved by BRP, could com-
promise fuel system integrity.

4 rmr2014-025
 Subsection 02 (FUEL TANK AND FUEL PUMP)

SYSTEM DESCRIPTION
The fuel system main components are:

rmr2014-025-035_a

FUEL SYSTEM MAIN COMPONENTS

1. Canister pre-filter
2. Evap purge valve
3. Fuel filter
4. Electric fuel pump module
5. Fuel tank
6. Evap canister
7. Vent valve

Fuel Pump Module

The fuel pump module is inserted through the top
of the fuel tank. It includes an electric fuel pump
and a float type fuel level sensor that varies in re-
sistance according to fuel level.

rmr2014-025-017_a

FUEL PUMP MODULE

1. Fuel pump module
2. Fuel level float
3. Fuel level sensor
A. Fuel level float range

Fuel Pressure Regulator

The fuel pressure regulator is integrated into the
fuel pump module mounted inside the fuel tank.
It controls the fuel pressure in the system.

rmr2014-025 5
Subsection 02 (FUEL TANK AND FUEL PUMP)

The nominal fuel pressure is set at 400 kPa 3. On charcoal canister side of purge solenoid
(58 PSI). valve, disconnect purge hose.

Evaporative Emission System (EVAP) REQUIRED TOOL

As the vehicle is sitting and not running, fuel evap- OETIKER PLIERS (P/N 295 000 070)
orates within the fuel tank.
4. On charcoal canister side of purge solenoid
The fuel tank vent is connected to an EVAP can- valve, install SNAP-ON SMOKE MACHINE
ister (charcoal) that is used to trap any hydrocar- (P/N EELD100) or equivalent smoke machine
bon emissions from the evaporated fuel prevent- onto purge hose.
ing them from escaping to the atmosphere. The
fuel vapors are absorbed by a charcoal medium in-
side the canister.
An EVAP purge valve is used in conjunction with
the EVAP canister. A hose connects the solenoid
operated valve to a vacuum port on the intake
manifold.
Once the engine is running and reaches predeter-
mined conditions, the ECM controls the purge so-
lenoid valve according to engine RPM and load.
Thus, vacuum from the engine draws (or purges)
the hydrocarbon emissions from the canister and
burns them during the combustion process. The rmr2014-025-033_a

ECM cycles the solenoid ON and OFF as neces- FUEL SYSTEM LEAK TEST
1. Install smoke machine here
sary.
In order for engine vacuum to draw in the hydro- 5. Pinch evap vent hose above canister pre-filter.
carbon emissions from the canister, a flow must
be created. As the hydrocarbon emissions are
drawn out of the canister, they are replaced with
fresh air by means of the canister pre-filter. Thus
ensuring proper fuel system venting.
The vent valve ensures that, if the vehicle is ever
upside-down, liquid fuel cannot flow through the
vent line.

INSPECTION
DEPRESSURIZING FUEL SYSTEM rmr2014-025-034_a

FUEL SYSTEM LEAK TEST

It is recommended to depressurize the fuel sys- 1. Pinch canister pre-filter hose here
tem before disconnecting fuel hoses.
6. Pressurize the fuel system as per the following
1. Connect B.U.D.S. and go to the ACTIVATION
specifications.
page.
2. Start and idle engine. FUEL SYSTEM LEAK TEST
3. Deactivate the fuel pump and allow the engine TIME WITHOUT
PRESSURE
to stall. PRESSURE DROP
21 kPa (3 PSI) 30 seconds
FUEL SYSTEM LEAK TEST
If pressure drops, locate leak(s) and repair/replace
1. Remove body parts on the LH side of the ve- leaking component(s).
hicle as required to access fuel system compo-
nents. Refer to the BODY subsection. 7. Reinstall fuel tank purge hose on purge sole-
noid valve.
2. Fill up fuel tank (recommended).

6 rmr2014-025
 Subsection 02 (FUEL TANK AND FUEL PUMP)

8. Reinstall all removed body parts, refer to BODY

subsection.

FUEL SYSTEM PRESSURE TESTS

The fuel system pressure tests provide an indi-
cation of the available pressure in the fuel sys-
tem. They validate the pressure regulator, the fuel
pump and injectors. 529036023

NOTE: Ensure vehicle battery is fully charged be-

fore performing tests. 5. Install fuel hose adapter as illustrated.
If pressure is not within specifications, refer to
DIAGNOSTIC FLOW CHART (FUEL PUMP) in
TROUBLESHOOTING in this subsection
Fuel System Pressure Test (Static)
This test allows the following fuel system checks:
– Internal component and external fuel system
leak checks (high pressure system)
– Static fuel pressure test (engine not running).
1. Ensure there is enough gas in fuel tank.
2. Remove body parts on the RH side of the vehi- rmr2014-025-031_a
cle as required to access the fuel pump. Refer 1. Fuel hose adapter location
to BODY subsection.
3. Depressurize the fuel system. Refer to: DE- 6. Set engine stop switch to RUN.
PRESSURIZING FUEL SYSTEM in this subsec- 7. Turn ignition key to ON. Do not crank engine.
tion. 8. Observe fuel pressure on test gauge while
pump is running.
WARNING
Cover the fuel hose connection with an ab- 9. Turn ignition key to OFF.
sorbent shop rag. Slowly disconnect the fuel 10. Repeat the test 3 - 4 times to ensure a consis-
hose to minimize spilling. Wipe off any fuel tent pressure reading.
spillage. FUEL SYSTEM PRESSURE TEST (STATIC)

4. Connect a fuel PRESSURE GAUGE (P/N 529 035 FUEL Minimum 385 kPa (56 PSI)
709) to the FUEL HOSE ADAPTER (P/N 529 036 PRESSURE Maximum 430 kPa (62 PSI)
023).
If pressure is not within specifications within 5
seconds following KEY ON, check for:
– External leaks
– Proper fuel pump power and ground
NOTE: A symptom of a system that does not
maintain pressure after key off is longer start
time when hot.

Fuel System Pressure Test (Dynamic)

This test validates the following components in
the fuel system:
529035709 – Fuel pump (under partial load)
– Fuel supply and return hoses

rmr2014-025 7
Subsection 02 (FUEL TANK AND FUEL PUMP)

– Pressure regulator. PROCEDURES

– Fuel filter (if badly clogged)
1. Follow the instructions in the FUEL SYSTEM FUEL FILTER
PRESSURE TEST (STATIC) procedure to discon-
nect the fuel pump pressure hose and install
Fuel Filter Removal
the pressure gauge. 1. Remove body parts on the RH side of the ve-
hicle as required to access fuel system compo-
2. Start engine.
nents. Refer to the BODY subsection.
3. Safely operate vehicle to load engine.
2. Depressurize the fuel system. Refer to: DE-
4. Observe fuel pressure while operating. PRESSURIZING FUEL SYSTEM in this subsec-
NOTE: If engine is not loaded and throttle is tion.
snapped, fuel pressure may momentarily drop 3. Remove fuel filter retaining screws.
below specification. This is normal.
FUEL SYSTEM PRESSURE TEST (DYNAMIC)
Minimum
385 kPa (56 PSI)
FUEL PRESSURE
Maximum 430 kPa
(62 PSI)

5. Stop engine and turn ignition key to OFF.

Injector Balance Test

This test verifies that the injectors all inject the
same amount of fuel when given the same com-
mand. Refer to ELECTRONIC FUEL INJECTION
(EFI).
rmr2014-025-002_a
Injector Leak Test FUEL FILTER MOUNTING BRACKET RETAINING SCREWS - RH
This test verifies that the injectors do not leak VIEW
1. Fuel tank ground strap
fuel when closed. Refer to ELECTRONIC FUEL 2. Fuel filter retaining screws
INJECTION (EFI).
4. Remove fuel filter mounting bracket.
TROUBLESHOOTING 5. Note position of hoses on filter to ease installa-
tion.
TROUBLESHOOTING TIPS 6. Remove Oetiker clamps and remove fuel filter.
ENGINE SURGING OR NOT HOLDING A
STEADY SPEED
1. Fuel system pressure out of specification.
2. EVAP purge valve stuck opened.
3. Air intake system leak.
4. Leaking, kinked of obstructed fuel hoses.
rmr2014-025-018_a
5. Damaged component power wires or grounds.
FUEL HOSES
1. Fuel filter Oetiker clamps
ENGINE BACKFIRING OR MISFIRING
1. Inadequate fuel system pressure. Fuel Filter Installation
1. Install fuel filter on fuel hoses.
2. EVAP purge valve hoses incorrectly installed.
3. Leaking, kinked of obstructed fuel hoses.
4. Damaged component power wires or grounds.

8 rmr2014-025
 Subsection 02 (FUEL TANK AND FUEL PUMP)

NOTE: Be sure to install the fuel filter with the
flow direction arrow on the fuel filter in the direc-
tion of fuel flow; from fuel pump towards intake
manifold.
rmr2014-025-003_a
DIRECTION OF FLOW ARROW ON FUEL FILTER
4. Remove GPS electrical harness clips from tank
(RH side of tank if equipped).
5. Depressurize the fuel system. Refer to: DE-
PRESSURIZING FUEL SYSTEM in this subsec-
tion.
6. Disconnect fuel lines from fuel pump.
NOTE: Alternator electrical connector may be
damaged if not removed. Ensure parking brake
cable is clear of fuel tank near the master cylinder.
7. Remove gas cap.
8. Siphon fuel tank.
9. Remove the screws securing the RH lateral
frame support and fuel pump protector to the
frame, refer to FRAME subsection.
NOTE: Leave the RH lateral frame support on ve-
hicle.

2. Install new Oetiker clamps on fuel filter hoses.

WARNING
Always install new Oetiker clamps as per
PARTS CATALOG.

3. Secure fuel filter to chassis.

4. Reconnect fuel pump (FP) electrical connector.
5. Turn ignition switch ON to activate fuel pump
and check for:
– Proper fuel pump operation rmr2014-025-026_a

– Fuel leaks in the system. TYPICAL

Step 1: Remove lateral frame support screws
Step 2: Remove fuel pump protector
NOTICE When checking for fuel system
leaks, pay particular attention to the hose 10. Remove 2 retaining screws from the master
connections that were disconnected for the cylinder.
procedure.
6. Reinstall all removed body parts, refer to BODY
subsection.

FUEL TANK
Fuel Tank Draining
Siphon fuel from tank into an approved fuel stor-
age container.

Fuel Tank Removal

1. Remove body parts on both sides of the vehi-
cle as required to access the fuel tank, refer to
BODY subsection.
2. Remove both fuel tank covers.
rmr2008-022-018_a
3. Disconnect EVAP vent hose from intake mani-
TYPICAL - MASTER CYLINDER RETAINING SCREWS
fold.

rmr2014-025 9
Subsection 02 (FUEL TANK AND FUEL PUMP)
11. Remove the remaining screws that secure the
RH footpeg support to the frame, and remove
the support from the vehicle.
NOTE: The remaining screws are screwed into
the rear face of the foot peg support.
12. Remove fuel tank retaining screws. Refer to
exploded view at the beginning of this section.
13. Disconnect EVAP purge valve electrical con-
nector (EVAP).
rmr2014-025-032_a
EVAP VENT HOSE SUPPORT BRACKET
14. Remove hose from vent valve
14.1 Cut locking tie
14.2 Remove Oetiker clamp
rmr2014-025-038_a
15. Pull fuel tank up and out from RH side of ve-
hicle.
NOTE: Move master cylinder from side to side as
necessary to allow removal of fuel tank. Be spe-
cially careful not to damage brake oil hoses and
fittings.
Fuel Tank Inspection
Inspect fuel tank for any damage or cracks which
may result in fuel leaks. Replace fuel tank as re-
quired.
10
Fuel Tank Installation
Reverse the removal procedure. However, pay at-
tention to the following:
1. Reinstall fuel tank. Install hardware as illus-
trated in exploded view at the beginning of this
subsection.
NOTE: Be sure to install ground wires on the RH
fuel tank mounting screws and star washers. Re-
fer to exploded view.
rmr2014-025-025_a
1. Install fuel tank ground wires here
WARNING
Be sure to carry out a leak test and an opera-
tional test of the brake system as indicated in
the BRAKES subsection.
2. Use locking ties to secure wiring and hoses as
per factory specification.
3. Connect fuel supply hose and fuel return hose
quick connects. Flat section of quick connect
must face down towards fuel tank.
rmr2013-023-010_a
TYPICAL
1. Flat side
rmr2014-025
 Subsection 02 (FUEL TANK AND FUEL PUMP)

4. Pressurize fuel system by turning ignition key

ON, and checking for leaks.

FUEL PUMP
Fuel Pump Location
The fuel pump module is mounted on top of the
fuel tank.

Fuel Pump Quick Test

1. Open the seat for access to top of fuel tank.

rmr2013-023-008_a

1. Fuel pump electrical connector

4. Connect a 12 Vdc test light to the fuel pump

harness connector as per following table.
5. Turn the ignition switch to ON.
FUEL PUMP POWER CIRCUIT TEST
USING A TEST LIGHT
PUMP HARNESS
GOOD RESULT
CONNECTOR
rmr2014-025-012_a

FUEL PUMP LOCATION UNDER SEAT Test light should turn ON for a
FP- C to FP-B
few seconds, then turn OFF
2. Apply the metal end of a screwdriver to the top
of the fuel pump module and, the other end
against your ear.
3. Turn ignition switch to ON and listen for the fuel
pump.
The fuel pump should run for a few seconds to
build up pressure in the fuel system, and then
shut off. If you do not hear the fuel pump func-
tion, check fuse. If fuse is good, carry out a FUEL
PUMP POWER CIRCUIT TEST USING A TEST
LIGHT.
Fuel Pump Power Circuit Test Using a rmr2014-025-030_a

Test Light
1. Remove the RH upper side panel, refer to
BODY subsection.
2. Remove the RH fuel tank cover, refer to BODY
subsection.
3. Disconnect fuel pump (FP) electrical connector.
FP
6. Turn the ignition switch to OFF.
If test light came ON for a few seconds and then
turned OFF, the fuel pump circuit and ECM are
functioning normally. Carry out the FUEL PUMP
OPERATIONAL TEST.
If the test light came ON dim or not at all, carry
out the FUEL PUMP POWER CIRCUIT VOLTAGE
TEST.

rmr2014-025 11
Subsection 02 (FUEL TANK AND FUEL PUMP)

Fuel Pump Operational Test Fuel Pump Power Circuit Continuity

Install small insulated jumper wires between the Test
fuel pump module connector and a known good 1. Remove fuse F8 in LFB.
12 volt battery as in following illustration. 2. Disconnect fuel pump (FP) electrical connector.
Ensure normal pump circuit polarity is respected 3. Set multimeter to and test circuit continuity
as illustrated. as per following table.
FUEL PUMP POWER CIRCUIT CONTINUITY TEST
PUMP
RESISTANCE
FUSE BOX HARNESS
@ 20°C (68°F)
CONNECTOR
LFB - B1 FP-B Close to 0

rmr2008-022-025_a

TYPICAL

If pump does not function, replace it.

Fuel Pump Power Circuit Voltage Test rmr2013-024-001_a

LFB
Disconnect fuel pump (FP) electrical connector.
Set multimeter to Vdc and test circuit voltage as If test failed, repair or replace the faulty wiring.
per FUEL PUMP POWER CIRCUIT TEST table. If test succeeded, wiring is good. Perform the
Turn ignition switch to ON. FUEL PUMP CONTROL CIRCUIT CONTINUITY
TEST.
NOTE: Fuel pump is powered for 3 seconds after
key on if engine is not started. Fuel Pump Control Circuit Continuity
Turn ignition switch ON Test
FUEL PUMP POWER CIRCUIT TEST 1. Remove main relay motor (R3) in LFB to re-
move power from the ECM, refer to POWER
PUMP HARNESS
CONNECTOR
GOOD RESULT DISTRIBUTION AND GROUNDS subsection.
2. Disconnect ECM connector “B” and install it on
FP-B to chassis
Close to battery voltage the ECM ADAPTER TOOL (P/N 529 036 166).
ground

If battery voltage IS NOT read, carry out a FUEL

PUMP POWER CIRCUIT CONTINUITY TEST.
If battery voltage IS read, carry out a FUEL PUMP
CONTROL CIRCUIT CONTINUITY TEST.
If voltage is low to battery ground, test for a short
or partial short circuit to ground with the pump
circuit isolated from parallel circuits, refer to the
WIRING DIAGRAM.
NOTE: A fault in the ECM or in a parallel circuit
may prevent fuel pump operation. Use B.U.D.S. 529036166

to check for fault codes.

12 rmr2014-025
 Subsection 02 (FUEL TANK AND FUEL PUMP)

3. Set multimeter to and test circuit continuity

as per following table.
FUEL PUMP CIRCUIT CONTINUITY
(CONTROL WIRE)
PUMP
ECM RESISTANCE
HARNESS
CONNECTOR @ 20°C (68°F)
CONNECTOR
ECMB- M1 FP-C Close to 0

If test failed, repair or replace the faulty wiring.

If test succeeded, wiring is good. Try a new ECM.
4. Reinstall main relay motor (R3).

Fuel Pump Removal rmr2008-022-022_a

1. Remove fuel tank, see FUEL TANK REMOVAL TYPICAL

in this subsection. Step 1: Rotate pump backward
Step 2: Pull out pump
2. Use an appropriate screwdriver to carefully pry
out the tapered end of fuel pump retainer ring. 5. Discard O-ring seal on pump module.

Fuel Pump Installation

Reverse removal procedure. However, pay atten-
tion to the following:

WARNING
Install a new fuel pump ring seal and retainer
ring.

1. Install and hold a NEW ring seal against fuel

pump flange.
NOTE: Apply some oil on ring seal to ease instal-
lation.
2. Carefully insert pump in fuel tank; be careful not
to damage the float arm on the fuel level sen-
rmr2008-022-021_a
sor.
3. Remove and discard retainer ring.
4. Carefully pull out fuel pump paying attention to
float arm.

rmr2008-022-023_a

TYPICAL - PUMP RING SEAL INSTALLATION

rmr2014-025 13
Subsection 02 (FUEL TANK AND FUEL PUMP)

3. Index fuel pump tab with notch in fuel tank

and ensure pump and O-ring seal are properly
seated.

rmr2008-066-002_a

CLUSTER CONNECTOR PIN OUT

If resistance readings are not as specified, carry

out the CONTINUITY TEST OF FUEL LEVEL SEN-
SOR WIRING.
If resistance readings are as specified, fuel level
sensor and harness wiring are good. Carry out a
rmr2008-022-024_a WOW test of the multifunction gauge using appli-
TYPICAL - PUMP INDEXING cable B.U.D.S. Refer to LIGHTS, GAUGE AND AC-
1. Index tab with notch CESSORIES subsection. Check for proper opera-
4. Install a new fuel pump retaining ring. tion of the fuel level indication during the WOW
test.
WARNING With Analog Fuel Gauge
Ensure retainer ring is properly seated and 1. Remove the analog fuel gauge connector (FG1).
locked.
2. Carry out a fuel level sensor resistance test as
5. Turn ON ignition key to activate fuel pump and per following table.
pressurize fuel system, then check for fuel TEST PROBES
leaks. Refer to FUEL SYSTEM LEAK TEST.
FG1-S Chassis ground
FUEL LEVEL SENSOR FUEL LEVEL SENSOR RESISTANCE TEST
Fuel Level Sensor Resistance Test RESISTANCE READING
FUEL LEVEL
AT 21°C (70°F)
With Digital Fuel Indication in Multifunction
Gauge Empty Approx. 290
1. Remove the multifunction gauge (cluster), re- Full Approx. 80
fer to the LIGHTS, GAUGE AND ACCESSORIES
subsection. If resistance readings are as specified, the fuel
2. Disconnect the multifunction gauge connector. level sensor and it's wiring harness are good. Re-
fer to the LIGHTS, GAUGE AND ACCESSORIES
3. Set multimeter to . subsection.
4. Alternately fill and empty fuel tank, and mea- If resistance readings are not as specified, carry
sure the fuel sensor resistance through the out the CONTINUITY TEST OF FUEL LEVEL SEN-
wiring harness as per following table. SOR WIRING that follows.
FUEL LEVEL SENSOR RESISTANCE TEST
Continuity Test of Fuel Level Sensor
RESISTANCE Wiring
CLUSTER
FUEL LEVEL READING AT
CONNECTOR 1. Disconnect the fuel pump module electrical
21°C (70°F)
connector.
Empty CL-15 to Approx. 290
Full chassis ground Approx. 80

14 rmr2014-025
 Subsection 02 (FUEL TANK AND FUEL PUMP)

With Digital Fuel Indication in Multifunction CONTINUITY TEST OF FUEL LEVEL

Gauge SENSOR WIRING
2. Measure for continuity of the wiring from the RESISTANCE
fuel pump connector (FP) and the multifunction PROBE CONNECTORS READING AT
gauge cluster connector (CL) as per following 21°C (70°F)
table. Refer to WIRING DIAGRAM for details.
FP-A Close to 0
CONTINUITY TEST OF FUEL LEVEL FG1-S
Chassis ground OL (infinite)
SENSOR WIRING
FP-D Chassis ground Close to 0
RESISTANCE
PROBE CONNECTORS READING AT
21°C (70°F) If resistance readings are as specified, refer to
FUEL LEVEL SENSOR BENCH TEST.
CL-15 Close to 0
FP-A If resistance readings are not as specified, carry
Chassis ground OL (infinite) out continuity test at DIC1-D connector pin. Re-
FP-D Chassis ground Close to 0
pair or replace wiring/connectors as required.
NOTE: The D1C1 connector is located between
the fuel gauge and the fuel level sensor.

Fuel Level Sensor Bench Test

1. Remove fuel pump module from fuel tank, refer
to FUEL PUMP in this subsection.
2. Ensure the fuel level sensor is properly con-
nected in the fuel pump module.
3. Measure the resistance at the fuel pump mod-
ule connector (FP).
FUEL LEVEL SENSOR BENCH TEST
rmr2014-025-004_a
FLOAT ROTATIONAL
TYPICAL - CONTINUITY TEST OF FUEL LEVEL SENSOR WIRING PROBE RESISTANCE
1. Fuel pump module connector
POSITION ANGLE
2. Cluster connector
FP- A to Empty 0.0° 290
If resistance readings are as specified, refer to FP-D Full 85° 80
THE FUEL LEVEL SENSOR BENCH TEST.
If resistance readings are not as specified, carry
out continuity test at DIC1-D connector pin. Re-
pair or replace wiring and connectors as required.
NOTE: The DIC1 connector is located between
the air inlet resonator and the instrument console.
With Analog Fuel Gauge
Measure for continuity of the wiring from the fuel
pump connector (FP) and the analog fuel gauge
connector (FG) as per following table. Refer to
WIRING DIAGRAM for details.

rmr2014-025 15
Subsection 02 (FUEL TANK AND FUEL PUMP)
rmr2011-082-005_a
FUEL PUMP
1. Full position
2. Empty position
4. When fuel level sensor travels from full to
empty or vice-versa, there should be a con-
stant linearity to the resistance readings. Any
spike or drop of resistance indicates a "flat
spot" in the fuel level sensor circuitry.
If fuel level sensor fails bench test, replace the
fuel pump module.
FUEL PRESSURE REGULATOR
The fuel pressure regulator is mounted inside the
fuel pump.
The fuel pump pressure hose is connected to the
fuel rail on the RH side of the vehicle. It provides
the full fuel pump pressure to the injector fuel rail.
The pressure regulator regulates the pressure
from the pump by bleeding away excess pres-
sure and returning it to the fuel pump.
16
rmr2014-025-005_a
FUEL PUMP
1. Fuel pressure regulator
2. Pressure outlet
3. Return inlet
4. Fuel pump prefilter
Fuel Pressure Regulator Test
Refer to FUEL SYSTEM PRESSURE TEST in this
subsection for testing procedure.
NOTE: The fuel pressure regulator is an internal
component of the fuel pump module.
Fuel Pressure Regulator Replacement
Replace the fuel pump module. Refer to FUEL
PUMP.
EVAP PURGE VALVE
EVAP Purge Valve Test Using B.U.D.S.
1. Remove LH side panels as required to access
the purge valve. Refer to the BODY subsection.
2. Turn ignition key ON.
3. Using B.U.D.S. software, activate the purge
valve as per following illustration.
rmr2014-025
 Subsection 02 (FUEL TANK AND FUEL PUMP)
rmr2014-025-036_a
TYPICAL - PURGE VALVE ACTIVATION IN B.U.D.S.
Step 1: Select Activation page tab
Step 2: Choose ECM page
Step 3: Click on purge valve icon
You should feel the solenoid within the purge
valve operating.
If operation of the solenoid is felt when activated,
carry out the EVAP PURGE VALVE OPERATION
TEST.
If solenoid does not function, carry out the EVAP
PURGE VALVE SOLENOID TEST.
EVAP Purge Valve Solenoid Test
1. Disconnect the purge valve connector.
2. Connect small jumper wires to the purge valve
solenoid.
3. Momentarily connect the jumper wires to a re-
mote 12 Vdc battery.
If the solenoid does not function, replace it.
If the solenoid functions, carry out the EVAP
PURGE VALVE INPUT VOLTAGE TEST.
EVAP Purge Valve Operational Test
1. Disconnect purge valve vacuum hose from the
intake manifold.
rmr2014-025
rmr2014-025-013_a
1. Purge valve vacuum hose
2. Install the VACUUM/PRESSURE PUMP (P/N 529
021 800) on the vacuum hose.
rmr2014-025-014_a
PURGE VALVE VACUUM HOSE
3. Set vacuum/pressure pump to vacuum func-
tion.
4. Activate vacuum/pressure pump lever until
vacuum reach the specification. Air should not
come through the purge valve. Otherwise,
replace the purge valve.
EVAP PURGE VALVE VACUUM TEST
20 kPa (3 PSI) for 10 seconds
5. Turn ignition key ON.
6. Using the applicable B.U.D.S. software, ac-
tivate the purge valve as illustrated in EVAP
PURGE VALVE TEST USING B.U.D.S.
Air should now flow through the purge valve
when you apply vacuum with the vacuum/pres-
sure pump. If it does not, replace purge valve.
7. Remove the vacuum/pressure pump and recon-
nect the vacuum hose on the intake manifold.
8. Install all removed parts in the reverse order of
removal.
17
Subsection 02 (FUEL TANK AND FUEL PUMP)

EVAP Purge Valve Input Voltage Test

1. Disconnect the purge valve connector.
2. Turn ignition switch to ON.
3. Set multimeter to Vdc and test circuit voltage
as per following table.
EVAP PURGE VALVE INPUT VOLTAGE TEST
PURGE VALVE
GOOD RESULT
SOLENOID
EVAP-2 to chassis
Close to battery voltage
ground rmr2013-024-001_a

LFB

If continuity is not good, repair or replace wiring

and connectors between fuse box and valve con-
nector.
If continuity is good, carry out the EVAP PURGE
VALVE CONTROL CIRCUIT TEST in this subsec-
tion.

EVAP Purge Valve Control Circuit Test

(Continuity)
rmr2014-025-029_a 1. Disconnect “A” connector from the ECM and
EVAP connect it to the ECM ADAPTER TOOL (P/N 529
036 166).
If input voltage is as specified, carry out the
PURGE VALVE CONTROL CIRCUIT TEST. 2. Set multimeter to and test for continuity of
the purge valve control circuit (ground) as per
If input voltage is not as specified, check fuse F8. following table.
NOTE: If fuse F8 is open, the starter solenoid will EVAP PURGE VALVE CONTROL CIRCUIT TEST
not function either.
EVAP PURGE
If fuse is good, carry out a PURGE VALVE INPUT ECM
VALVE RESISTANCE
CIRCUIT TEST (CONTINUITY) in this subsection. HARNESS
CONNECTOR
@ 20°C (68°F)
“A”
CONNECTOR
EVAP Purge Valve Input Circuit Test
(Continuity) Close to 0
EVAP-1 ECMA-M3
(continuity)
1. Remove fuse F8 in LFB.
2. Disconnect the purge valve connector. If ground circuit is faulty, repair/replace wiring/con-
3. Set multimeter to and test for continuity of nector.
the purge valve input circuit as per following ta- 3. Reinstall main relay motor (R3).
ble.
EVAP Purge Valve Replacement
EVAP PURGE VALVE INPUT CIRCUIT
TEST (CONTINUITY) EVAP Purge Valve Removal
EVAP PURGE 1. Remove LH side panels as required to access
VALVE RESISTANCE the purge valve. Refer to the BODY subsection.
LFB
HARNESS @ 20°C (68°F)
CONNECTOR
Close to 0
EVAP-2 LFB-D4
(continuity)

18 rmr2014-025
 Subsection 02 (FUEL TANK AND FUEL PUMP)

rmr2014-025-020_a
rmr2014-025-037_a
EVAP VENT HOSE ROUTING
EVAP PURGE VALVE LOCATION
1. EVAP purge valve
5. Reconnect purge valve connector.
2. Disconnect purge valve electrical connector
(EVAP). Evap Canister
3. Remove Oetiker clamps securing hoses to Evap Canister Removal
purge valve. 1. Remove rear cargo module. Refer to BODY.
4. Pull hoses off valve.
EVAP Purge Valve Installation
1. Carry out a functional test of the purge valve
prior to installation using a remote 12 Vdc bat-
tery and the VACUUM/PRESSURE PUMP (P/N 529
021 800) as described in PURGE VALVE OPER-
ATIONAL TEST in this subsection.
2. Install purge valve with flow arrow pointing to-
wards intake manifold. rmr2014-025-024_a

REAR CARGO MODULE

rmr2011-023-003_b rmr2014-025-022_a

1. Purge valve location EVAP CANITER LOCATION

3. Secure hoses to the purge valve using NEW 2. Release locking tab and slide evap canister to-
Oetiker clamps. wards rear of vehicle.
4. Ensure proper EVAP vent hose routing. Refer
to exploded view if necessary.

rmr2014-025 19
Subsection 02 (FUEL TANK AND FUEL PUMP)

rmr2014-025-021_a

CANISTER PRE-FILTER ON VEHICLE

rmr2014-025-023_a
Canister Pre-Filter Inspection
EVAP CANISTER - RH VIEW
1. Locking tab No inspection necessary, replace according to PE-
RIODIC MAINTENANCE SCHEDULE.
3. Remove Oetiker clamps securing hoses to evap
canister. Canister Pre-Filter Installation
Evap Canister Inspection Reverse the removal procedure.
Check canister and vent hoses for: Vent valve
– Proper rooting an kinks
Vent Valve Removal
– Leaks
– Cracks 1. Remove body parts on the LH side of the vehi-
cle as required to access the vent valve. Refer
– Loose connections to the BODY subsection.
– Secure Oetiker clamps
2. Disconnect vent hose from vent valve.
Evap Canister Installation 3. Push down on vent valve and rotate to remove.
Reverse the removal procedure.
NOTE: Use the exploded view to ensure proper CAUTION The vent valve must be pushed
vent hose routing. down for the entire quarter turn to not damage
the locking mechanism.
Canister Pre-Filter
Canister pre-Filter Removal
1. Remove body parts on the LH side of the vehi-
cle as required to access canister pre-filter. Re-
fer to the BODY subsection.
2. Remove Oetiker clamp securing hose to canis-
ter pre-filter.
3. Disconnect vent line from canister pre-filter.
4. Remove push pins securing canister pre-filter to
chassis.

rmr2014-025-019_a

VENT VALVE ON FUEL TANK

Vent Valve Inspection

1. Install VACUUM/PRESSURE PUMP (P/N 529 021
800) onto vent valve.

20 rmr2014-025
 Subsection 02 (FUEL TANK AND FUEL PUMP)

2. Set vacuum/pressure pump to vacuum and

draw air through vent valve fitting.
2.1 When vent valve is upright, air should flow.
2.2 When vent valve is upside down, air
should not flow.
Vent Valve Installation
Reverse the removal procedure, ensure not to
pinch hoses - respect proper routing shown in
exploded view.

rmr2014-025 21
 Subsection 01 (POWER DISTRIBUTION AND GROUNDS)

POWER DISTRIBUTION AND GROUNDS

GENERAL
POWER DISTRIBUTION DIAGRAM
Use the POWER DISTRIBUTION DIAGRAMS lo- Power Bus Bar
cated in the pocket on the back cover page of the The fuse boxes are single bus bar type which feed
manual. power to the main fuses (J-case type) through
CONNECTOR CODE DESCRIPTION their lower contact. Power comes either directly
from the battery or from the alternator.
ACC Accessories
ACS Adjustable controlled suspension
BLS Brake lights switch
CAN/US Canada/United States
CAPS Camshaft position sensor
CSS Compressor suspension sensor
CSV Clutch valve solenoid
CTG Coolant temperature gauge
D.E.S.S. Digitally encoded security system rmr2013-024-002_b

FUSE BOX (LFB AND RFB)

DLC Diagnostic link connector 1. Power bus bar

DPS Dynamic power steering Power Top Contacts

ECM Engine control module The top contacts distribute power to the sec-
ondary fuses (blade type) and relays, which in
VR Voltage regulator
turn, redistribute it to the subsystems or compo-
FHGS Front heated grip switch nents.
FGS Fog light switch
HAS Hood Actuator Switch
MSR Multifunction switch right
LFB Left fuse box
PBM Parking brake module
PBS Parking brake switch
PRS Pillion rider (passenger) switch
RFB Right fuse box
rmr2013-024-200_a

SAS Steering angle sensor FUSE BOX (LFB AND RFB)

1. Power top contacts
TCM Transmission control module
VCM Vehicle control module
WPM Windshield and parking brake module
YRS Yaw rate sensor

rmr2014-026 1
Subsection 01 (POWER DISTRIBUTION AND GROUNDS)

MAIN POWER AND GROUND LEFT FUSE BOX (LFB)

CABLES

rmr2013-024-002_a

J-Case Fuse Identification (J1 to J5)

rmr2014-026-001_a

1. RFB Direct battery power is supplied J1 to J5 fuses.

2. LFB
3. DPS ground J-CASE
4. Chassis ground DESCRIPTION RATING
5. Engine ground FUSE NO.
6. Starter B+
7. Alternator B+
8. Starter solenoid J1 VCM pump 40 A

J2 VCM valves 25 A
FUSES AND RELAYS LOCATION
J3 DPS 40 A
There are 2 fuse boxes and they are located in the
front storage compartment. J4 Main control 40 A
Relays are located in both fuse boxes. J5 Not Used

rmo2013-003-011_a

INSIDE FRONT STORAGE COMPARTMENT

1. Left fuse box (LFB)
2. Right fuse box (RFB)

2 rmr2014-026
 Subsection 01 (POWER DISTRIBUTION AND GROUNDS)

Blade Fuse Identification (F1 to F8) Relay Identification (R1 to R6)

NO. DESCRIPTION Direct battery power is supplied to R3, R4 and
Direct battery power: R5.
– Cluster (clock) NO. DESCRIPTION
F1 – 15 A
R1 Reverse actuator
– Hazard lights
– Diagnostic link connector (DLC) R2 Pre-starting
Through ignition switch (KEY ON):
R3 Main power
– Steering angle sensor (SAS)
– Yaw rate sensor (YRS) R4 Suspension
F2 – Vehicle control module (VCM) 10 A R5 Not used
– Engine control module (ECM)
R6 Main headlamps
– D.E.S.S.
– Pillion rider switch (PRS)
Power from main power relay (KEY RIGHT FUSE BOX (RFB)
F3 ON) (R3): NA
– Alternator exciting circuit
Power from main power relay (KEY ON)
F4 (R3) 20 A
– WPM
Power from main relay (KEY ON) (R3)
F5 Through fuse: 5A
– ECM
Power from main power relay (R3)
F6 Through fuse: 15 A
– Injectors / Coils
rmr2013-024-002_a
Power from main power relay (KEY ON)
(R3)
Through fuse:
J-Case Fuse Identification (J1 to J5)
– Wake-up TCM Direct battery power is supplied J1 to J5 fuses.
– DLC J-CASE
– DPS FUSE DESCRIPTION RATING
– Cluster NO.
F7 – Coolant temp gauge (some models) 10 A J1 Cooling fan 30 A
– Fuel gauge (some models)
J2 Accessories 40 A
– Front storage LED (some models)
– Hood actuator switch (some models) J3 TCM solenoids 20 A
– Illumination (gauges/switches) J4 LO headlamps 30 A
– DC acc plug relay (R6) (control)
J5 HI headlamps 20 A
– Reverse acuator relay (R1) (control)
– Cooling fan relay (R3) (control)
Power from main power relay (KEY ON)
(R3)
Through fuse:
– H02S
F8 – CAPS 15 A
– Fuel pump
– EVAP
– Clutch solenoid valve
– Pre-starting relay (R2)

rmr2014-026 3
Subsection 01 (POWER DISTRIBUTION AND GROUNDS)

Blade Fuse Identification (F1 to F8) RELAYS

NO. DESCRIPTION Relays
Direct battery power: NOTE: The 4-pin relays can be inverted by 180° at
– Ignition switch installation.
Through ignition switch: Relay Activation
F1 – Day lights 15 A
RELAY ACTIVATION CONDITION
– Pilot lights
– Tail lights Main
– License plate light power relay
When key ON
(Left fuse box
Direct battery power: - LFB)
F2 – Brake light switch 10 A
When engine speed
– Hazard switch Load shedding reaches approx. 600 RPM
Direct battery power (some models): (Right fuse box AND
F3 15 A - RFB) Battery voltage is higher
– Radio
than 11 Vdc.
Direct battery power (some models):
F4 10 A
– Trailer Relay Deactivation
Direct battery power: RELAY DEACTIVATION CONDITION
F5 – Horn 20 A Main
– Load shedding relay (R3) power relay
Approx. 40 minutes after key OFF
Power from main power relay (KEY (Left fuse box
F6 ON) (R3) 10 A - LFB)
– DC front/rear acc plug relay When engine speed is lower
Load shedding than approx. 600 RPM
Direct battery power: (Right fuse OR
F7 10 A box - RFB) Battery voltage is lower
– Front/rear DC acc plugs
than 11 Vdc
F8 NOT USED NA
Relay Pin Identification
DC PLUGS: FRONT/REAR ACCESSORY PLUGS MAIN RELAY ACCESSORIES
From factory: Powered when (R3) PIN IDENTIFICATION
key ON (Vkey) through F6 (LEFT FUSE BOX - LFB)
FUSE
Customization: Always powered (Vbat); remove FUNCTION BOX CONDITION
fuse at F6 location and install at F7 location PIN
12 V input Direct battery power
Relay Identification (R1 to R6) at winding
LFB-86
From J4
Direct battery power is supplied to R1, R2, R3 Grounded by ECM B,
and R5. pin H2 with Key ON
Control LFB-85
NO. DESCRIPTION Turns OFF approx. 40
minutes after key OFF
R1 Hi headlamp
12 V input Direct battery power
R2 Lo headlamp LFB-30
at contacts From J4
R3 Cooling fans 12 V See POWER DISTRIBUTION
LFB-87
R4 Load shedding
output DIAGRAM

R5 Fans reverse 1
R6 Fans reverse 2

4 rmr2014-026
 Subsection 01 (POWER DISTRIBUTION AND GROUNDS)

LOAD SHEDDING RELAY

(R4) PIN IDENTIFICATION
(RIGHT FUSE BOX - RFB)
FUSE
FUNCTION BOX CONDITION
PIN
Direct battery power
12 V input
RFB-C8
at winding
From J2, then F5
Grounded by Cluster, pin 1 rmr2014-026-005_a
Control RFB-D7 when engine reaches approx. MAIN GROUND CABLE - MOT
800 RPM
Direct battery power
12 V input
RFB-C7
at contacts
From J2, then F5
See POWER DISTRIBUTION
12 V output RFB-D8
DIAGRAM

FUSE BOX PIN IDENTIFICATION

rmr2014-026-004_a

MAIN GROUND CABLE - DPS

Electrostatic Grounds
For fuel tank grounds, refer to exploded view in
FUEL TANK AND FUEL PUMP subsection.

rmr2013-024-300_a

LH AND RH FUSE BOXES

GROUNDS
Main Ground Locations

rmr2014-025-025_a

STATIC GROUND - GND7

1. Fuel tank ground wires

Antenna support ground (not shown on wiring di-

agram).

rmr2014-026-003_a

MAIN GROUND CABLE - GND1

rmr2014-026 5
Subsection 01 (POWER DISTRIBUTION AND GROUNDS)

rmr2014-026-006_a

STATIC GROUND
1. Antenna support
2. Braided ground

6 rmr2014-026
 Subsection XX (WIRING HARNESS AND CONNECTORS)

WIRING HARNESS AND CONNECTORS

SERVICE TOOLS
Description Part Number Page
CRIMPING TOOL (HEAVY GAUGE WIRE) .................................... 529 035 730 ........................................... 14
CRIMPING TOOL (KOSTAL).......................................................... 529 035 909 ........................................... 11
ECM ADAPTER TOOL................................................................... 529 036 166 ............................................. 8
ECM TERMINAL REMOVER 2.25................................................. 529 036 175 ............................................. 8
ECM TERMINAL REMOVER 3.36................................................. 529 036 174 ............................................. 8
KOSTAL DIE .................................................................................. 529 035 906 ........................................... 11

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
DELPHI TERMINAL EXTRACTOR ................................................. 12094429 ........................................... 10
TOOL ............................................................................................. AMP- ..................................... 11–12
755430-2

GENERAL
The illustrations in this subsection are typical. Several variants of the connector types, such as different
number of pin cavities, are used on the vehicle.

CONNECTOR ABBREVIATION DESCRIPTION

ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION
Ambient Air Pressure ant Temperature CIC Cargo Inter-connector
AAPTS
Sensor
CL Cluster
ANT Antenna (D.E.S.S.)
COIL Ignition Coil
ACS Adjustable Control Suspension
CSS Compressor Suspension Switch
AUX Audio Connector
CSV Clutch Solenoid Valve
BA Backup Actuator
CTG Coolant Temperature Gauge
BAT Battery
CTS Coolant Temperature Sensor
BLS Brake Light Switch
CES Clutch Switch CL Cluster
BSF Brake Fluid Level Sensor CPS Crankshaft Position Sensor
D2 Diode (starter solenoid)
BHL Bottom Headlight
D3 Diode (ground JT BK10, D3-C, D3-A)
BL Backup Light
DC Accessories 12 Vdc
BLS Brake Light Switch
BST Booster post
CAPS Camshaft Position Sensor
CB Citizen Band DIC Dashboard Inter-connector
CES Clutch Engage Switch
CHAS Ground (frame)

rmr2013-025 1
Subsection XX (WIRING HARNESS AND CONNECTORS)

ABBREVIATION DESCRIPTION HIC Harness Inter-Connector

DLC Diagnostic Link Connector
HL Headlight
HN Horn
HO2S
DPS Dynamic Power Steering Oxygen Sensor

HS Headset

ECM Engine Control Module INJ Injector

EOPS Engine Oil Pressure Switch IK Ignition Key Switch

ETA Electric Throttle Actuator KIC Ignition Key

EVAP EVAP Purge Valve KS Knock Sensor

FB Rectifier/regulator fuse
LBHL Right Bottom Headlight
FCS Front Storage Switch
LCS Left Case Switch
FG
Fuel Gauge LDL Left Daylight

FGS Fog Light Switch LED Front Case LED

FHS Front Heated Grip Switch LHL Left Headlight

FL Fog Light LFB Left Fuse Box

FLF Front Left Flasher LPS Low Brake Pressure Switch

FLH Front Left Heated Grip LRHL Left/Right Headlight

FLS Left Tail Light

Front Left Speaker LTL (Brake, position and turn signal
lights)
FP Fuel Pump MAPS Manifold Absolute Pressure Sensor
FPL MOT Ground (engine)
Front Position Lights

FRF Front Right Flasher

FRH Front Right Heated Grip
FRS MSL
Front Right Speaker Left Multifunction Switch

FSA Front Storage Actuator MSR Right Multifunction Switch

FSS Front Storage Switch
GBPS Gearbox Position Sensor
PBM
GND Ground
Parking Brake Module

PBS Parking Brake Switch

GPS
GPS (global positioning system) PIC
Panel Inter-Connector
GSC Gear Solenoid Connector
PL License Plate Light
HA Hood Actuator
PRC Passenger Radio Control
HBS Parking Brake Light Switch

2 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

PRS Pillion Rider Switch VCM Vehicle Control Module

Pressure and Temperature Sensor VIM Vehicle Immobilizer Module
PTS
Connector (AAPTS) (theft protection device)
R1, R4, R5 Resistor (compressor suspension switch) VR Voltage Regulator
RBHL Right Bottom Headlight VSS
RCF Cooling Fan (right) Vehicle Wheel Speed Sensor
RCS Right Case Switch
RDL Right Daylight WM
Adjustable Windshield Motor
RDO1 Radio
RFB Right Fuse Box WPM Windshield and Parking Brake Module

RHL Right Headlight YRS Yaw Rate Sensor

RHS Rear Heated Grip Control

RLF Rear Left Flasher
RLH Rear Left Heated Grip
RLS
Rear Left Speaker

RRF Rear Right Flasher

RRH Rear Right Heated Grip
RRS
Rear Right Speaker

Right Tail Light

RTL (Brake, position and turn signal
lights)
SAS Steering Angle Sensor
SH Shutter (HI/LO beam)
SM Starter Motor
SPK Spark plug
SPS Suspension Position Sensor
SRS Suspension Release Sensor
SRV Suspension Release Valve
STS Starter Solenoid

TANK Ground (fuel tank)

TAS Throttle Accelerator Sensor
TCM Transmission Control Module
TCS Top Case Switch
TIC Transmission Control Module (interface)
TL Tail Light
TPS Throttle Position Sensor

rmr2013-025 3
Subsection XX (WIRING HARNESS AND CONNECTORS)

PROCEDURES
WIRING HARNESS
Wiring Harness Replacement
The wiring harness is routed through the center of
the SST frame.

rdd2011-001-025

Begin by taping all the connectors together flat

and lined up behind one another.

rdd2011-001-023

It exits through the bottom rear of the SST frame.

rdd2011-001-026_a

1. Upper frame member opening

Leave the pull through loop that is incorporated

into the harness exposed.

rdd2011-001-024

All these connectors need to be pulled through

the frame.

rdd2011-001-027

4 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

Snake a pull wire through the frame and loop it 1

through the pull loop. Secure the pull wire so it
does not come out of the loop. Spray the harness
and top frame tube inside liberally with WD-40® or
equivalent.
Carefully pull the harness through the frame from
the front to the rear.

F18Z0LA 2
TYPICAL
1. Flat screwdriver
2. Deutsch connectors

rdd2011-001-028

DEUTSCH CONNECTOR
Deutsch Connector Identification
The Deutcsh connectors are easily identified by
the orange secondary lock inserted in front of the
female terminals.

F18Z0NA 2 1
3 1
TYPICAL
1. Deutsch connectors
2. Press release button

Deutsch Terminal Replacement

NOTICE Do not apply dielectric grease on ter-
minal inside connector.
3
2 To remove terminals from connector, proceed as
4 follows:
F00H1CA
– Using a long nose pliers, pull out the lock.
1. Male connector
2. Female connector
3. Secondary lock (orange)
4. Sealing cap

Deutsch Connector Removal

To disconnect the Deutsch connectors, twist a
small flat screwdriver between each housing to
disengage, press the release button and discon-
nect them.

rmr2013-025 5
Subsection XX (WIRING HARNESS AND CONNECTORS)

V01G0QA 1
TYPICAL — FEMALE CONNECTOR
V01G0OA 1 1. Retaining tab

TYPICAL — FEMALE CONNECTOR To install:

1. Female lock
3. For insertion of a terminal, make sure the lock
is removed.
4. Insert terminal into appropriate cavity and push
as far as it will go.
5. Pull back on the terminal wire to be sure the
retention fingers are holding the terminal.
6. After all required terminals have been inserted,
the lock must be installed.

1 1
V01G0PA 1
TYPICAL — MALE CONNECTOR
1. Male lock

NOTE: Before extraction, push wire forward to re-

lieve pressure on retaining tab.
1. Insert a 4.8 mm (.189 in) wide screwdriver F04H6LA
blade inside the front of the terminal cavity.
TYPICAL
2. Pry back the retaining tab while gently pulling 1. Wire identification numbers
wire back until terminal is removed.
MOLEX CONNECTOR (ECM)
There are two 48-pinconnectors on the ECM.

6 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

CONNECTOR
CONNECTION
IDENTIFICATION
A Engine wiring harness
B Vehicle wiring harness

Do not apply any lubricant product to the pins of

the connector on the ECM.

smr2009-045-012_a

Pull out connector.

smr2009-027-005

ECM CONNECTORS

MOLEX Connector Removal

To reach ECM connector, refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.
Push and hold the locking tab of the desired con-
nector.

smr2009-045-013_a

MOLEX Connector Installation

Fully open connector lock.

smr2009-045-011_a

Rotate connector lock until it stops.

smr2009-045-013_b

Install connector to ECM.

Rotate connector lock until it snaps locked.

rmr2013-025 7
Subsection XX (WIRING HARNESS AND CONNECTORS)

NOTICE Never probe directly on ECM har-

ness connector. This could change the shape
or enlarge the terminals and create intermit-
tent or permanent contact problems.

MOLEX Terminal Replacement

(Harness Connector)
To remove a signal terminal from ECM harness
connector, use the ECM TERMINAL REMOVER 2.25
(P/N 529 036 175). To remove a power terminal,
use the ECM TERMINAL REMOVER 3.36 (P/N 529
036 174).

smr2009-045-011_b

1. Locked here

MOLEX Connector Probing

The most recommended and safest method to
probe ECM connector terminals is to use the ECM
ADAPTER TOOL (P/N 529 036 166). This tool will
prevent deforming or enlarging terminals which
would lead to bad ECM terminal contact creating 529036175

intermittent or permanent problems.

Remove rear protector from connector.
Pull out the connector lock.

529036166

Disconnect the desired ECM connector and re-

connect on the probing tool. Probe required
terminals directly in the tool holes.
smr2009-045-025_a

Insert tool to unlock terminal.

vmr2008-139-016_a

TYPICAL
1. ECM connector
2. ECM adapter

8 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

smr2009-045-026_a

1. Unlock here

vmr2006-032-001_a

TYPICAL – GAUGE CONNECTOR

Packard Connector Terminal

Replacement
Push on both tabs to remove retainer.

smr2009-045-027_a

WARNING
Before terminal installation, ensure all ter-
minals are properly crimped on wires. After
rmr2008-078-053_a
plugging connectors, ensure they are prop-
TYPICAL – TCM CONNECTOR
erly fastened. 1. Retainer
2. Tab (one on each side)

PACKARD CONNECTOR (TCM
AND GAUGE)
Packard Connector Removal
Firmly push down tab and hold to unlock connec-
tor while pulling it out.
Cut locking tie securing connector housing to har-
ness.
Open housing by lifting 3 tabs.

rmr2008-078-054_a

TYPICAL – TCM CONNECTOR

1. Tabs

rmr2013-025 9
Subsection XX (WIRING HARNESS AND CONNECTORS)

Lift the top plastic lock of the female terminal to

be removed and hold in position. Lift the female
terminal to unlock from the housing and push out
of housing.

smr2009-045-014_a

1. Unlock terminal here

A32E3XA

TYPICAL
1. Lift and hold plastic lock
2. Lift to unlock and push out smr2009-045-015_a

WARNING
Before terminal installation, ensure all ter-
minals are properly crimped on wires. After
plugging connectors, ensure they are prop-
erly fastened.
WARNING
Before terminal installation, ensure all ter-
minals are properly crimped on wires. After
plugging connectors, ensure they are prop-
erly fastened.

DELPHI CONNECTORS (DPS) AMP MULTILOCK CONNECTOR

Delphi Connector Terminal Connector Disassembly (Male
Replacement Housing)
To remove a terminal from connector, use a spe-
cial tool such as the DELPHI TERMINAL EXTRAC-
TOR (P/N 12094429).
NOTE: Grinding the tool end to make it smaller is
required.

A32Z01A

10 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

Insert TOOL (P/N AMP-755430-2) under lock and

twist to lift it.

1
A32Z05A 1
FEMALE HOUSING — CUT-AWAY
1. Lock

Terminal Crimping (Multilock and AMP

8-circuits)
To crimp a new connector terminal, use the
A32Z02A
CRIMPING TOOL (KOSTAL) (P/N 529 035 909) and
the KOSTAL DIE (P/N 529 035 906).
MALE HOUSING — CUT-AWAY
1. Lock

Female terminals can be removed from housing

with sharp head pin.

Connector Disassembly (Female

Housing)
529035909

CRIMPING TOOL

To properly crimp the wires, strictly follow this pro-

cedure.
Strip the wire to a maximum of 3 mm (1/8 in).

A
A32E2QA

TYPICAL
A. 3 mm (1/8 in) max.

A32Z04A
Position wire in terminal.
Squeeze the terminal tabs with your fingers to
Insert TOOL (P/N AMP-755430-2) under lock and temporarily retain terminal in place.
twist to lift it.

rmr2013-025 11
Subsection XX (WIRING HARNESS AND CONNECTORS)

A33Z04A 1
1. Lock
A32E3YA

Insert TOOL (P/N AMP-755430-2) under tab and pry

Insert terminal with wire in crimping pliers and po- it to free connector. Pull on the female terminal
sition so that top of terminal tabs are flush with wire to remove female terminal from housing.
pliers edge or a little bit lower as shown.

A33Z05A 1
AMP 8-CIRCUIT CONNECTOR — CUT-AWAY
1. Tab

Terminal Crimping
Refer to TERMINAL CRIMPING (MULTILOCK
A32E3ZA
AND AMP 8-CIRCUITS) for procedure.
1. Top of terminal tabs
2. Align tabs with pliers edge
DELPHI CONNECTOR (VCM)
Crimp terminal. Ensure no tiny wire goes out of
terminal. This might cause strange problems of
VCM Connector Removal
the electrical system. WARNING
VCM motor and valves are continuously
AMP CONNECTOR (8-CIRCUIT) powered from battery. Always disconnect
Connector Disassembly the battery prior to disconnecting VCM con-
nector.
Pry housing to release lock.

NOTICE Improper connector handling may

lead to breakage.
Slide out the RED locking device.

12 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

VCM Connector Installation

Ensure lock lever it fully opened.

rmr2013-025-230_a

1. RED locking device

Pull the locking lever.

rmr2013-025-232_a

1. Lock lever fully opened

Position the connector on the ECM.

Pivot lock lever to the end of its stroke.
Fully slide the RED locking device to secure the
locking lever.

rmr2013-025-231_a

1. Locking lever

Pivot lock lever until it reaches the end of its

stroke.

rmr2013-025-230_b

rmr2013-025-232_a

1. Lock lever fully opened

Pull out connector.

rmr2013-025 13
Subsection XX (WIRING HARNESS AND CONNECTORS)

VCM Connector Disassembly

A32E2RA

INSTALLATION OF TERMINAL

Follow the instructions provided with the CRIMP-

ING TOOL (HEAVY GAUGE WIRE) (P/N 529 035 730)
to select the proper position of the tool.

rmr2013-025-233_a

Step 1: Cut locking ties

Step 2: Slide down cover
Step 3: Unlock cover here (both sides) 529035730
Step 4: Lift up cover
NOTE: Different wires require different crimp pli-
Use an appropriate terminal extraction tool to un- ers settings, so make sure to follow the instruc-
lock and push terminal out. tion supplied with the tool.

BATTERY CABLE TERMINAL

Terminal Installation
Carefully strip the wire approximately to 13 mm
1
(1/2 in) in length, using a wire stripping tool or
sharp blade/knife.

2
A A32E2SA

A32E2QA
POSITIONING THE CRIMP PLIERS
Step 1: Press
A. 13 mm (1/2 in) Step 2: Rotate

NOTE: Make sure not to cut wire strands while After positioning the crimp pliers, crimp the termi-
stripping the wire. nal already installed on wire.
Install the appropriate terminal on the wire ac-
cording to the requirement. Refer to appropriate
PARTS CATALOG.

14 rmr2013-025
 Subsection XX (WIRING HARNESS AND CONNECTORS)

A32E2TA

CRIMPING OF WIRE

A32E2UA

PROPERLY CRIMPED WIRE

To verify, if the wire is properly crimped, apply

some pulling force on wire and the terminal at the
same time from both directions.
NOTICE Never solder the wire to the termi-
nal. Soldering can change the property of the
wire and it can become brittle and break.
Install the protective heat shrink rubber tube on
the terminal. Heat the heat shrink rubber tube us-
ing the heat gun so that it grasps the wire and the
terminal.
NOTICE Make sure that the protective heat
shrink rubber tube has been properly installed
and no part of wire is exposed.

rmr2013-025 15
 Subsection 03 (IGNITION SYSTEM)

IGNITION SYSTEM
SERVICE TOOLS
Description Part Number Page
ECM ADAPTER TOOL................................................................... 529 036 166 ................................. 3, 6–7, 9
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................................. 3, 6–7, 9

SERVICE PRODUCTS
Description Part Number Page
HEAT-SINK PASTE P12.................................................................. 420 897 186 ............................................. 8
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 8

GENERAL Cylinder 1 is on the RH side of the engine (clutch

side).
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed, must be
replaced (e.g.: locking tabs, elastic stop nuts,
self-locking fasteners, cotter pins, etc.).

Cables and locking ties removed during a proce-

dure must be reinstalled as per factory standards.
NOTICE Never force a multimeter probe into
an electrical terminal.

SYSTEM DESCRIPTION
The engine control module (ECM) controls the ig- rmr2014-027-001_a

TYPICAL - SE6 ENGINE ILLUSTRATED

nition system, as well as many other engine re- 1. Ignition coil #1 (RH, clutch side)
lated functions. 2. Ignition coil #2 (center)
3. Ignition coil #3 (LH, belt side)
The battery supplies power to the primary side of 4. ECM
the ignition coils through a relay while the ECM
completes the circuit to each coil primary winding Ignition Timing
by switching it to ground at the appropriate mo- Ignition timing is not adjustable.
ment.
The ECM is programmed with ignition maps that
The ignition system is a digital inductive type (IDI) it uses along with data received from a variety of
system. sensors to establish optimum ignition timing un-
Ignition system parameters such as ignition tim- der all engine operating conditions.
ing, dwell time, and firing order, are controlled by The firing of each spark plug is independent of the
the ECM in order to meet engine operational re- other(s).
quirements.
Direct ignition coils (stick coils) are used for each Engine RPM Limiter
cylinder. The ECM will limit the maximum engine speed by
When the ground signal provided to an ignition coil cutting off ignition spark and fuel at a predeter-
primary winding is cut off by the ECM, a high volt- mined engine RPM.
age is induced in the ignition coil secondary wind-
ing that is used to produce a spark at the spark
plug electrode.

rmr2014-027 1
Subsection 03 (IGNITION SYSTEM)
ENGINE SPEED LIMITATION
8100 RPM with drivetrain engaged
7500 RPM in neutral or with clutch disengaged
TROUBLESHOOTING
It is good practice to check for fault codes using
B.U.D.S. as a first troubleshooting step. Refer to
DIAGNOSTIC AND FAULT CODES subsection.
Refer to POWER DISTRIBUTION AND GROUNDS
for information on fuses and relays.
Always refer to the WIRING DIAGRAM when
troubleshooting an electrical circuit.
NOTE: Install a battery charger on battery termi-
nals in front storage compartment for any tests
that involve a prolonged "key ON" period. If bat-
tery voltage gets too low, some accessories are
shut off by the ECM and test results can be al-
tered.
NOTICE Never force a multimeter probe into
an electrical terminal.
TROUBLESHOOTING
GUIDELINES
Lights or Gauge do not come on when
the Ignition Switch is turned ON
1. Check battery and battery cable condition.
2. Carry out an IGNITION SWITCH OPERATION
TEST see procedure in this subsection.
Misfires or no Ignition Spark
1. Check fuse F6 in LH fuse box (LFB).
2. Ensure ignition coils are properly installed and
connected.
3. Check spark plug(s), refer to SPARK PLUGS in
this subsection.
4. Ensure the HIC connector (engine harness to
main vehicle harness interconnect) is properly
connected. Check condition of connector pins
and ensure they are properly locked in the con-
nector. Pay particular attention to pins 1, 2 and
3.
5. Carry out an ignition coil test using B.U.D.S..
Refer to IGNITION COILS in this subsection.
2 rmr2014-027
PROCEDURES
IGNITION SWITCH
Ignition Switch Circuit Functions
IGNITION SWITCH CIRCUIT FUNCTIONS
PINS CIRCUIT FUNCTIONS
A – G Ignition
B – F Lights
M – I Ignition circuit to ground
Ignition Switch Operation Test
Turn ignition switch ON. The following should
come on:
– Multifunction gauge (assuming it works)
– LH and RH marker lights
– License plate light
– LH and RH taillights.
If Nothing Came ON, Check the Following in
this Order:
1. J4 main fuse in LH fuse box (LFB).
2. Fuses F1 (RFB) and F2 in (LFB) (both must be
blown for complete quick test failure).
3. Voltage at J4 fuse input terminal.
If there is no voltage, check for an open circuit be-
tween battery and LH fuse box.
If there is voltage, check for an open circuit be-
tween J4 fuse and fuses F1 (RFB) and F2 (LFB).
If Lights Came ON but the Multifunction
Gauge did not, Check the Following in this
Order:
1. Fuse F2 in LH fuse box.
2. Main relay R3 in LFB and related circuits, re-
fer to POWER DISTRIBUTION AND GROUNDS
subsection and the WIRING DIAGRAM.
3. Multifunction gauge connector, and associated
circuits.
4. Carry out an IGNITION SWITCH OUTPUT VOLT-
AGE TEST (TO ECM).
Ignition Switch Output Voltage Test
(to ECM)
NOTE: This circuit provides the ECM wake-up
voltage signal.
1. To gain access to the ECM connector, refer
to ECM LOCATION ACCESS in ELECTRONIC
FUEL INJECTION (EFI) subsection.
 Subsection 03 (IGNITION SYSTEM)

2. Disconnect ECM-B connector and install it on Probe switch contacts as per table below and note
the ECM adapter tool. For connector identifi- resistance values.
cation, refer to WIRING HARNESS AND CON-
NECTOR subsection.
3. Set multimeter to Vdc.
REQUIRED TOOLS
FLUKE 115
ECM ADAPTER TOOL
MULTIMETER
(P/N 529 036 166)
(P/N 529 035 868)

4. Turn ignition switch ON.

rmr2008-023-503_a
NOTE: Because of lights and accessories current
consumption, a slight battery voltage drop is nor- IGNITION SWITCH CONTINUITY TEST
mal.
IGNITION SW IGNITION SW
5. Measure voltage as per table. TEST PROBES
OFF ON
A – G Infinite (OL) Close to 0
B – F Infinite (OL) Close to 0
M – I Close to 0 Infinite (OL)
Any other pin
Infinite (OL) Infinite (OL)
combinations
Any pin to
Infinite (OL) Infinite (OL)
battery ground

The following gives the circuit functions through

smr2009-030-010_d ignition switch:
IGNITION SWITCH OUTPUT VOLTAGE If you do not obtain the above resistance values,
TEST (TO ECM) replace the ignition switch.
TEST PROBES VOLTAGE NOTE: Replace ignition switch and D.E.S.S. mod-
ule as a unit.
ECM connector
Ground Battery voltage
"B" pin A2 Ignition Switch Removal
If voltage is adequate, the ignition switch circuit to 1. Remove console module, refer to BODY sub-
the ECM is functioning normally. section.
If there is no voltage, check for an open circuit, 2. Unhook latch cables (seat and front storage
refer to WIRING DIAGRAM. compartment) and glove box lock cable.
If no wire is open, refer to IGNITION SWITCH
CONTINUITY TEST in this subsection.
NOTE: Use B.U.D.S. to reset fault codes gener-
ated when voltage check was carried out with
ECM adapter.

Ignition Switch Continuity Test

Remove the ignition switch (refer to IGNITION
SWITCH REMOVAL).
Set multimeter to .
rmr2014-027 3
Subsection 03 (IGNITION SYSTEM)

rmr2010-026-002_b

1. Latch and lock cables

rmr2013-029-002_c
3. Cut locking tie and slide ignition switch protec-
1. D.E.S.S. module
tor downwards. 2. D.E.S.S. antenna connector

6. Remove ignition switch retaining screws.

rmr2010-026-002_c

4. Disconnect ignition switch main connector (at rmr2010-026-004_a

switch). 1. Retaining screws

5. Disconnect ignition switch antenna D.E.S.S. 7. Remove ignition key.

connector. It is located above the D.E.S.S.
module. Refer to the DIGITALLY ENCODED
SECURITY SYSTEM (D.E.S.S.) subsection for
procedures to gain access to the connector.
8. Raise ignition switch and hold in this position.
9. Turn ignition switch top cover counterclockwise
to unlock.
10. Pull out top cover.

4 rmr2014-027
 Subsection 03 (IGNITION SYSTEM)

rmr2014-027-002_a
rmr2008-023-010_a
TYPICAL - SE6 ENGINE ILLUSTRATED
TYPICAL 1. Ignition coil #1 (RH, clutch side)
Step 1: Raise ignition switch 2. Ignition coil #2 (center)
Step 2: Turn top cover 3. Ignition coil #3 (LH, belt side)
Step 3: Remove top cover

11. Remove ignition switch. Ignition Coil Access

Ignition Switch Installation
For installation, reverse removal procedures.
However, pay attention to the following.
NOTE: Program new keys before completing in-
stallation. Refer to DIGITALLY ENCODED SECU-
RITY SYSTEM (D.E.S.S.) subsection.
Install latch cables on switch as shown.
rmr2010-026-002_a
Refer to BODY subsection and remove the follow-
ing:
– RH and LH upper side panels
– RH and LH acoustic panels.
Refer to AIR INLET SYSTEM and remove the pri-
mary air inlet silencer (air filter housing).
Ignition Coil Quick Test using B.U.D.S.
This test confirms the working condition of the
ignition circuit and ignition coil for the cylinder
tested.
1. Refer to IGNITION COIL ACCESS and remove
parts required for access to the ignition coils
from the RH side of the vehicle.
2. Connect vehicle to the latest applicable
B.U.D.S. version, refer to COMMUNICATION
TOOLS AND B.U.D.S. subsection.
3. Turn ignition key to ON.
4. In B.U.D.S., select;
– Read Data

TYPICAL - RT MODELS
– Activationpage tab
1. RH SIDE: To seat – ECM page.
2. CENTER: To glove box
3. LH SIDE: To front storage compartment 5. As you energize the ignition coil by selecting it
on the engine illustration in B.U.D.S., listen for
IGNITION COILS the ignition spark.
NOTE: The sound of the ignition spark is faint. If
Ignition Coil Location you have difficulty hearing the spark, use a me-
Direct ignition coils (stick coils) are used. They are chanics stethoscope or a common screwdriver
mounted over the spark plug of each cylinder. applied to the cylinder head cover. You should
then be able to hear a repetitive sound such as;
tic, tic ,tic, tic ,tic tic.

rmr2014-027 5
Subsection 03 (IGNITION SYSTEM)

rmr2014-027-003_a

TYPICAL — IGNITION COIL INPUT VOLTAGE TEST

mmr2009-122-002
TEST RESULT SERVICE ACTION
TYPICAL — IGNITION COIL ACTIVATION
Test ignition coil ground
If there is no spark, carry out the following tests. Battery voltage signal wire. Refer to
is read IGNITION COIL CIRCUIT
Ignition Coil Input Voltage Test CONTINUITY TEST
1. Remove parts required for access, refer to IG- Test ignition coil power
NITION COIL ACCESS in this subsection. Battery voltage input wire. Refer to
2. Disconnect the ignition coil connector. NOT read IGNITION COIL CIRCUIT
CONTINUITY TEST
3. Set ignition switch to ON to wake up the ECM.
4. Measure voltage as per following table. Ignition Coil Circuit Continuity Test
REQUIRED TOOL Power Input Wire (Ignition Coil)
FLUKE 115 MULTIMETER 1. Remove parts required for access, refer to IG-
(P/N 529 035 868) NITION COIL ACCESS in this subsection.
2. Ensure ignition switch is set to OFF.
NOTE: Test is valid only if ECM is active (gauge 3. Remove ignition/injector fuse (F6) in the LH
will be on). fuse box. Refer to POWER DISTRIBUTION
IGNITION COIL INPUT VOLTAGE TEST
AND GROUNDS subsection.
4. Disconnect ignition coil connector.
TEST PROBES VOLTAGE
5. Set multimeter to selection.
# 1 coil (RH, clutch side)
Pin 1 6. Test for continuity of circuit as per following ta-
ble.
# 2 coil (center) Battery Battery
Pin 2 ground voltage REQUIRED TOOL
# 3 coil (LH, belt side)
Pin 3 ECM ADAPTER TOOL
(P/N 529 036 166)

6 rmr2014-027
 Subsection 03 (IGNITION SYSTEM)

POWER INPUT WIRE CONTINUITY TEST 3. Test for continuity of ignition coil ground signal
(IGNITION COIL TO FUSE BOX) circuit as per following table.
IGNITION REQUIRED TOOLS
LH FUSE
IGNITION COIL
BOX RESISTANCE FLUKE 115
COIL CONNECTOR ECM ADAPTER TOOL
CONTACT MULTIMETER
PIN (P/N 529 036 166)
(P/N 529 035 868)
# 1 Coil,
RH Pin 1
(clutch side)
# 2 Coil, Close to 0
Pin 2 B3
(center) (continuity)
# 3 Coil, GROUND SIGNAL WIRE CONTINUITY TEST
LH Pin 3 (IGNITION COIL TO ECM)
(belt side) IGNITION
IGNITION COIL
ECM-A RESISTANCE
COIL CONNECTOR
PIN
# 1 Coil
RH, Pin 3 Pin M4
(clutch side)
# 2Coil Close to 0
Pin 3 Pin M2
(center) (continuity)
# 3 Coil
LH Pin 3 Pin M1
(belt side)

rmr2013-024-300_a

FUSE BOX PINOUT

rmr2014-027-003_c

TYPICAL — IGNITION COIL GROUND SIGNAL WIRE

rmr2014-027-003_b
TYPICAL — POWER INPUT WIRE CONTINUITY TEST (IGNITION
COIL)
If continuity is not measured as specified, test the
engine and vehicle harnesses.
Ground Signal Wire (Ignition Coil)
1. Disconnect ECM connector A. Refer to ELEC-
TRONIC FUEL INJECTION subsection.
2. Disconnect ignition coil connector.
CONTINUITY TEST
If continuity is not measured as specified, repair
the connector or replace the engine wiring har-
ness.
Ignition Coil Resistance Test
An ignition coil with a good resistance measure-
ment can still be faulty. Current leakage can occur
at high voltage levels which is not detectable with
an ohmmeter. Replacing the ignition coil may be
necessary as a test.

rmr2014-027 7
Subsection 03 (IGNITION SYSTEM)

Primary Winding SERVICE PRODUCT

1. Remove ignition coil. Refer to IGNITION COIL LOCTITE 243 (BLUE) (P/N 293 800 060)
REMOVAL in this subsection.
NEW VALVE COVER
2. Set the multimeter to and measure primary
winding resistance as specified. 14 N•m ± 2 N•m
Retaining Screw Torque
(124 lbf•in ± 18 lbf•in)
REUSED VALVE COVER
11 N•m ± 1 N•m
Retaining Screw Torque
(97 lbf•in ± 9 lbf•in)

4. Connect ignition coil connector.

SPARK PLUGS
Spark Plug Application
SPARK PLUG GAP
mmr2009-122-009_a
0.7 mm to 0.8 mm
TYPICAL NGK MR7BI-8
(.028 in to .031 in)
RESISTANCE @
CIRCUIT PIN Spark Plug Installation
20°C (68°F)
Primary 1 and 3 0.8 - 0.97 SERVICE PRODUCT
HEAT-SINK PASTE P12 (P/N 420 897 186)
If resistance is not within specification, replace ig-
(except first 2 threads)
nition coil.
RETAINING SCREW TORQUE
Secondary Winding
13.5 N•m ± 1.5 N•m (119 lbf•in ± 13 lbf•in)
The secondary winding on this type of ignition coil
cannot be tested.

Ignition Coil Removal

1. Disconnect ignition coil connector.
2. Remove ignition coil retaining screw.
NOTICE Do not pry on ignition coil with a
tool.
3. Remove ignition coil from spark plug by rotating vmr2008-024-002_a

coil side to side as you pull up. TYPICAL

1. Heat-sink paste in this area

Ignition Coil Installation

EMERGENCY ENGINE STOP
1. Align the retaining screw hole of the ignition coil
with the threaded hole on the valve cover. SWITCH
2. Install ignition coil on the spark plug and push Emergency Engine Stop Switch
it all the way down until it rests on the valve Operation
cover. The emergency engine stop switch provides a
3. Install retaining screw as per following table. ground signal to the ECM when RUN is selected.
The ground signal is applied to the ECM as per
following table.

8 rmr2014-027
 Subsection 03 (IGNITION SYSTEM)

APPLICATION OF EMERGENCY ENGINE STOP

SWITCH GROUND SIGNAL
ECM-B
Pin E4

Emergency Engine Stop Switch

Continuity Test
1. Refer to BODY subsection and remove the fol-
lowing:
– LH and RH top side panels
– LH and RH bottom side panels
– LH and RH acoustic panels. rmr2014-029-006_a

1. Connector MSR2 location

2. Disconnect ECM-B connector and install it on
the ECM adapter tool. 5. Check switch continuity as per following table.
3. Check switch continuity as per following table. EMERGENCY ENGINE STOP SWITCH
CONTINUITY TEST (AT MSR2)
REQUIRED TOOLS
SWITCH
FLUKE 115 TEST PROBES RESISTANCE
ECM ADAPTER TOOL POSITION
MULTIMETER
(P/N 529 036 166)
(P/N 529 035 868) STOP BK BK/YE Infinite (OL)
RUN wire wire Close to 0

If readings are as specified, check wiring and con-

nectors between emergency engine stop switch
connector (MSR2-3) and ECMB-E4.
EMERGENCY ENGINE STOP SWITCH If readings are not as specified in table, check
CONTINUITY TEST (AT ECM)
wiring and connections going to switch. If good,
SWITCH
TEST PROBES RESISTANCE
replace switch.
POSITION
STOP Battery Infinite (OL)
ECMB-E4
RUN ground Close to 0

If readings are as specified, the emergency en-

gine stop switch and its circuit to the ECM are
good.
If readings are not as specified, carry on with the
following steps.
4. Disconnect the RH multifunction switch con-
nector (MSR2).

rmr2014-027 9

CHARGING SYSTEM
SERVICE TOOLS
Description
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ..................................... 2, 4–5
SERVICE TOOLS – OTHER SUPPLIER
Description
EXTECH AMMETER ..................................................................... model
NAPA ULTRA PRO BATTERY LOAD TESTER ............................... 95260
SERVICE PRODUCTS
Description
DIELECTRIC GREASE ................................................................... 293 550 004 ............................................. 6
GENERAL
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed, must be
replaced (e.g.: locking tabs, elastic stop nuts,
self-locking fasteners, cotter pins, etc.).
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory stan-
dards.
SYSTEM DESCRIPTION
The purpose of the charging system is to keep
the battery at a full state of charge and to provide
the electrical system with the required electrical
power for normal vehicle operation.
Alternator
An alternator capable of providing 90 amperes
of current and 1200 Watts of power is used as
the primary source of electrical power, and to
recharge the battery. It transforms a magnetic
field into an alternating current (AC). An internal
voltage regulator and rectifier circuit transforms
the AC current into a regulated 12 VDC output.
The ECM receives a reference voltage directly
from the alternator. Should the current demand
on the alternator suddenly increase sharply, the
DC bus voltage would drop as well as the engine
RPM. This is due to the high current load on the
rmr2014-028
Subsection 04 (CHARGING SYSTEM)
Part Number Page
Part Number Page
............................................. 3
380941
............................................. 5
Part Number Page
alternator. The ECM can sense this change and
react quickly by increasing the engine torque to
maintain engine RPM.
Should the ECM not receive the reference volt-
age from the alternator due to an open circuit,
the check engine light would come on and torque
compensation with changes in electrical loads
would cease. Engine RPM would then drop with
sudden increases in electrical loads (ex: cooling
fans coming on, heated handles turned on, in-
creased DPS loads).
Refer to theALTERNATOR subsection for alterna-
tor replacement procedures.
Alternator Fuse (LFB F3)
The alternator fuse is located in the left hand fuse
box (LFB).
It protects all other loads in the power distribution
system should there be a short circuit in the fuse
circuit, or should the alternator fail in such a way
as to demand excessive field current.
Should this fuse be open circuit, there will not be
any alternator output.
Alternator Resistor (R10)
The alternator resistor (R10) completes the alter-
nator fail light circuit. A traditional alternator fail
light is not used in this system charging system
and is replaced by the resistor.
Should this resistor be open circuit, there will not
be any alternator output.
1
Subsection 04 (CHARGING SYSTEM)

Battery TEST RESULTS

The battery supplies DC power to the electric VOLTAGE INDICATION WHAT TO DO
starter for cranking the engine. During engine
starting, it also supplies DC power to all electrical Completely recharge
Lower than Bad state of
and electronic systems, including alternator field battery before
specification charge
current. At low engine RPM operation and high continuing
current load conditions, it supplements the alter- Above Superficial Carry out a test with
nator output (if required), and helps to maintain a specification charge the engine running
steady system voltage.
7. Start engine.
INSPECTION 8. Load the electrical system by turning ON:
– Headlights on high beam
CHARGING SYSTEM OUTPUT – Heated grips to high.
DC Voltage Output Test During the test:
1. Open front storage compartment cover. – Do not turn the handlebar to avoid DPS current
draw
2. Remove battery access cover. – Do not activate any other accessories
3. Remove RED rubber protector from positive (+) – Make sure the cooling fan does not turn ON.
battery terminal.
9. Read voltage.
4. Set multimeter to Vdc scale.
Voltage should be within following specification.
REQUIRED TOOLS
DC VOLTAGE OUTPUT TEST
FLUKE 115 TEST ENGINE SPEED VOLTAGE
MULTIMETER
4000 RPM 13.5 - 14.5 Vdc
(P/N 529 035 868)
TEST RESULTS
5. Connect multimeter between the positive (+) VOLTAGE WHAT TO DO
and negative (-) battery posts.
Within Complete inspection with the DC
6. Read battery voltage.
specification CURRENT OUTPUT TEST.
Significantly
above Replace alternator.
specification
– The RED battery indicator light
will come on in the
Exceeds
multifunction gauge.
16 Vdc
– The HIGH BATT VOLT fault
message will be displayed.
Turn engine OFF and check the
following:
– Alternator connectors are clean,
corrosion free, and properly
connected.
rmr2014-029-005_b
– 10 amp alternator fuse (F3) in
Does not
the left hand fuse box. Refer to
STATIC BATTERY VOLTAGE increase or
POWER DISTRIBUTION AND
drops
12.6 Vdc minimum GROUNDS subsection.
– Connection condition at battery
posts.
– Alternator mounting surfaces are
clean, corrosion free and alternator
is properly secured

2 rmr2014-028
 Subsection 04 (CHARGING SYSTEM)

DC Current Output Test NOTE: A current above specification indicates the

This test should be carried out as a complement
to the DC voltage output test.
Test vehicle under normal operating loads:
– No additional accessories turned on
– Do not turn handlebar to avoid DPS current
draw
– Make sure the cooling fan does not turn ON.
NOTICE Use an inductive ammeter capable
of measuring over 20 A.
1. Refer to BODY subsection and remove the fol-
lowing:
– LH top side panel
– LH top acoustic panel.
2. Clamp an inductive ammeter such as the EX-
TECH AMMETER (P/N MODEL 380941) over the
FB fuse cable coming from the alternator.
charging system is working harder than expected
because of a weak battery or an electric device
turned ON.
TROUBLESHOOTING
It is good practice to check for fault codes using
the B.U.D.S. as a first troubleshooting step. Refer
to DIAGNOSTIC AND FAULT CODES subsection.
Refer to POWER DISTRIBUTION AND GROUNDS
for information on fuses and relays.
Always refer to the WIRING DIAGRAM when
troubleshooting an electrical circuit.
Install a battery charger on the battery for any
tests that involve a prolonged "key ON" period. If
battery voltage gets too low, some accessories
are shut off by the ECM and test results can be
altered.
NOTICE Never force a multimeter probe into
an electrical terminal.

TROUBLESHOOTING
GUIDELINES
Weak or Discharged Battery
If the battery is weak or discharged, check the fol-
lowing:
– High key off current draw.
• Normal current draw: 10 - 20 mA
– Check battery and connections. Refer to BAT-
TERY in this subsection.
– Check junctions JT RD1, JT RD2 and JT RD3.
rmr2014-028-001_a – Check connections to LH and RH fuse box 12
OUTPUT DC CURRENT TEST Vdc bus bars.
1. Alternator
2. Alternator power output cable – Check items in LOW OR NO CHARGING SYS-
3. Inductive ammeter TEM VOLTAGE.
3. Start engine. – Check charging current output, refer to IN-
SPECTION in this subsection.
4. Read current.
OUTPUT DC CURRENT TEST Low or No Charging System Voltage
TEST ENGINE SPEED CURRENT If charging system voltage is low, the engine may
be unstable, or stall.
4000 RPM Minimum 10 A
Test the following items:
If current reading is significantly below specifica- – Alternator fuse (F3) in LH fuse box (LFB).
tion: – Charging system voltage, refer to INSPECTION
– Check for low output voltage at the alternator in this subsection.
output terminal. – Alternator, refer to ALTERNATOR subsection.
– Check for bad connections (or wiring) between – Wiring and connections, refer to WIRING DIA-
alternator and fuse boxes. GRAM.

rmr2014-028 3
Subsection 04 (CHARGING SYSTEM)

Repetitively Blown Alternator Fuse ALTERNATOR RESISTOR R10 TEST

(LFB F3)
ALT
The possible causes for a repetitively blown F3 LFB CONTACT READING
CONNECTOR
are:
B6 Pin 4 50 ohms
– Voltage regulator/rectifier internal circuit
shorted to ground. If resistance reading is significantly different from
– DC output (RED) wire shorted to ground. specification, short circuit, or open circuit, replace
– Voltage sensing wire to alternator contact ALT-2 the resistor.
shorted to ground.
– Resistor R10 or resistor wire to alternator con- BATTERY
tact ALT-4 shorted to ground.
Battery Information
PROCEDURES These vehicles are equipped with a VRLA battery
(Valve Regulated Lead Acid).
ALTERNATOR RESISTOR (R10) It is a sealed, maintenance-free, non-spillable
type battery.
Alternator Resistor Location
Refer to the battery manufacturer's instructions
The R10 resistor is located in the alternator control for proper charging procedures.
wire harness close to where it joins with the main
vehicle harness. Battery Voltage Test (No Load Applied)
NOTE: A voltage test is carried out on a battery
without discharging current. It is the simplest and
most commonly used. However, be aware that a
3 2 voltage test can indicate that the battery is good
even though the battery does not have enough
power to crank the engine.
A voltage reading provides an instant indication of
the state of charge of the battery, not of its current
output capacity. A load test provides a more ac-
curate indication of the battery condition.
If the battery has just received a charge, allow it to
rest for 1-2 hours before taking a voltage reading.
Set multimeter to Vdc and connect to battery ter-
1 minals.
rmr2014-028-002_a

1. Power output cable from alternator REQUIRED TOOLS

2. Control wire harness to alternator
3. Approximate R10 resistor location
FLUKE 115
MULTIMETER
Alternator Resistor Test (P/N 529 035 868)
1. Remove alternator fuse (LFB F3).
2. Disconnect alternator control connector.
3. Measure the resistor as follows.
REQUIRED TOOL

FLUKE 115 MULTIMETER

(P/N 529 035 868)

4 rmr2014-028
 Subsection 04 (CHARGING SYSTEM)

3. With the multimeter still connected, crank

engine with throttle fully open to initiate the
"drown mode" to prevent engine from starting
while reading multimeter.

WARNING
While using the drown mode, always release
START button before throttle.

BATTERY LOAD TEST

BATTERY VOLTAGE WHILE CRANKING
10 Vdc minimum
rmr2014-029-005_b

Assuming the starting system is in good condi-

BATTERY VOLTAGE TEST (NO LOAD)
FULLY CHARGED BATTERY VOLTAGE
12.6 Vdc minimum
NOTE: A battery that shows a voltage of 12.0 Vdc
is considered completely discharged and needs to
be recharged.
Battery Load Test (Engine Cranking)
Battery must be fully charged, refer to BATTERY
VOLTAGE TEST (NO LOAD APPLIED).
1. Set multimeter to Vdc and connect it to the bat-
tery.
REQUIRED TOOLS
FLUKE 115
MULTIMETER
(P/N 529 035 868)
2. Measure battery voltage at rest.
tion, a battery voltage that drops below specifica-
tion suggests a worn-out or defective battery.
NOTE: Before replacing the battery, make sure
the charging system is in good condition.
Battery Load Test (Using a Battery
Load Tester)
This is the best test to determine the battery
condition.
Use a load testing device such as the NAPA ULTRA
PRO BATTERY LOAD TESTER (P/N 95260). It has a
500 A carbon pile adjustable load.
Battery must be fully charged.
1. If battery has just been recharged, allow battery
to rest for 1-2 hours.
2. Follow battery load tester instructions.
3. Carry out a test as per table.
BATTERY LOAD TEST
TIME TO
LOAD MEASURE VOLTAGE
INTO TEST
150 A 5 seconds Minimum 10 Vdc

If battery voltage has dropped below specifica-

tion, replace battery.
NOTE: Note, before replacing the battery, make
sure the charging system is in good condition.

Battery Removal
1. Open front storage compartment.
2. Remove the battery access panel.
rmr2014-029-005_b

rmr2014-028 5
Subsection 04 (CHARGING SYSTEM)

Apply a light coat of DIELECTRIC GREASE (P/N 293

550 004) on terminals.

Battery Inspection
Visually inspect battery casing for cracks or any
other damage. If casing is damaged, replace bat-
tery and thoroughly clean battery rack with a wa-
ter and baking soda solution.
Inspect battery posts, connectors, battery rack,
battery holding strap and strap attachment points.

Battery Storage
rmo2013-003-007_b
It is not necessary to remove the battery during
1. Remove screws
2. Battery access panel vehicle storage but is recommended for long term
storage.
3. Disconnect the BLACK (-) battery cable first. Recharge the battery once a month with an ap-
NOTICE Always disconnect the NEGATIVE (-) proved battery charger as per manufacturer's rec-
cable first. ommendations.
Clean battery, battery rack and connections as re-
4. Pull back the RED rubber protector on the posi- quired, refer to BATTERY CLEANING in this sub-
tive (+) battery post, then disconnect the cable. section.
5. Remove battery retaining strap. For other recommendations during storage, refer
6. Lift top plate. to the battery manufacturer's instructions.
7. Pull out battery.
Battery Installation
1. Insert battery in its rack.
2. Install top plate.
2.1 Align tabs of top plate into frame slots.

rmr2013-027-003_a

Step 1: Disconnect first

Step 2: Disconnect last
Step 3: Remove retaining strap
Step 4: Lift top plate
Step 5: Pull out
rmr2013-027-004_a

Battery Cleaning 1. Top plate

With the battery removed from vehicle, clean the
battery rack, cables, battery casing and posts us-
ing a solution of baking soda and water.
Remove any corrosion from battery cable termi-
nals and battery posts using a firm wire brush.
Rinse with clear water and dry thoroughly using
a clean cloth.
2. Plate tabs in slots
3. Install battery retaining strap.
NOTICE Always connect RED (+) cable first
then BLACK (-) cable.
4. Connect the RED (+) battery cable. Position the
RED protective rubber boot over the contact.

6 rmr2014-028
 Subsection 04 (CHARGING SYSTEM)

5. Connect the BLACK (-) battery cable.

rmr2013-027-003_b

Step 1: Install in rack

Step 2: Secure in frame slots
Step 3: Secure retaining strap
Step 4: Connect first
Step 5: Connect last

6. Install battery access panel.

7. Turn ignition key ON then OFF to prevent bat-
tery drain from the D.E.S.S. system.

Battery Main Ground Connection

Refer to POWER DISTRIBUTION AND GROUNDS
subsection for vehicle grounds location.
Ensure all ground connections are clean, tight and
free of corrosion.

rmr2014-028 7
 Subsection 05 (STARTING SYSTEM)

STARTING SYSTEM
SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................... 3–4, 7–10

GENERAL – Transmission in neutral

– Brake pedal depressed
SYSTEM DESCRIPTION – D.E.S.S. recognizes the key
Starting System Operation – Start button pressed in.
NOTE: If the transmission was not in neutral
SEQUENCE OF OPERATION when the engine was shut off, the HCM (hy-
Start button sends a ground signal to the draulic control module) will automatically shift the
1
ECM and pre-starting relay transmission to neutral at the next engine start
Pre-starting relay provides battery voltage to
to allow engine starting (if there is sufficient oil
the starter solenoid coil and ECM pressure).
2
ECM provides ground to the starter The parking brake state will not affect engine
solenoid coil ST1 terminal cranking.
If the start button is activated when engine speed
is above 1250 RPM, engine cranking will not be TROUBLESHOOTING
allowed. In other words, if the engine is running,
no cranking will take place. TROUBLESHOOTING TIPS
If the start switch is activated while the throttle is It is good practice to check for fault codes using
opened more than 50%, the engine will not be al- B.U.D.S.as a first troubleshooting step. Refer to
lowed to start but the starter will crank the engine COMMUNICATION TOOLS AND B.U.D.S. sub-
(engine drown mode). section.
Refer to POWER DISTRIBUTION AND GROUNDS
Engine Cranking Conditions
for fuses and relays information.
SM6 Model Always refer to the WIRING DIAGRAM when
The following conditions must be met to allow en- troubleshooting an electrical circuit.
gine cranking: Install a battery charger on jump start posts in
– Ignition switch ON front storage compartment for any tests that
– Emergency engine stop switch to RUN involve a prolonged "key ON" period. If battery
– Mode button pressed in once (safety message voltage gets too low, test results can be altered.
acknowledgement) NOTICE Never force a multimeter probe into
– Transmission in neutral (or in gear with clutch an electrical terminal.
lever depressed)
– Brake pedal depressed STARTING SYSTEM
– D.E.S.S. recognizes the key TROUBLESHOOTING
– Start button pressed in.
If the gauge or lights do not come on when igni-
SE6 Model tion switch is ON, refer to TROUBLESHOOTING
The following conditions must be met to allow en- in IGNITION SYSTEM subsection.
gine cranking: If gauge and lights come ON with the ignition
– Ignition switch ON switch ON and starter does not engage, start
– Emergency engine stop switch to RUN your testing sequence by carrying out STARTER
– Mode button pressed in once (safety message OPERATION TEST in this subsection.
acknowledgement)

rmr2014-029 1
Subsection 05 (STARTING SYSTEM)

Refer to the following list for possible causes: 2. Emergency engine stop switch to RUN.
– F8 fuse 3. Throttle to wide open throttle position to pre-
– Battery or connections (refer to CHARGING vent engine starting (drowned mode).
SYSTEM) 4. Start button pressed to engage starter.
– D2 diode
– Start button Starter Terminal Access
– Engine stop switch For a quick access to the starter terminal (SM) for
– Starter solenoid electrical testing using a multimeter, the terminal
– Clutch engagement switch (SM6 model) may be accessed through a hole in the bottom
– Gear position sensor (SM6 model) pan, near the lower suspension arm attachment
point of the LH front suspension.
– D.E.S.S.
– Brake light switch (SE6 model) if transmission
in gear)
– Electrical cables/connections
– ECM.
If fuse F8 continuously blows, isolate the follow-
ing components to determine the source of the
short circuit:
– Pre-starting relay
– Starter solenoid
– Heated oxygen sensors
– EVAP purge valve
– Fuel pump
– D2 diode
– Clutch solenoid valve (SM6 model) rmr2014-029-001_a

QUICK ACCESS TO STARTER TERMINAL

– Camshaft position sensor 1. Access to starter terminal through bottom pan hole
– Reverse actuator relay (R1). 2. Left front wheel assembly

On SM6 model: For greater access, remove the air inlet grill near
– If starter cranks only with the clutch lever de- the LH front suspension. Refer to BODY subsec-
pressed, verify the GBPS (gearbox position sen- tion.
sor) and its circuits. Refer to GEARBOX sub-
section.
– If starter cranks only in neutral, carry out the
CLUTCH SWITCH CONTINUITY TEST in this
subsection.

PROCEDURES
ELECTRIC STARTER
Cranking Engine in Drowned Mode
Drowned mode allows the engine to be cranked
with the injection system disabled. It can be used
to crank the engine to vent it of excess fuel vapors
when the engine is drowned, or for testing proce- rmr2014-029-002_a

dures. GREATER ACCESS TO STARTER TERMINAL

1. Starter terminal location
NOTICE Starter should not be engaged con-
tinuously for more than 5 seconds or starter
damage may occur.
1. Ignition switch to ON.
2 rmr2014-029
 Subsection 05 (STARTING SYSTEM)

Starter Operation Test

Before testing, make sure the battery is in good
condition and fully charged.
1. Apply parking brake.
2. Crank engine with throttle fully open to initiate
the "drown mode" to prevent engine from start-
ing.
The starter should rotate smoothly.
If the starter does not run smoothly, refer to the
ELECTRIC STARTER AND STARTER DRIVE sub-
section.
If the starter does not rotate or rotates slowly, rmr2008-025-001_a

carry out a STARTER INPUT VOLTAGE TEST. TYPICAL- STARTER INPUT VOLTAGE TEST

Starter Input Voltage Test TEST RESULTS

1. For access to the starter terminal, refer to READING WHAT TO DO

STARTER TERMINAL ACCESS (SM) in this Check Start button and Stop button
subsection. No voltage
using B.U.D.S.
2. Set multimeter to Vdc. Carry out a STARTER CABLE
Voltage is low
3. Rotate throttle fully open to initiate "drowned VOLTAGE DROP TEST.
mode". Refer to CRANKING ENGINE IN Make sure engine is not seized.
DROWNED MODE in this subsection. Voltage is If engine is not seized, carry out
4. Press start button to crank engine. good a GROUND CIRCUIT VOLTAGE
DROP TEST.
5. While cranking engine in "drowned mode",
measure voltage as per table.
Starter Cable Voltage Drop Test
REQUIRED TOOLS
This test confirms if there is parasitic resistance in
the cable, solenoid or connections.
FLUKE 115
MULTIMETER 1. Set multimeter to Vdc.
(P/N 529 035 868) 2. Connect multimeter probes to the starter termi-
nal (SM) and battery positive post.
STARTER INPUT VOLTAGE TEST 3. While cranking engine in "drowned mode",
RESULT measure voltage drop as follows. Refer to
TEST PROBES (WHILE PRESSING CRANKING ENGINE IN DROWNED MODE in
START BUTTON) this subsection.
Battery REQUIRED TOOLS
Starter terminal
negative Battery voltage
(SM)
post FLUKE 115
MULTIMETER
NOTE: Battery voltage will drop and fluctuate (P/N 529 035 868)
with starter cranking load.
STARTER CABLE VOLTAGE DROP TEST
RESULT (WHILE
PROBES
STARTING)
Starter
Battery
terminal 1 Vdc maximum
positive post
(SM)

rmr2014-029 3
Subsection 05 (STARTING SYSTEM)

rmr2008-025-001_b rmr2008-025-001_c

STARTER CABLE VOLTAGE DROP TEST TYPICAL - STARTER GROUND CIRCUIT VOLTAGE DROP TEST

If voltage exceeds the specification, test voltage If voltage exceeds the specification, check ground
drop between the following points using the same cables and connections from battery to front LH
method to determine what part of the circuit is at side of engine.
fault: If voltage is as per specification, test starter mo-
– Battery positive post and starter solenoid STS3 tor, refer to ELECTRIC STARTER AND STARTER
– Starter solenoid STS3 and STS4 DRIVE subsection.
– Starter solenoid STS4 and starter terminal (SM).
Starter Replacement
Replace cable or solenoid if necessary.
If the starter has to be replaced, refer to the ELEC-
Starter Ground Circuit Voltage Drop TRIC STARTER AND STARTER DRIVE subsection.
Test
This test confirms if there is parasitic resistance in D2 DIODE (STARTER SOLENOID)
the ground cables or connections. D2 Diode Troubleshooting
1. Set multimeter to Vdc. A defective D2 diode will result in the following
2. Connect multimeter probes to the starter hous- conditions.
ing and battery negative post.
Shorted Diode
3. While cranking engine in "drowned mode",
measure voltage drop as follows. Refer to Fuse F8 will blow continually.
CRANKING ENGINE IN DROWNED MODE in Open Diode
this subsection.
Diode will not provide protection to the sensitive
REQUIRED TOOLS electronic components. Malfunction or damage
may occur to the ECM.
FLUKE 115
MULTIMETER D2 Diode Test
(P/N 529 035 868) Remove front cargo box. Refer to BODY subsec-
tion.
STARTER GROUND CIRCUIT VOLTAGE Diode D2 must be isolated from other parallel cir-
DROP TEST cuits for proper testing.
RESULT (WHILE – Turn ignition switch OFF.
PROBES
STARTING) – Disconnect ECM connector B. Refer to ELEC-
Starter Battery TRONIC FUEL INJECTION (EFI) subsection.
0.8 Vdc maximum
housing negative post – Disconnect small connectors on the starter so-
lenoid.
Set multimeter as shown.

4 rmr2014-029
 Subsection 05 (STARTING SYSTEM)

NOTE: It is important to install the BLACK multi- Diode Replacement

meter probe in the BLACK “com” connector of
the multimeter and the RED probe in the RED con-
nector for proper testing of diode polarity.
The diode (D2) is located in the main harness,
above the starter solenoid harness junction.
1. Remove battery for access to main harness and
D2 diode.

rmr2014-029-003_a

1. Starter solenoid
vmr2006-020-005 2. Approximate D2 diode location

Test diode D2 as follows.

rmr2013-028-001_a

1. Main harness
rmr2013-028-030_a 2. Starter solenoid
SMALL CONNECTORS OF SOLENOID 3. Starter solenoid junction harness
4. Approximate diode D2 location
D2 DIODE TEST
2. Open the harness protective sheath to access
SOLENOID STS1 STS2 the diode.
HARNESS (YELLOW/ (VIOLET/ READING
CONNECTOR PINK) BEIGE) NOTICE Be very careful not to damage wire
insulation while opening protective sheath.
RD BK 0.6 V
TEST PROBES
BK RD Infinite OL

If results are not as specified, replace diode.

rmr2014-029 5
Subsection 05 (STARTING SYSTEM)

TEST RESULTS
STOP BUTTON
INDICATOR IN WHAT TO DO
B.U.D.S.
Comes ON when The switch and wiring are
switch is in RUN good and the D.E.S.S. module
position gets the signal. Make sure
Comes OFF when Start button tests good, then
rmr2008-025-002
switch is in STOP carry out a PRE-STARTING
TYPICAL DIODE WITHIN HARNESS
position RELAY QUICK TEST
NOTE: When replacing the diode, always test the
Check for an open circuit
new diode with the "diode check" on the multime- or defective Stop switch,
ter, before installing it in the circuit. Does not change refer to WIRING DIAGRAM.
3. Replace diode making sure to install it in the cor- when switch is Keep in mind that one side
rect direction. Use the "diode check" function toggled ON and of the switch is connected
of the multimeter and refer to the WIRING DI- OFF to the D.E.S.S. module and
AGRAM. a failure of this circuit will
disable starting.
NOTE: If the diode is installed in the reverse di-
rection, the starter solenoid will not function and
fuse F8 will probably blow and open the circuit. START BUTTON
Start Button Test with B.U.D.S.
ENGINE STOP SWITCH
1. Connect the vehicle diagnostic connector to a
NOTE: The engine stop switch is located on the computer with the appropriate version of the
RH multifunction switch housing. B.U.D.S. software.
2. Select the Read Data button.
Engine Stop Switch Test with B.U.D.S.
3. Select the Monitoring and ECM tabs.
1. Connect the vehicle diagnostic connector to a
computer with the appropriate version of the 4. Press the engine start button and look at the
B.U.D.S. software. Start Button indicator.
2. Select the Read Data button.
3. Select the Monitoring and ECM tabs.
4. Place engine stop switch to RUN, then to STOP
and look at the Stop Button indicator.

rmr2014-029-004_b

1. Monitoring tab
2. ECM tab
3. Start Button indicator

rmr2014-029-004_a

1. Monitoring tab
2. ECM tab
3. Stop Button indicator

6 rmr2014-029
 Subsection 05 (STARTING SYSTEM)

TEST RESULTS PRE-STARTING RELAY INPUT VOLTAGE TEST

START BUTTON TEST PROBES RESULT
INDICATOR IN WHAT TO DO
B.U.D.S. LH fuse box pin A9 Battery
Ground
LH fuse box pin A10 voltage
The starting system
input side is functioning
normally (start button, ECM, If there is no voltage at any test, check for an open
Comes ON while circuit.
wiring and connections).
start button is
Make sure engine stop switch If voltage is as specified, carry out a PRE-START-
pressed in
tests good, then carry out a ING RELAY CONTROL CIRCUIT TEST.
PRE-STARTING RELAY QUICK
TEST. Pre-Starting Relay Control Circuit Test
Does not come ON Check for an open circuit or 1. Remove pre-starting relay.
while start button defective switch, refer to
is pressed in WIRING DIAGRAM. 2. Set multimeter to Vdc.
3. Turn ignition switch (key) ON.
PRE-STARTING RELAY 4. Read voltage as per table.
NOTE: Refer to POWER DISTRIBUTION AND
Pre-Starting Relay Quick Test GROUNDS for LH fuse box pinout.
1. Locate pre-starting relay in the LH fuse
box, refer to POWER DISTRIBUTION AND REQUIRED TOOLS
GROUNDS.
FLUKE 115
2. While carrying out a start, touch the relay. You MULTIMETER
should feel it "click" when you press start but- (P/N 529 035 868)
ton.
If relay does not click, temporarily substitute relay 5. Measure voltage while pressing start button.
with a known good one and retest.
– If it now works, replace relay. PRE-STARTING RELAY CONTROL CIRCUIT TEST
– If it still does not work, carry out a PRE-START- RESULT (WHILE
ING RELAY INPUT VOLTAGE TEST. TEST PROBES PRESSING START
BUTTON)
If relay clicks, carry out a STARTER SOLENOID IN-
PUT VOLTAGE TEST. Battery
LH fuse box
positive Battery voltage
pin B9
Pre-Starting Relay Input Voltage Test post
1. Remove pre-starting relay. If voltage is as specified, the relay gets a proper
2. Set multimeter to Vdc. ground signal.
3. Turn ignition switch (key) ON. If voltage is not as specified, check for an open
4. Read voltage as per table. circuit as follows.
NOTE: Refer to POWER DISTRIBUTION AND CONTROL CIRCUIT CONTINUITY TEST
GROUNDS for LH fuse box pinout. RESULT (WHILE
REQUIRED TOOLS TEST PROBES PRESSING START
BUTTON)
FLUKE 115 LH fuse box
MULTIMETER MSR2-4
pin B9 Close to 0
(P/N 529 035 868)
ECMB-C4 MSR2-4

rmr2014-029 7
Subsection 05 (STARTING SYSTEM)

rmr2014-029-006_a rmr2014-029-005_a

1. Connector MSR2 location 1. Screws

2. Battery access panel

STARTER SOLENOID Starter Solenoid Input Voltage Test

Starter Solenoid Location
NOTE: In following illustration, the front storage
compartment module is removed.
1. Disconnect small terminal from solenoid as per
table and test voltage as follows.
2. Turn ignition key ON.
3. Read voltage while start button is pressed in.
REQUIRED TOOLS

FLUKE 115
MULTIMETER
(P/N 529 035 868)

STARTER SOLENOID INPUT VOLTAGE TEST

1 RESULT
(WHILE
TEST PROBES PRESSING
START
BUTTON)
rmr2014-029-003_b Battery
1. Starter Solenoid ST2 (VT/BG) Battery voltage
negative post

Starter Solenoid Connector Access

NOTE: The starter solenoid is mounted besides
the battery.
To access starter solenoid:
– Open front storage compartment.
– Remove battery access panel.

rmr2014-029-007_a

1. Starter solenoid
2. Violet/Beige wire

8 rmr2014-029
 Subsection 05 (STARTING SYSTEM)

If there is no voltage while pressing start button, REQUIRED TOOLS

check for an open circuit including pre-starting re-
lay mechanical contacts. FLUKE 115
If voltage is as specified, carry out a STARTER SO- MULTIMETER
LENOID CONTROL CIRCUIT TEST. (P/N 529 035 868)

Starter Solenoid Control Circuit Test SOLENOID WINDING CONTINUITY TEST

1. Disconnect small terminal from solenoid.
MEASUREMENT
2. Use a 12 Vdc test light and probe as per table. SOLENOID
TERMINALS RESISTANCE
IMPORTANT: Using a voltmeter could lead to @ 20°C (68°F)
false results.
STS1 STS2 Approximately 5
3. Observe test light while start button is pressed
in.
STARTER SOLENOID CONTROL CIRCUIT TEST
RESULT (WHILE
TEST LIGHT PROBES PRESSING START
BUTTON)
Battery
Test light should
ST1 (YE/PK) positive
be bright
terminal

rmr2013-028-003_b

Test for a stuck solenoid plunger as follows.

SOLENOID CONTACTS CONTINUITY TEST
SOLENOID CONNECTOR MEASUREMENT
Battery Starter
Open circuit
terminal terminal
rmr2014-029-007_b

1. 12 Vdc Test light

2. Yellow/Pink wire

If test light does not turn on or is dimmed while

cranking, check for an open circuit.
If test light is bright, the solenoid gets a proper
ground signal. Carry out a STARTER SOLENOID
STATIC TEST: CONTINUITY.
Starter Solenoid Static Test: Continuity
Disconnect battery.
Disconnect small terminals (ST1 and ST2) from so-
lenoid.
Measure the solenoid coil winding resistance as
follows.
rmr2013-028-003_a

rmr2014-029 9
Subsection 05 (STARTING SYSTEM)

If any measurement is out of specification, re- If any test failed, switch is defective. Replace with
place solenoid. a new one.
Reconnect battery and starter solenoid terminals. If switch is good, test related wiring/connectors.

Starter Solenoid Removal Clutch Switch Removal

Disconnect the battery. Remove clutch lever from handlebar, refer to
Remove front storage compartment module. CLUTCH subsection.
Remove the four electrical connections from the Push switch towards lever.
starter solenoid.
Remove the two mounting screws.

Starter Solenoid Installation

Install the new solenoid in the reverse order of the
removal procedure.
Carry out an engine start to validate that the new
solenoid functions.

CLUTCH SWITCH
SM6 Model rmr2008-028-032_a

Step 1: Push switch

Clutch Switch Continuity Test Lift switch to remove it.
Remove RH front panel to access clutch switch
connector. Refer to BODY subsection.
Disconnect clutch switch connector on RH side of
vehicle.

rmr2008-028-033_a

Step 2: Lift switch

Remove the console module, refer to BODY sub-

section.
Disconnect the clutch switch connector then re-
move the connector housing from the connector
support.

rmr2013-028-004_a
Clutch Switch Installation
1. Clutch switch connector Clutch switch installation is the reverse of the re-
moval procedure.
Using the FLUKE 115 MULTIMETER (P/N 529 035
868), probe connector pins as per table.
CLUTCH SWITCH CONTINUITY TEST
CLUTCH SWITCH RESISTANCE @
PIN
POSITION 20°C (68°F)
Lever fully depressed Below 3
A B
Released Infinite (OL)

10 rmr2014-029
 Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

DIGITALLY ENCODED SECURITY

SYSTEM (D.E.S.S.)
SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................................. 6

GENERAL
D.E.S.S. SYSTEM DESCRIPTION
The D.E.S.S. system is an electronic anti-start sys-
tem that allows engine starting only with a pro-
grammed key.
It is composed to the following components:
– The ignition key(s)
– The D.E.S.S. antenna
– The D.E.S.S. module
– The ECM.
rmr2014-040-007_a

TYPICAL
1. Ignition switch
2. Ignition key with a ROM chip
3. D.E.S.S. antenna
4. D.E.S.S. module

D.E.S.S. Antenna
The D.E.S.S. antenna is mounted around the key
end of the ignition switch.
When the D.E.S.S. system is powered up at key
ON, the antenna energizes the microcircuit in the
key and receives the digital code transmitted by
the key.
The D.E.S.S. antenna can only be acquired as
part of the ignition switch assembly. The assem-
bly can be replaced independently of the other
D.E.S.S. system components without requiring
rmr2014-040-008_a
any reprogramming of the keys into the system.
TYPICAL
1. Ignition switch
2. Ignition key with ROM chip
3. D.E.S.S. antenna
4. D.E.S.S. module

rmr2014-040 1
Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))
D.E.S.S. Module
rmr2014-040-006
When the D.E.S.S. module is powered up at key
ON, it energizes the D.E.S.S. antenna and reads
the key code that is transmitted to the antenna by
the key microcircuit.
The D.E.S.S. module then passes on the unique
key code to the ECM, for comparison with the key
codes it has stored in memory.
The D.E.S.S. module can be replaced indepen-
dently of the other D.E.S.S. system components
without requiring any reprogramming of the keys
into the system.
Ignition Keys
The ignition key(s) contain a ROM chip that is pro-
grammed with a unique digital type code (D.E.S.S.
code).
The key codes of the 2 keys that come with the
vehicle are programmed into the D.E.S.S. system
at the factory. Up to 8 keys can be programmed
on the Spyder Roadster.
The ignition keys can ONLY be programmed into
the system using B.U.D.S.. Key codes already
programmed in the system can be erased from
the ECM memory individually, or all at once.
Note that the D.E.S.S. circuitry on all new ECM
is already activated. However, the ECM does not
have any key codes stored in its memory.
Engine Control Module (ECM)
As part of the D.E.S.S. system, the ECM stores
the ignition key digital codes (D.E.S.S. codes),
and compares the key code it receives from the
D.E.S.S. module to the programmed key codes it
has stored in memory.
If the ECM recognizes the key code, it allows en-
gine starting.
2 rmr2014-040
If the ECM does not recognize the key code, it
does not allow engine starting. It will also trigger
the BAD KEY message in the multifunction gauge
as well as a CHECK ENGINE light.
When replacing the ECM, the vehicle keys must
be reprogrammed into its memory.
TROUBLESHOOTING
DIAGNOSTIC TIPS
NOTE: It is good practice to check for fault codes
using B.U.D.S. software as a first troubleshooting
step.
If a key is not recognized by the ECM, it will
trigger a BAD KEY message in the multifunction
gauge and set fault code P0513 (D.E.S.S. key in-
valid). Any problem in the system will trigger this
response as the ECM is not able to determine
why it cannot recognize the ignition key.
The ECM may not recognize the key for any of the
following reasons:
– The key is not programmed into ECM memory.
– The key, although programmed into memory, is
now defective (bad ROM chip or microcircuit).
– The antenna is open circuit.
– The D.E.S.S. module is faulty.
– There is an open circuit in the system wiring.
– When programming two keys, READ DATA
was selected between the first and second
key. The first key code has therefor not been
stored in ECM memory, even if WRITE DATA
was selected at the end of the procedure.
– When programming a key (or keys), WRITE
DATA was not selected after the key(s) were
added. The new data (key codes) was not
stored into ECM memory.
TROUBLE SHOOTING STEPS
1. Try every key that has been programmed to the
vehicle.
If a key cannot be recognized, it is probably at
fault. Try reprogramming the key into ECM mem-
ory. If it cannot be reprogrammed into the sys-
tem, replace it.
If none of the keys are recognized, they are prob-
ably not at fault.
2. Connect vehicle to B.U.D.S. and carry out the
following.
– Try reprogramming existing key(s) into ECM
memory.
 Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

– Carry out a wiring continuity check between SITUATION WHAT TO DO

ECM and D.E.S.S. module. Refer to WIRING
DIAGRAM. Defective Replace ignition switch. Refer to
D.E.S.S. IGNITION SYSTEM subsection.
– Carry out a D.E.S.S. MODULE INPUT VOLTAGE antenna Erase all key codes from ECM
TEST. memory and program new keys
– Carry out a D.E.S.S. ANTENNA CONTINUITY into ECM memory. Refer to KEY
TEST. PROGRAMMING in this subsection.
– Try a new D.E.S.S. module. Start vehicle to ensure proper
operation of new keys with D.E.S.S.
– Try programming a new key into ECM memory. system.
– Try a new ECM.
Defective Replace D.E.S.S. module.
D.E.S.S. Start vehicle to ensure proper
PARTS REPLACEMENT module operation of D.E.S.S. system.
GUIDELINE NOTE: It is not necessary to
reprogram the keys to the system.
Replace part(s) according to situation as per fol-
lowing table. Defective Replace ECM. Refer to
ECM ELECTRONIC FUEL INJECTION
SITUATION WHAT TO DO SYSTEM (EFI) subsection.
Program ignition keys into new ECM.
Adding a Ensure new key is mechanically Start vehicle to ensure proper
new key coded to the ignition switch barrel. operation of D.E.S.S. system.
Program new key into ECM
memory. Refer to KEY
PROGRAMMING in this subsection. PROCEDURES
Start vehicle to ensure
proper operation of new
key with D.E.S.S. system. KEY PROGRAMMING
Replacing a Erase all key codes from ECM memory Use the latest applicable B.U.D.S. version avail-
bad or lost and program new and existing good able from BOSSWeb. Refer to COMMUNICA-
key key into ECM memory. Refer to KEY TION TOOLS AND B.U.D.S. SOFTWARE subsec-
PROGRAMMING in this subsection. tion for proper connection instructions.
Start vehicle to ensure proper
operation of programmed keys with B.U.D.S. Setup for Key Programming
D.E.S.S. system.
1. Connect vehicle to B.U.D.S.
All keys Replace ignition switch. Refer to 2. Insert the key to be programmed in the ignition
have been IGNITION SYSTEM subsection. switch.
lost Erase all key codes from ECM
memory and program new keys NOTE: The key to be programmed must be me-
Ignition into ECM memory. Refer to KEY chanically coded (cut) to the ignition switch.
key broken PROGRAMMING in this subsection.
in ignition 3. Turn ignition switch to ON. DO NOT start the
Start vehicle to ensure proper engine.
switch operation of new keys with D.E.S.S.
Defective system.
ignition
switch
Defective Ensure all connector pins are clean,
wiring or corrosion free and make good contact.
connectors Repair or replace
wiring and connectors.
NOTE: Do not use dielectric
grease in D.E.S.S. system connectors.

rmr2014-040 3
Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

vmr2006-012-100_aen

8. Click on Keys tab.

rmr2008-039-002

TYPICAL - IGNITION KEY ON

4. Start B.U.D.S. and logon.

5. Wait during detection setup.
NOTE: If the following message does not auto-
matically go away, click the Retry button.

rmr2014-040-002_a

KEYS TAB

smr2014-026-003_a

RETRY BUTTON
6. Ensure the status bar shows the Kw2000 pro-
tocol and the appropriate number of modules to
its right according to the vehicle model.
Programming a Key
1. Carry out steps in B.U.D.S. SETUP FOR KEY
PROGRAMMING.
2. In B.U.D.S.,click on Keys tab.
3. Click on Add Normal Key button.

rbg2012-006-007

TYPICAL - EXAMPLE SUCCESSFUL CONNECTION

NUMBER OF MODULES
MODEL
CONNECTED
RT SM6 6
RT SE6 7
rmr2014-040-003_c
NOTE: If a CAN Configuration Kit (CCK) is in-
1. Click here to program a key
stalled, the number of modules listed in B.U.D.S.
will be increased by one. The following message should appear.
7. Click the Read Data button.

4 rmr2014-040
 Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

11. Click on EXIT button to end session.

rmr2014-040-004_a
4. Click "OK" to confirm the action.
If the following message appears, then the key
code of the key you are trying to program is al-
ready stored in the ECM memory. Click "OK" to
confirm message and try another key.
12. Turn ignition switch to OFF.
13. Disconnect all cables and hardware from vehi-
cle.
14. Store DLC connector in its holder.
15. Start vehicle to ensure the key is properly pro-
grammed into memory and recognized by the
ECM.
Erasing a Key
1. Using the key to be erased, carry out steps in
B.U.D.S. SETUP FOR KEY PROGRAMMING.
2. Click on Erase Key button.

rmr2014-040-005_a

NOTE: If programming more than one key, carry

on with the following steps. If only one key is to
be programmed, continue with step 10.
5. Turn ignition switch to OFF. Remove the pro-
grammed key.
6. Insert other key to be programmed.
7. Turn ignition key to ON.
rmr2014-040-003_a
8. Program the other key. 1. Click here to erase the key
9. Repeat previous steps to program other keys
(up to 8 keys may be programmed). The following message should appear.
10. When the desired amount of keys have been
programmed, click on Write Data button to
transfer new information to the ECM.

rmr2014-040-009_a

3. Click "OK" to confirm the action.

4. Click on Write Data button to transfer new set-
tings and information to the ECM.

vmr2006-012-100_ben

WRITE DATA BUTTON

NOTE: The Write Data button may be selected

after each key programming to immediately store
its code in the ECM memory. If Read Data is se-
lected instead of Write Data, the key code that
has just been programmed will not be stored in
the ECM and the key will not be recognized.

rmr2014-040 5
Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

vmr2006-012-100_ben vmr2006-012-100_ben

WRITE DATA BUTTON WRITE DATA BUTTON

5. Click on EXIT button to end session.
6. Turn ignition key to OFF.
7. Disconnect all cables and hardware from vehi-
cle.
8. Return the DLC connector into its holder.
5. Click on EXIT button to end session.
6. Turn ignition key to OFF.
7. Disconnect all cables and hardware from vehi-
cle.
8. Return the DLC connector into its holder.

Erasing All Keys D.E.S.S. ANTENNA

1. Carry out steps in B.U.D.S. SETUP FOR KEY
PROGRAMMING.
2. Click on Erase All Keys button.
D.E.S.S. Antenna Continuity Test
1. Remove front cargo module, refer to BODY
subsection.
2. Disconnect the D.E.S.S. antenna connector
from the D.E.S.S. module.

rmr2014-040-003_b

1. Click here to erase all keys

The following message should appear.

rmr2014-040-001_d

1. D.E.S.S. module
2. D.E.S.S. antenna connector

3. Using a multimeter set to setting, check for

continuity through the antenna.
REQUIRED TOOL
smr2010-039-001
FLUKE 115
3. Click "YES" to confirm the action. MULTIMETER
(P/N 529 035 868)
4. Click on Write Data button to transfer new set-
tings and information to the ECM.

6 rmr2014-040
 Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

D.E.S.S. ANTENNA CONTINUITY TEST

READING RESULT ACTION
Low resistance Good
Refer to
(aproximately antenna
TROUBLESHOOTING
14 ) circuit
Antenna
or its
Open circuit Replace antenna
wiring
bad

NOTE: The antenna is replaced as part of the

ignition switch assembly. Refer to D.E.S.S. AN-
TENNA REPLACEMENT that follows.
rmr2014-040-001_a

D.E.S.S. Antenna Replacement
1. Attach a long string to the antenna connector.
It will be used to feed the new antenna wiring
harness from the ignition switch to the D.E.S.S.
module.
2. Remove ignition switch from vehicle, refer to
IGNITION SYSTEM subsection.
NOTE: Ensure the string that is attached to the
antenna connector remains in the vehicle and is
accessible at the D.E.S.S. module and at the igni-
tion switch.
3. Attach string to antenna connector on new igni-
tion switch assembly and feed it through to the
D.E.S.S. module.
4. Electrically connect ignition switch and an-
tenna.
5. Turn ignition key to ON and ensure key is recog-
nized and D.E.S.S. system is functioning prop-
erly.
6. Complete ignition switch installation, refer to
IGNITION SYSTEM subsection.
7. Using B.U.D.S., reset fault codes, refer to DI-
AGNOSTICS AND FAULT CODES. subsection.
8. Install remaining removed parts and return vehi-
cle to service. Refer to applicable subsections.
1. D.E.S.S. module
2. Battery
3. RH fuse box
4. LH fuse box
D.E.S.S. Module Testing
The D.E.S.S. module cannot be tested.
To confirm if the D.E.S.S. module is at fault, dis-
connect it and connect a new D.E.S.S. module in
its place.
NOTE: D.E.S.S. modules for 2014 vehicles are
not compatible with modules of previous model
years.
Turn ignition switch to ON and wait to see if the
ignition key is recognized.
If the key is not recognized with a new module,
the old module is not at fault.
If the key is recognized, replace the old D.E.S.S.
module with the new one. Refer to D.E.S.S.
MODULE REPLACEMENT that follows.
D.E.S.S. Module Replacement
1. Refer to BODY subsection and remove front
cargo module.
2. Remove the D.E.S.S. module as per following
illustration.

D.E.S.S. MODULE
D.E.S.S. Module Location
The D.E.S.S. module is located behind front stor-
age compartment, just above battery.

rmr2014-040 7
Subsection XX (DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.))

rmr2014-040-001_c

Step 1: Disconnect antenna connector

Step 2: Disconnect D.E.S.S. connector
Step 3: Remove locking tie
Step 4: Remove retaining screws

3. For installation, reverse the removal proce-

dures. Tighten D.E.S.S. module retaining
screws to specification.
TIGHTENING TORQUE
D.E.S.S. module 7 N•m ± 1 N•m
retaining screws (62 lbf•in ± 9 lbf•in)

NOTICE Do not apply any dielectric grease in

the D.E.S.S. module connectors.
NOTE: Since the D.E.S.S. key codes are stored
in the ECM, It is not necessary to reprogram the
keys when replacing the D.E.S.S. module.
4. Turn ignition key to ON and ensure key is recog-
nized and D.E.S.S. system is functioning prop-
erly.
5. Using B.U.D.S., reset fault codes, refer to DI-
AGNOSTICS AND FAULT CODES. subsection.
6. Install remaining removed parts and return vehi-
cle to service. Refer to applicable subsections.

ECM REPLACEMENT
For ECM replacement, refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.
IMPORTANT: Ensure all vehicle keys are pro-
grammed into the new ECM, recognized at key
ON, and that the D.E.S.S. system is functioning
properly. Refer to KEY PROGRAMMING in this
subsection.

8 rmr2014-040
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

LIGHTS, GAUGE AND ACCESSORIES

SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ............................... 15, 18–21

GENERAL SYSTEM DESCRIPTION

Refer to WIRING DIAGRAM INFORMATION sub- (LIGHTING SYSTEM)
section for diagnostic tips on troubleshooting
electrical problems.

WARNING
It is recommended to always disconnect the
battery when replacing any electrical compo-
nent. Always disconnect battery as specified,
BLACK (-) cable first. Do not place tools on
battery.

Clean threads before applying a threadlocker. Re-

fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedures.

WARNING
rmo2014-005-017_a
Torque wrench tightening specifications
TYPICAL - LIGHTS LOCATION — FRONT OF VEHICLE
must be strictly adhered to. Locking de- 1. Headlight — high beam
vices when removed, must be replaced (e.g.: 2. Headlight — low beam
3. Position light
locking tabs, elastic stop nuts, self-locking
fasteners, cotter pins, etc.).

rmo2010-001-047_e

LIGHTS LOCATION – REAR OF VEHICLE

1. License plate light
2. Backup light
3. Turn signal light

rmr2014-030 1
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)
Japanese Models Only
rmo2014-005-022_a
LIGHTS LOCATION – REAR OF VEHICLE
1. License plate light
2. Backup light
3. Turn signal light
Headlights
The headlights automatically come ON when the
engine is started and reaches 600 RPM, and go
OFF automatically 20 seconds after engine shut
down.
SYSTEM DESCRIPTION
(MULTIFUNCTION GAUGE)
Multifunction Gauge Operation
WARNING
Watching or using the multifunction gauge
or the infotainment center can distract the
driver from the operation of the vehicle. Al-
ways keep on observing the traffic and make
sure the surrounding is clear and safe before
doing so.
The multifunction gauge includes analog
speedometer and tachometer, indicator lamps
and an infotainment center with a digital screen.
In addition, the gauge itself is a module. Through
CAN (Controller Area Network) it is in constant
communication with the various other on-board
modules. It also directly controls certain functions
of the vehicle such as the following.
– Load shedding relay ground
– Output signal to optional analog temperature
gauge
– Reads the low fuel level of optional analog fuel
gauge
2 rmr2014-030
– Left and right turn signal control
– Back-up lights output
– ACS (Air Controlled Suspension) operation
– Radio, iPod, XM radio and CB control
– Provides power to the left multifunction switch
– Provides power to the radio.
For more information on CAN refer to the CON-
TROLLER AREA NETWORK (CAN) subsection.
rmo2014-005-027_a
TYPICAL
1. Analog speedometer
2. Analog tachometer (RPM)
3. Indicator lamps
4. Digital display
1) Analog Speedometer
Displays vehicle speed in kilometers (km/h) or
miles per hour (MPH). To change units, refer to
PREFERENCES SCREEN or use B.U.D.S.
2) Analog Tachometer (RPM)
Displays engine revolutions per minute (RPM).
Multiply by 1000 to obtain actual revolutions.
3) Indicator Lamps and Messages
Indicator lamps inform of various conditions or
problems.
An indicator lamp can be on or flash alone or in
combination with another lamp.
The digital display provides a brief description for
some of the conditions or problems in conjunction
with an indicator lamp.
The message displayed is large and colored.
When a digital warning appears, it will show the
warning for 6 seconds and then the warning will
disappear for 60 seconds. During the 60 seconds,
the small digital indicator will flash. This sequence
will be repeated three times and then will stop for
15 minutes. During the 15 minutes only the indi-
cator lamps will be activated.
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

rmo2014-005-028_b

TYPICAL
1. Message/icon

Indicator Lamps
INDICATOR LAMPS (MALFUNCTIONS)
INDICATOR DIGITAL DIGITAL
CAUSE SYMPTOMS / WHAT TO DO
LAMP(S) INDICATOR WARNING

N R E displayed
instead of NONE
Gearbox
position sensor
Stop vehicle and allow to reach
neutral.
FLASHING selected gear malfunction

Wrong or
NONE KEY ERR Try another key or reprogram key.
defective key

– Stop and wait for engine

to cool off.
Engine is
NONE NONE – Check for leaks.
ON overheating
– Check coolant level and
adjust.
Low or high
NONE NONE Check charging system
ON battery voltage
ABS malfunction. No ABS operation. Wheel lock may
ABS NONE NONE
No ABS operation occur when braking hard.
ON
Engine RPM and vehicle speed
NONE NONE VSS malfunction is limited to maintain safe vehicle
ON operation.
BRAKE FAILURE No EBD operation. Rear wheel
BRAKE
OR
! FAILURE
EBD malfunction lock may occur under hard braking.
Check brake system
! ON BRAKE FAILURE BRAKE
Low brake fluid – Check for brake fluid leaks.
FAILURE -
OR
! LOW BRAKE
level or faulty – Check brake fluid level and
sensor adjust.
FLUID

! Faulty parking
NONE NONE brake or Check brake system
ON+BEEPING AT component
KEY OFF

rmr2014-030 3
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

INDICATOR LAMPS (MALFUNCTIONS)

INDICATOR DIGITAL DIGITAL
CAUSE SYMPTOMS / WHAT TO DO
LAMP(S) INDICATOR WARNING
Engine
Engine RPM may be limited to protect
management
NONE engine depending on the fault.
component
A fault code is active.
malfunction
Dynamic
Partial or no assist from DPS depending
NONE power steering
ON on the fault.
component
Engine RPM may be limited.
Transmission
Shifting may be harsh.
NONE Control Module
Transmission may not shift or
component
may have restrictions.
Important engine
management Vehicle speed and/or engine RPM is
LIMP HOME
component or limited.
FLASHING VSS malfunction
– Check for oil leaks.
NONE NONE Low oil pressure
ON – Check oil level and adjust
A combination of two different warnings can occur.
* BRP recommends having the vehicle transported when in LIMP HOME. If you operate the vehicle in LIMP
HOME, avoid abrupt maneuvers. In LIMP HOME, the engine RPM is limited and therefore the vehicle speed.

4) Digital Display
Displays useful real-time information to the rider
and is used as an interface for the infotainment
center.
For a complete description of the digital display,
refer to DIGITAL DISPLAY DESCRIPTION.
Important information messages can also be dis-
played, refer to MESSAGES IN MULTIFUNCTION
GAUGE.
Multifunction Gauge Startup
Information
A self test is initiated every time the ignition key
is turned on. The default riding screen will turn on
and indicator lights will turn on for a moment. This
allows the operator to validate that all indicators rmo2014-005-021_b

are working properly. 1. Category icons

2. Ambient temperature
Anytime the ignition switch is turned ON after 3. Clock
4. Gearbox position or upshift indicator arrow
having been in the OFF position for 5 minutes or 5. Cruise control status
more, the digital display will show the following 6. Trip meter
7. CB communication status (optional)
message: 8. Odometer
– BEFORE OPERATING READ THE SAFETY 9. Main screen
10. ECO mode icon
CARD ABOVE THEN PRESS MODE BUTTON.
Press the MODE button to acknowledge this mes- 1) Category Icons
sage to allow engine starting. There are 5 selectable category icons. Each icon
is linked to a different screen. See table below.
Digital Display Description
The display is divided in several areas as follows.

4 rmr2014-030
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

CATEGORY 7) CB Communication Status (Optional)

CATEGORY ICON SCREEN
ICON Displays wether the CB (citizens' band) is receiv-
ing (RX) or transmitting (TX).
Default riding
8) Odometer
Audio (option package) Total distance travelled in kilometers or miles
since the delivery from the factory. To change
CB (optional) units, refer to PREFERENCES SCREEN.
9) Main Screen
Trip meter
The main screen is the area where the most infor-
Preferences (only available mation is displayed. The display will change when
when vehicle is stopped) navigating through the available gauge functions.
For a complete description, refer to CATEGORY
ICON SCREEN DESCRIPTION.
You can navigate through the category icons to se-
lect several functions and to change certain set-
tings using the RECC (Roadster Electronic Com-
mand Center).
2) Ambient Temperature
The ambient air temperature is displayed in °C
or °F. To change units, refer to PREFERENCES
SCREEN.
3) Clock
The current time is displayed in 24h or am/pm
format. To change the format, refer to PREFER-
ENCES SCREEN. rmo2010-001-015_en

DEFAULT RIDING SCREEN SHOWN

4) Gearbox Position or Upshift Indicator
Arrow For a complete description of the screens, refer to
CATEGORY ICON SCREEN DESCRIPTION.
Displays the selected gearbox position or the up-
shift indicator arrow (refer to ECO MODE ICON). 10) ECO Mode Icon
5) Cruise Control Status The ECO (fuel economy mode) setting reduces
fuel consumption by limiting throttle response and
NOTE: To use the cruise control, the vehicle maximum throttle opening to maintain an optimal
speed must be above approximately 40 km/h cruising setting.
(25 MPH).
To activate ECO mode press the mode button for
Displays ON when the cruise control is turned on 2 seconds when in the main screen.
but not set to any speed.
Displays SET when the cruise control is in opera-
tion and a speed has been set.
6) Trip Meter
Time. distance travelled and average speed since
the last reset. Two trip meters are available and
they are identified as "A and "B". To change units,
refer to PREFERENCES SCREEN.
As a second function, the trip meter may display
an icon to inform the driver of a malfunction.

rmr2014-030 5
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

rmr2010-030-001

DIMMED DISPLAY FOR LOW LIGHT CONDITIONS

rmo2014-005-021_a
Day and night time contrast may be set indepen-
1. ECO mode icon
dently.
When ECO mode is activated, a green arrow will
alternate with the gearbox position indicator to in- Navigating in the Digital Display
dicate the optimal timing to shift up transmission. We recommend you practice selecting some
NOTE: Gearbox position indicator will return functions on the infotainment center before get-
when transmission is shifted. ting on the road. You will get used to them and
they will be easier to use on the road.
To deactivate ECO mode, press the mode button
for 2 seconds when in the main screen. Use the RECC (Roadster Electronic Command
Center) to control the display functions.
The ECO activation and deactivation can happen
only when the main screen is displayed.
The cluster send the ECO mode status via CAN.
The ECO mode appears in the cluster as soon as
the user presses and holds the button for 2s. The
ECM may wait for the throttle to be released to
activate the ECO mode.
The ECO mode is remembered at key off.

Automatic Digital Display Dimming

The multifunction gauge contains a photo sensor.
In low light conditions the display will automati-
cally change to the nighttime viewing screen.
rmo2010-001-020_a

1. RECC

Pressing the MODE button will move a selection

through the category icons, located at the top left
area of the screen, in this order: Default riding
screen, Audio, CB, Trip meter and Preferences.
Each press of the button will move the selection
to the next available icon. When an icon is se-
lected, its related screen will appear.
NOTE: The audio or CB icons are skipped when
the vehicle is not equipped with these features.
The Preferences screen is skipped when vehi-
cle is above 5 km/h (3 MPH), except for the SE6
model for the towing mode.

6 rmr2014-030
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

1 After acknowledging the initial safety message at

gauge startup, or after a few seconds elapsed in
any other screen without pressing any RECC but-
2 ton, the display will automatically return to the de-
fault riding screen.

Category Icon Screen Description

Default Riding Screen

rmo2010-001-015_ben

1. Category icons
2. Default riding icon selected
1 2
When the selection is on the last icon, it will then
move to the first icon when the MODE button will
be pressed.
In some screens, vertical or horizontal arrows
are visible. This indicates that you have to use
the LEFT/RIGHT button to change the setting
enclosed by the horizontal arrows and to use the 4 5
UP/DOWN button to change the setting enclosed rmo2010-001-401_aen

by the vertical arrows. TYPICAL - DEFAULT RIDING SCREEN

Pressing an arrow button repeatedly on single or
double arrows will move one selection at a time.
Holding an arrow button on a double arrow will
move to the end or beginning of the selection.
Holding the DOWN button on the audio volume
lower arrow will mute the audio system. Pressing
the UP arrows brings volume to the last setting.
2 Analog Gauges):
1 Bar gauge that continuously indicates the amount
rmo2010-001-022_cen
TYPICAL
1. Use the UP/DOWN button to select the vertical arrows
2. Use the LEFT/RIGHT button to select the horizontal arrows
When an item is selected, this sets the item to the
current value.
1. Engine coolant temperature (option package)
2. Fuel level (option package)
3. Digital speedometer
4. Engine speed (not factory set)
5. Radio preset or radio frequency (not factory set)
1) Engine Coolant Temperature (except models
with Separate Analog Gauges):
Bar gauge that continuously indicates the engine
coolant temperature.
NOTE: On models with a separate analog engine
coolant temperature gauge, the bar gauge is not
displayed in the digital display.
2) Fuel Level (except models with Separate
of fuel left in the fuel tank.
NOTE: On models with a separate analog fuel
level gauge, the bar gauge is not displayed in the
digital display.
NOTE: Low fuel indicator lamp turns on when
quantity of fuel is left for 50 km (31 mi) if riding
steady at speed of 100 km/h (62 MPH) in 6th gear.
3) Digital Speedometer:
Displays vehicle speed in kilometers (km/h) or
miles per hour (MPH). To change units, refer to
PREFERENCES SCREEN.
4) Engine Speed:

rmr2014-030 7
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

Displays engine speed in revolutions per minute Radio (FM, AM, WX, XM)
(RPM).
NOTE: This is not a default setting. To activate 1 3
this function, refer to PREFERENCES SCREEN.
5) Radio Preset or Radio Frequency:
Displays the selected radio preset or radio fre-
quency.
NOTE: This is not a default function. To activate
this function, refer to PREFERENCES SCREEN. 2 4
Audio Screen (Option)
This screen is only available when an audio sys-
tem is installed.
The audio screen will appear with its last configu-
ration. rmo2010-001-022_aen

TYPICAL - FM RADIO SHOWN

1. Current selected band
1 2. Station number preset
3. Current station
4. Volume level

Press the LEFT/RIGHT button to select the de-

rmo2010-001-022_ben
TYPICAL
1. Current selected audio device
Repeatedly pressing the SET button will display
the available audio devices in this order: FM,
AM, WX (weather channel), iPOD or AUX and XM
(satellite radio).
AUDIO SYSTEM ENABLING
Ignition switch ON
Press MODE button for 3 seconds immediately
after ignition switch is turned OFF
sired preset radio station.
Press and hold the LEFT/RIGHT button for more
than one second to SEEK the next available radio
station. The radio will remain tuned to that station.
Press the SET button and hold for more than one
second to enter the setup screen.
In the setup screen, press the LEFT/RIGHT button
to tune the radio frequency in increments of 0.2.
NOTE: When a frequency is already recorded in a
preset, its preset number will appear.
To record up to 15 station presets:
Press the DOWN button to record the actual fre-
quency to the preset number displayed.
NOTE: While riding, the radio station will be au-
tomatically recorded to the next available preset
number. If all preset numbers are already used,
the preset number 15 will be over written.

AUDIO SYSTEM DISABLING

Ignition switch ON, then OFF
Press MODE button for 10 seconds

NOTE: The FM, AM and WX radio bands will only

appear if a radio is installed. The XM radio will
only appear if a satellite radio is installed. If an
iPOD player is connected, iPOD will be displayed
instead of AUX.

8 rmr2014-030
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

1 Press and hold the LEFT/RIGHT button for more

than one second to change the playlist if the
playlist item is selected, to change the artist if the
artist item is selected and to change the album if
the album item is selected.
While riding, the available functions are:
2 – Audio volume and mute
– Previous or next song selection (iPod)
– Artist, album or playlist selection (iPod).

3 CB Screen (Optional)
This screen is only available when a CB is in-
stalled.
rmo2010-001-027_aen NOTE: The CB screen will appear whenever the
TYPICAL PTT (push to talk) button is pressed whatever the
1. LEFT/RIGHT button to select the frequency
2. UP button to select the preset number (vehicle stopped) screen that was displayed.
3. DOWN button to record the radio station

While riding, the available functions are: 1 2 3 4 5 6

– Audio volume
– Mute and seek (XM radio) functions
– Radio preset functions (selection and storing).
iPOD or AUX
When a MP3 player is connected to the vehicle
audio connector (option package), the AUX screen
will appear. It will play as set at the time of the
connection. Only the volume control will be avail-
able for this type of player.
When an iPOD is connected to the vehicle iPOD
connector (option package) the iPOD screen will
appear.
rmo2010-001-023_aen

TYPICAL
1. Current channel
2. CB communication status: RX (receiving), TX (transmitting) and
OFF
3. Squelch adjustment
4. Volume adjustment
5. Intercom volume adjustment (i-com)
6. Voice activation sensitivity adjustment (vox)

Use the LEFT/RIGHT buttons to select the item to

change (channel, squelch, headset volume, inter-
com volume and voice activation sensitivity).
Use the UP/DOWN buttons to set a value.
Press and hold the DOWN button for more than
one second to set the item to its lowest value.

rmr2011-079-011_en

TYPICAL iPOD SCREEN

Press the LEFT/RIGHT button to change the song

in the current folder.

rmr2014-030 9
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

Trip Meter Screen Within a column, use the UP/DOWN button to se-
lect the desired item. If more items are available
to the next right column, use the RIGHT button to
1 2 3
select the column then use again the UP/DOWN
button to select the desired item. Continue using
this pattern to reach the desired item.
When an item is selected, this sets the item to the
current value. You may then go to any screen, the
value will be kept.
NOTE: When in the 2nd or 3rd column, you can go
back to the column at the left using the LEFT but-
ton.
NOTE: When the units are changed they will be
changed on both the analog and the digital dis-
plays. The units will be used for the odometer and
both trip meters.

rmo2010-001-024_aen
1. Display selection: Trip A, B or Total
2. Pause or resume the selected trip meter
3. Reset the selected trip meter
Press the LEFT/RIGHT button to select the de-
sired trip meter.
Press the UP button to pause or resume the se-
lected trip meter.
Press the DOWN button to reset the selected trip
meter.
Preferences Screen
TROUBLESHOOTING
LOAD SHEDDING RELAY (LSR)
The Load shedding relay is commanded closed
(ON) by the cluster when engine RPM is above
600 RPM.
DIAGNOSTIC TIPS
IMPORTANT: When solving an electrical problem,
the first thing to do is to check the battery condi-
tion as well as its cables and connections.
Install a battery charger on battery terminals (un-
der seat) for any tests that involve a prolonged
"key ON" period. If battery voltage gets too low,
not only test results can be altered, but the vehi-
cle electrical system may not operate normally.
Pay attention to ground wires. They could be-
come loose or corroded which causes them to
act as an additional load in a circuit, dropping
voltage and reducing current to components.
Some components may be grounded through
their outer casing and mounted hardware. This
should also be considered.

rmr2010-030-058_aen
1. 1st column: Main category
2. 2nd column: Secondary category or item
3. 3rd column: Unit or setting
Electrical Connectors
Pay particular attention to ensure that pins are not
out of their connectors, loose, or damaged. The
troubleshooting procedures may not cover prob-
lems resulting from one of these causes.

This screen is only available when vehicle is

stopped.
Use the LEFT/RIGHT button to select the desired
column.

10 rmr2014-030
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

NOTICE Ensure all terminals are properly Lower Headlight Units (European Models Only)
crimped on wires and connector housings are 1. Remove both middle side panels.
properly fastened. When replacing any electric
or electronic part(s), always check electrical 2. To adjust headlight beam, turn the appropriate
connections. Make sure that they are clean, adjustment knob. Adjust evenly on both sides.
corrosion-free, tight and make good contact.
The voltage and current might be too weak to
go through dirty or corroded connector pins
or terminals.

MULTIFUNCTION GAUGE
TROUBLESHOOTING
GAUGE FUNCTIONS INOPERATIVE OR
WORKING INTERMITTENTLY
1. Power supply or ground problem
- Check power supply and ground circuits.

PROCEDURES
HEADLIGHTS
rmo2014-005-014_a

Headlights Aiming Adjustment RH SIDE SHOWN

1. Adjustment knob "HB" (High beam)
1. Remove both middle side panels. Refer to 2. Adjustment knob "LB" (Low beam)
BODY subsection.
3. Reinstall side panels.
Upper Headlight Units
HEADLIGHT BEAM ADJUSTMENT
To adjust headlight beam, turn the adjustment
knob. Adjust both headlights evenly. Raise beam Turn knob clockwise
Lower beam Turn knob counterclockwise

Beam Selector Switch Test with

B.U.D.S.
1. In B.U.D.S., select Monitoring and Cluster
tabs.
2. Monitor the High Beam indicator in the Switch
Inputs field.

rmo2014-005-011_b

RH SIDE SHOWN
1. Adjustment knob "HB"

HEADLIGHT BEAM ADJUSTMENT rmr2011-079-003_a

1. High Beam indicator

Raise beam Turn knob clockwise
Lower beam Turn knob counterclockwise If the indicator turns ON when high beam is se-
lected, an input signal in sent to the gauge.

rmr2014-030 11
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

If the indicator does not turn ON when high beam LO HEADLIGHT RELAY VOLTAGE TEST - R2
is selected, check switch and wiring continuity.
VOLTAGE
TEST PROBES CONDITION
Headlight Wire Identification (DC)

Refer to appropriate wiring diagram. Close to

A9 to chassis
At all times battery
ground
Headlight Circuit Protection voltage
Refer to appropriate wiring diagram. If results are as specified, try a new relay.
Headlight Relay Voltage Test If results are not as specified, check headlights re-
lay (R6) repair wiring/connectors.
1. Make sure circuit fuse(s) is in good condition
and powered. Headlight Voltage Test
2. Check for voltage at the LFB, headlight relay 1. To test for voltage at the headlight bulb and or
(R6) location using the following table: shutter solenoid, disconnect the headlight con-
HEADLIGHT RELAY VOLTAGE TEST nector, refer to HEADLIGHT REPLACEMENT in
this subsection.
VOLTAGE
TEST PROBES CONDITION 2. Test for power at the headlight connector as per
(DC)
the following chart:
Close to
LFB-C3 to chassis 3. Start engine.
At all times battery
ground
voltage HEADLIGHT VOLTAGE TEST
Close to HEADLIGHT
LFB-C1 to chassis
At all times battery BEAM
ground
voltage TEST PROBES SELECTOR RESULT
SWITCH
If results are as specified, try a new relay. POSITION
If results are not as specified, repair wiring/con- LHL-1 or RHL-1 to Close to
nectors. Low beam
chassis ground battery voltage

HI and LO Headlight Relay Voltage Test LHL-1 to LHL-4 or Close to

Low beam
RHL-1 to RHL-4 battery voltage
1. Make sure fuses J4 and J5 of RFB are in good
condition and powered. LHL-3 or RHL-3 to Close to
High beam
chassis ground battery voltage
2. Check for voltage at the RFB, HI (R1) and LO
(R2) headlight relays location using the follow- LHL-3 to LHL-4 or Close to
High beam
ing chart. RHL-3 to RHL-4 battery voltage

HI HEADLIGHT RELAY VOLTAGE TEST - R1 If there is no voltage at pin 1 in the low beam po-
VOLTAGE sition, check the headlight and HI/LO headlight re-
TEST PROBES CONDITION lays.
(DC)
Close to If there is no voltage at pin 3 in the high beam
A11 and A10 to position, check the HI/LO headlight relay.
At all times battery
chassis ground
voltage If voltage is within specification from pin 1 to
Engine pin 4, however the headlight does not illuminate,
Close to replace the headlight bulb.
A12 to chassis running and
battery
ground High beam
selected
voltage North American models only
If voltage is within specification from pin 3 to pin 4,
however the high beam shutter does not function,
replace the high beam shutter.

12 rmr2014-030
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

Headlight Beam Selector Switch Test Fog Light Circuit Protection

NOTE: Due to the electronic circuitry of the head- Refer to appropriate wiring diagram.
light beam selector switch, it must be tested us-
ing a voltmeter while headlights are ON. Fog Light Voltage Test at Auxiliary
1. Remove the left side acoustic panel. Refer to Light Connector
BODY subsection. NOTE: Fog lights are low head lamps outside
2. Back probe connector terminal and connect North America.
multimeter as indicated. 1. Make sure circuit fuse(s) is in good condition
3. Turn ignition switch ON. and powered.
2. Remove the middle side panel. Refer to BODY
subsection.
3. Disconnect the fog light connector to be tested.
4. Start engine.
5. Check for voltage at the fog light connector as
per the following chart.
FOG LIGHTS VOLTAGE TEST AT AUXILIARY
LIGHT CONNECTOR
FOG LIGHT
SWITCH
CONNECTOR RESULT
POSITION
(LBHL OR RBHL)
Close to
Pin 2 to pin 3 Switch ON battery
voltage
rmr2010-030-002_a

1. MSL2 connector Close to

Pin 3 to chassis
2. MSL3 connector Switch ON battery
ground
voltage
HEADLIGHT BEAM SELECTOR SWITCH TESTING
Close to
SWITCH SWITCH Pin 2 to positive
RESULT Switch OFF battery
CONNECTOR POSITION battery connection
voltage
Close to
Connector MSL2-2 If there is no voltage at pin 3 with the headlight
Low beam battery
to chassis ground switch ON, perform the FOG LIGHT VOLTAGE
voltage
TEST AT SWITCH.
High beam
Connector MSL2-2 Close to If result at pin 2 is not as specified, repair ground
or flash high
to chassis ground 0.45 Vdc circuit.
beam

If the headlight beam selector switch test is within Fog Light Voltage Test at Switch
specification, however the high beam relay volt- 1. Make sure circuit fuse(s) is in good condition
age test failed, test the continuity between left and powered.
multifunction connector MSL2-2 and R6 relay ter-
2. Remove the central panel to access the back of
minal LFB-D1.
the fog light switch. Refer to BODY subsection.
If the test is not to specification perform the LEFT
3. Perform the test at the back of the fog light
MULTIFUNCTION SWITCH VOLTAGE TEST in this
switch with the switch connected.
subsection.
4. Start engine.
FOG LIGHTS (OPTION PACKAGE) 5. Perform the test using the following illustration
and chart.
Fog Lights Wire Identification
Refer to appropriate wiring diagram.

rmr2014-030 13
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

Licence Plate Light Test

1. Make sure circuit fuse(s) is in good condition
and powered.
2. Remove the licence plate light.
3. Perform the test on the licence plate light as per
the following chart using a multimeter.
LICENCE PLATE LIGHT TEST
LICENCE IGNITION
PLATE LIGHT SWITCH RESULT
CONNECTOR POSITION

rmr2010-30-040_a
Close to
PL-1 to PL-2 ON battery
BACK OF FOG LIGHT CONNECTOR (PIN-OUT)
voltage
FOG LIGHTS VOLTAGE TESTING AT SWITCH Close to
PL-1 to chassis
FOG LIGHTS ON battery
SWITCH ground
SWITCH RESULTS voltage
POSITION
CONNECTOR Close to
PL-2 to positive
Close to Any battery
Pin 2 to chassis battery connection
Any battery voltage
ground
voltage
If the test is within specification, replace the li-
Close to cence plate light bulb.
Pin 3 to chassis
Switch ON battery
ground If results are not as specified, check wiring/con-
voltage
nectors.
If there is voltage at pin 2 to but no voltage at
pin 3 when the switch is ON, replace the fog lights TURN SIGNAL LIGHTS/HAZARD
switch. WARNING LIGHTS
If there is no voltage from pin 2 to chassis ground,
test load shedding relay. Refer to POWER DISTRI- Turn Signal Lights/Hazard Warning
BUTION AND GROUNDS subsection. Wire Identification
If there is voltage at pin 3, check the continuity Refer to appropriate wiring diagram.
from pin 3 of the fog lights switch and pin 3 of the
fog light connector. Repair the wires/connectors Turn Signal Lights/Hazard Warning
as necessary. Circuit Protection
Refer to appropriate wiring diagram.
LICENSE PLATE LIGHT
Front Turn Signal Test
License Plate Light Wire Identification 1. Make sure circuit fuse(s) is in good condition
Refer to appropriate wiring diagram. and powered.
2. Remove the front mirror assembly of the turn
License Plate Light Circuit Protection signal to be tested. Refer to BODY.
Refer to appropriate wiring diagram.
3. Perform the following test at the front turn sig-
nal connector using a multimeter.
4. Turn ignition on and activate turn signal switch
on the vehicle side to be tested.

14 rmr2014-030
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

FRONT TURN SIGNAL TEST FLASHER WIRE CONTINUITY TEST

PROBE RESULTS MULTIFUNCTION
TURN SIGNAL
GAUGE RESULTS
Pin 1 Pin 2 Pulsing 8 to 12 Vdc CONNECTOR
CONNECTOR (CL)
Pin 1 Chassis ground Pulsing 8 to 12 Vdc Left front turn Close to
Pin 4
Positive signal pin 1 0.2
Pin 2 battery Close to battery voltage Left rear turn Close to
connection Pin 4
signal pin 4 0.2
If results are as specified, replace turn signal. Right front turn
Pin 5
Close to
signal pin 1 0.2
If there is no voltage at pin 1, carry out TURN SIG-
NAL SWITCH TEST WITH B.U.D.S. in this subsec- Right rear turn
Pin 5
Close to
tion. signal pin 4 0.2
If result at pin 2 is not as specified, repair ground
If all the turn signal tests and the turn signal
circuit.
switch test with B.U.D.S. are satisfactory, replace
Rear Turn Signal Test the multifunction gauge.
1. Make sure circuit fuse(s) is in good condition If result is not as specified, repair defective circuit.
and powered.
Rear Turn Signal Bulb Replacement
2. Remove the rear taillight to be tested. Refer (Japanese Models Only)
to TAILLIGHT/BRAKE LIGHT REPLACEMENT
in this subsection.
3. Perform the following test at the rear taillight
connector using the FLUKE 115 MULTIMETER
(P/N 529 035 868).
4. Turn ignition ON and activate turn signal switch
on vehicle side to be tested.
REAR TURN SIGNAL TEST
PROBE RESULTS
Pin 4 Pin 5 Pulsing 8 to 12 Vdc
Pin 4 Chassis ground Pulsing 8 to 12 Vdc
Positive
Pin 5 battery Close to battery voltage
connection
rmo2014-005-022_b

1. Flashers
If results are as specified, replace turn signal bulb.
If there is no voltage at pin 4, carry out TURN SIG- 1. Remove screw and lens from flasher to access
NAL SWITCH TEST WITH B.U.D.S. in this subsec- the bulb.
tion. 2. Replace the bulb.
If result at pin 5 is not as specified, repair ground
circuit. TURN SIGNAL SWITCH
Turn Signal Wire Continuity Test Turn Signal Switch Test with B.U.D.S.
1. Remove the multifunction gauge. Refer to 1. In B.U.D.S., select Monitoring and Cluster
MULTIFUNCTION GAUGE in this subsection. tabs.
2. Perform the following test between the turn 2. Monitor the Flasher L and Flasher R indicators
signal connector and the multifunction gauge in the Switch Inputs field.
connector using a multimeter.

rmr2014-030 15
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

Hazard Warning Lights Switch Test at

Gauge Connector
Before proceeding with this test, inspect the 10 A
fuse RFB-F2.
If the turn signals function, however the hazard
warning switch does not function, perform the fol-
lowing test.
1. Remove the multifunction gauge, refer to MUL-
TIFUNCTION GAUGE in this subsection.
rmr2011-079-003_b 2. Perform the following test at the multifunction
1. Flasher L and Flasher R indicators gauge connector.

If the indicator turns ON when the correspond- HAZARD WARNING LIGHTS SWITCH TEST
ing turn signal is selected, the switch is good and AT GAUGE CONNECTOR (CL)
the gauge receives the signal. Carry out the TURN SWITCH
TEST PROBES RESULT
SIGNAL WIRE CONTINUITY TEST in this subsec- CONDITION
tion. Close to
CL-10 and chassis
If the indicator does not turn ON when the corre- Activated battery
ground
sponding turn signal is selected, replace switch. voltage

HAZARD WARNING LIGHTS If test is within specification, replace the multi-

function gauge.
SWITCH
If test is not within specification, perform the
Hazard Warning Lights Switch Test HAZARD WARNING SWITCH TEST AT RH MUL-
with B.U.D.S. TIFUNCTION SWITCH CONNECTOR.
1. In B.U.D.S., select Monitoring and Cluster
tabs.
Hazard Warning Lights Switch Test at
RH Multifunction Switch Connector
2. Monitor the Hazard indicator in the Switch In-
puts field. This test is performed at the MSR2 connector.

rmr2011-030-001_c

1. Hazard indicator

If the indicator turns ON when the hazard warning rmr2010-030-004

lights are on, an input signal is sent to the gauge.
If the indicator does not turn ON, check wiring
continuity and carry out HAZARD WARNING
LIGHTS SWITCH TEST AT GAUGE CONNECTOR.
MSR2 CONNECTOR
1. Remove the left hand acoustic panel, refer to
BODY subsection.
NOTE: The hazard switch is an Hall Effect switch.
It must be tested using a voltmeter while circuit is
ON.
Back-probe the connector with a multimeter.

16 rmr2014-030
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

2. Turn the ignition switch ON. TAILLIGHT/BRAKE LIGHT TEST (CONNECTORS

3. Perform the test using the following chart: RTL OR LTL)

HAZARD WARNING LIGHTS SWITCH TEST AT TAILLIGHT SWITCH

RESULTS
RH MULTIFUNCTION SWITCH CONNECTOR CONNECTOR CONDITIONS

SWITCH Close to
TEST PROBES RESULTS Pin 2 to chassis Ignition
POSITION battery
ground switch ON
voltage
Close to
MSR2-6 to chassis Close to
ON battery Pin 1 to chassis
ground Brake applied battery
voltage ground
voltage
Close to
MSR2-1 to chassis Close to
Any battery Pin 5 to positive
ground Any battery
voltage battery connection
voltage
MSR2-2 to chassis
OFF Close to 0 Vdc
ground If there is no voltage at pin 2 of the taillight con-
MSR2-2 to chassis nector, check continuity from taillight connector to
ON 11 to 12 Vdc pin F of the ignition switch. Repair as necessary.
ground
If there is no voltage at pin 1 of the taillight con-
If all tests are within specification, check the con- nector, check for voltage at the brake light switch.
tinuity from the MSR2 connector to cluster CL-10 Perform also the BRAKE LIGHT SWITCH TEST.
and repair as necessary. Refer to BRAKES subsection.
If there is no voltage at MSR2-6, check the conti- If result at pin 5 is not as specified, repair ground
nuity from MSR2-6 to IK-G of the ignition switch circuit.
and repair as necessary.
If there is no voltage at MSR2-1, check continuity POSITION LIGHTS
between circuit fuse and pin MSR2-1. Repair as
necessary. Position Lights Wire Identification
If there is voltage at MSR2-1 and MSR2-6 but not Refer to appropriate wiring diagram.
at MSR2-2 when the switch is activated, replace
the hazard switch. Position Lights Circuit Protection
Refer to appropriate wiring diagram.
TAILLIGHT/BRAKE LIGHT
Position Lights (Pilot light)Test
Taillight/Brake Light Wire Identification 1. If taillight, position and licence lights are inoper-
Refer to appropriate wiring diagram. ative, check if circuit protection is in good con-
dition and powered.
Taillight/Brake Light Circuit Protection 2. Remove the position light bulb. Refer to PO-
Refer to appropriate wiring diagram. SITION LIGHTS BULB REPLACEMENT in this
subsection.
Taillight/Brake Light Test
3. Perform the test on the position light as per the
If no lights function check thelight circuit protec- following chart using a multimeter.
tion fuse.
1. Remove taillight to be tested.
2. Perform the following test at the taillight con-
nector using the following illustration and chart.

rmr2014-030 17
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

POSITION LIGHTS TEST (FPL1 OR FPL2) BACK UP LIGHTS TEST (RTL OR LTL)
IGNITION PROBE RESULTS
POSITION LIGHT
SWITCH RESULTS
CONNECTOR Pin 3 Pin 5 Close to 12 Vdc
POSITION
Close to Chassis
Pin 3 Close to 12 Vdc
Pin 1 to pin 2 Switch ON battery ground
voltage Positive
Close to Pin 5 battery Close to 12 Vdc
Pin 1 to chassis connection
Switch ON battery
ground
voltage
If the test from pin 3 to pin 5 is within specifica-
Close to tion, replace the back up light bulb.
Pin 2 to positive
Any battery
battery connection If the test from pin 3 to chassis ground is not
voltage
within specification, perform the BACK UP
If the test is within specification, replace the posi- LIGHTS WIRE CONTINUITY TEST on defec-
tion light bulb. Refer to POSITION LIGHTS BULB tive circuit.
REPLACEMENT in this subsection. If result at pin 5 is not as specified, repair ground
If there is no voltage at pin 1, check continuity circuit.
from pin F of the ignition switch connector to pin 1
of the position light connector. Repair wire as nec- Back Up Lights Wire Continuity Test
essary. 1. Remove the multifunction gauge. Refer to
If result at pin 2 is not as specified, repair ground MULTIFUNCTION GAUGE in this subsection.
circuit. 2. Perform the following test between the turn
signal connector and the multifunction gauge
BACK UP LIGHTS connector using the FLUKE 115 MULTIMETER
(P/N 529 035 868).
Back Up Lights Type
BACK UP LIGHTS WIRE CONTINUITY TEST
Back up lights are light bulbs located in the rear
taillights. MULTIFUNCTION
TAILLIGHT GAUGE
RESULT
Back Up Lights Wire Identification CONNECTOR CONNECTOR
(CLUSTER)
Refer to appropriate wiring diagram.
Close to
Pin 1 (LTL or RTL) Pin 7 (CL)
Back Up Lights Circuit Protection 0.2

Refer to appropriate wiring diagram.
Back Up Lights Test
1. Remove the rear taillight to be tested. Refer to
TAILLIGHT/BRAKE LIGHT in this subsection.
2. Perform the following test at the rear taillight
connector using the FLUKE 115 MULTIMETER
(P/N 529 035 868).
3. Turn ignition on and put vehicle in reverse.
If all back up lights tests are within specifications,
replace the multifunction gauge.
MULTIFUNCTION GAUGE
Multifunction Gauge (Cluster) Wire
Identification
Refer to appropriate wiring diagram.
Multifunction Gauge Test Using
B.U.D.S.
Connect vehicle to the latest applicable B.U.D.S.
version. Refer to COMMUNICATION TOOLS
AND B.U.D.S. subsection.
In B.U.D.S., select the Activation and Cluster
tabs.
Click on the WOW Test button.

18 rmr2014-030
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

MULTIFUNCTION GAUGE (CLUSTER) POWER

TEST WITH MULTIMETER
IGNITION VOLTAGE
TEST PROBES
POSITION DC
Multifunction Close to
Chassis
connector Any battery
ground
pin 9 (CL) voltage
Multifunction Close to
Chassis
connector ON battery
ground
rmr2014-030-002_a
pin 8 (CL) voltage

All indications will come and stay ON so that you MULTIFUNCTION GAUGE (CLUSTER) POWER
can verify each indication. TEST WITH TEST LIGHT

NOTE: The WOW Test only tests the gauge Ana- IGNITION TEST
TEST PROBES
log displays, LEDs, and LCD. It does not test the POSITION LIGHT
actual circuit functions related to each indication. Multifunction
Chassis Bright
connector Any
ground light
Multifunction Gauge Power Test pin 9 (CL)
If the multifunction gauge is inoperative, first Multifunction
check for fault codes with B.U.D.S., record all Chassis Bright
connector ON
ground light
faults then erase them. Reactivate the electrical pin 8 (CL)
system and recheck for faults. If any fault code
appears, perform service actions required. Re- If there is no power at pin 9, check fuses and the
fer to COMMUNICATION TOOLS AND B.U.D.S. related circuit.
subsection. If there is no power at pin 8, check fuses, main
1. Remove multifunction gauge. relay and the related circuit.
2. Perform testing at multifunction gauge connec- If the power test is within specification, continue
tor as per following illustration and tables. with the MULTIFUNCTION GAUGE GROUND
TEST.
Multifunction Gauge (Cluster) Ground
Test
Perform the multifunction gauge ground tests
with the FLUKE 115 MULTIMETER (P/N 529 035 868)
set to OHMS and then with a test light.
MULTIFUNCTION GAUGE GROUND TEST
WITH MULTIMETER
TEST PROBES OHMS ( )
Multifunction
rmr2010-030-014_a Chassis
connector pin 11 Close to .2
MULTIFUNCTION GAUGE CONNECTOR (PIN-OUT) ground
(CL)
3. Perform the multifunction gauge power tests
with the FLUKE 115 MULTIMETER (P/N 529 035 MULTIFUNCTION GAUGE GROUND TEST
WITH TEST LIGHT
868) set to Vdc and then with a test light.
TEST PROBES TEST LIGHT
Multifunction Positive
connector pin 11 battery Bright light
(CL) connection

If the ground at pin 11 is not within specification,

check the related circuit.

rmr2014-030 19
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

If the ground tested to specification, continue

with the MULTIFUNCTION GAUGE CAN WIRE
TEST.
Multifunction Gauge CAN Wire Test
1. Remove the right side service panel. Refer to
BODY subsection.
vmr2006-020-058_aen
2. Perform the multifunction gauge CAN wire test
with the FLUKE 115 MULTIMETER (P/N 529 035 Make sure you have the right type and gauge
868) set to the OHMS. Perform the test be- model for the vehicle you are working on before
tween the multifunction gauge connector and answering Yes, otherwise it will not function
the DLC (Diagnostic Link Connector) located properly. Select Yes to continue.
underneath the right side service panel.
Once the gauge has been matched to the ECM,
MULTIFUNCTION GAUGE (CLUSTER) you will need to set the units of measurement,
CAN WIRE TEST miles or kilometers.
TEST PROBES OHMS ( ) In B.U.D.S., select Read Data.
DLC1 Select Setting and Cluster tabs and select the de-
Multifunction
connector pin 24
(Diagnostic Close to sired unit.
Link Connector) 0.2
(CL) (CAN HI)
connector pin 1
DLC1
Multifunction
(Diagnostic Close to
connector pin 23
Link Connector) 0.2
(CL)(CAN LO)
connector pin 2

If the CAN wire verification test fails, check the

related circuit.
If the multifunction gauge functions, however
there is a suspected communication problem with
another component, perform this test between
the multifunction gauge and that component.
If the multifunction gauge power, ground and
CAN verification tests are all to specifications and rmr2011-079-007_a

the multifunction gauge is inoperative, replace 1. Cluster Units

the multifunction gauge.
Multifunction Gauge Replacement
NOTE: If the multifunction gauge is replaced, the
engine may not start because of the security ex-
change coding. The gauge must be matched to
the ECM for the vehicle to start.
Connect vehicle to B.U.D.S. Refer to COMMUNI-
CATION TOOLS AND B.U.D.S. subsection.
Once connected, you will see a message similar
to the following illustration.
NOTE: The units of measurement may also be
set using the MODE button on the RECC on the
left hand multifunction switch. Refer to the PREF-
ERENCES SCREEN in CATEGORY ICON SCREEN
DESCRIPTION located in this subsection.
The SPS (Suspension Position Sensor) must be re-
set with B.U.D.S. Refer to REAR SUSPENSION
subsection for the complete reset procedure.
Select the Faults tab and see if there are any
active fault codes. If the faults have all been
corrected, clear the occurred faults displayed and
start vehicle.
Finally, make sure the multifunction gauge func-
tions properly and that all settings and indications
are within parameters.

20 rmr2014-030
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

ANALOG COOLANT PASSENGER HEATED GRIP SWITCH (RLH OR

TEMPERATURE GAUGE RRH) TEST (AT SWITCH CONNECTOR)
TEST PROBES RESULTS
Analog Coolant Temperature Sensor
Wire Identification Pin 1 to Right Heated Grip Close to battery
Control (RHS-C) voltage
Refer to appropriate wiring diagram.
Pin 2 to Right Heated Grip Close to battery
ANALOG FUEL GAUGE Control (RHS-C) voltage
Close to battery
Analog Fuel Gauge Sensor Wire Pin 2 to chassis ground
voltage
Identification
Right Heated Grip Control
Refer to appropriate wiring diagram. Close to 0.2
(RHS-C) to chassis ground

LEFT MULTIFUNCTION SWITCH If test is to specification, proceed with the passen-

Left Multifunction Switch Wire
Identification
Refer to appropriate wiring diagram.
Left Multifunction Switch Circuit
Protection
Refer to appropriate wiring diagram.
FRONT HEATED GRIPS
Front Heated Grips Wire Identification
Refer to appropriate wiring diagram.
Front Heated Grips Circuit Protection
Refer to appropriate wiring diagram.
PASSENGER HEATED GRIP
SWITCH
Passenger Heated Grips Wire
Identification
Refer to appropriate wiring diagram.
Passenger Heated Grips Switch Circuit
Protection
Refer to appropriate wiring diagram.
Passenger Heated Grip Switch Test
1. Remove the battery panel and switch as-
sembly. Refer to PASSENGER HEATED GRIP
SWITCH REMOVAL in this subsection.
2. Turn ignition switch to ON position and start en-
gine.
3. Perform the test with the FLUKE 115 MULTIME-
TER (P/N 529 035 868) using the following table.
ger heated grip element resistance test.
If there is no voltage from the Pin 2 wire to chassis
ground, check the circuit fuse and relay.Refer to
the WIRING DIAGRAM.
If there is no voltage from the Pin 1 wire to chassis
ground, proceed with the passenger heated grip
element resistance test.
If there is no continuity from BK wire to chassis
ground, check the ground wire and repair as nec-
essary.
Passenger Heated Grip Element
Resistance Test
1. Remove the right or left rear switch panels to
access the rear grip connector.
2. Perform the test with the FLUKE 115 MULTIME-
TER (P/N 529 035 868) using the following table.
PASSENGER HEATED GRIP ELEMENT
RESISTANCE TEST
TEST PROBES RESULTS
PIN 1 to PIN 2 of either grip
8 to 10
element (RLH or RRH)
If the resistance of either grip element is not
within specification, replace the defective grip.
If the resistance is within specification and the
voltage and ground to the switch are also good,
replace the passenger rear heated grip switch.
RADIO MODULE
Radio Module Wire Identification
Refer to appropriate wiring diagram.
Radio Module Circuit Protection
Refer to appropriate wiring diagram.

rmr2014-030 21
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

Radio Tests Guidelines

Ensure the circuit is powered. Refer to the appro-
priate WIRING DIAGRAM.
The following voltage tests can be carried out us-
ing a test light. A dim test light indicates a possi-
ble parasitic resistance in the tested circuit.
To access the radio connector, refer to RADIO RE-
MOVAL in this subsection.
Radio Constant Power Voltage Test
1. Refer to BODY subsection and remove the fol-
lowing:
– Right middle side panel
rmr2010-030-022_a
– Right top side panel RADIO CONNECTOR PIN-OUT (RDO1)
– Right rear side panel.
2. Remove right radio control panel and switch as- RADIO CONSTANT POWER CIRCUIT
VOLTAGE TEST
sembly.
3. Disconnect radio connector. TEST PROBES VOLTAGE DC
Close to battery
RDO1-27 Chassis ground
voltage
Close to battery
RDO1-28 Chassis ground
voltage
Close to battery
RDO1-29 Chassis ground
voltage

If voltage is within specification, carry out RADIO

ACTIVATION POWER VOLTAGE TEST.
If voltage is not within specification, carry out RA-
DIO CONSTANT POWER CIRCUIT CONTINUITY
TEST.
Radio Activation Power Voltage Test
rmr2010-030-021
1. Turn ignition switch to the RUN position.
4. Test the radio voltage power at the at the radio 2. Perform the following test with a multimeter.
connector as per following tables and illustra-
RADIO ACTIVATION POWER CIRCUIT
tion using a multimeter.
VOLTAGE TEST
TEST PROBES VOLTAGE DC
Close to battery
RDO1-33 Chassis ground
voltage

If voltage is within specification, carry out RADIO

GROUND CIRCUIT TEST.
If voltage is not within specification, perform RA-
DIO ACTIVATION POWER CIRCUIT CONTINUITY
TEST.

22 rmr2014-030
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

Radio Constant Power Circuit RADIO GROUND CIRCUIT TEST

Continuity Test
TEST PROBES RESULT
Test the radio voltage power continuity with multi-
meter between the radio connector and the front Chassis
RDO1-30 Close to 0.1
fuse block as per the following table. ground
Chassis
RADIO CONSTANT POWER CIRCUIT RDO1-31 Close to 0.1
ground
CONTINUITY TEST
Chassis
RADIO RH FUSE RDO1-32 Close to 0.1
RESULTS ground
CONNECTOR BOX (RFB)
RDO1-27 RFB-B6 Close to 0.1 If continuity test fails, repair defective circuit.
RDO1-28 RFB-B6 Close to 0.1
Radio CAN Wire Test
RDO1-29 RFB-B6 Close to 0.1 If the radio turns on but cannot be controlled by
the multifunction switch, perform the radio CAN
If continuity test fails, repair defective circuit. wire verification test.
Radio Activation Power Circuit 1. To access the radio connector, refer to RADIO
Continuity Test REMOVAL in this subsection.
1. Remove the multifunction gauge. 2. Remove the right front service panel to access
the DLC connector. Refer to BODY subsection.
2. Test the radio activation voltage power continu-
ity with multimeter between the multifunction RADIO CAN WIRE VERIFICATION TEST
gauge connector and the radio connector as per TEST PROBES OHMS ( )
the following table.
DLC
RADIO POWER CIRCUIT CONTINUITY TEST (CAN (Diagnostic
(ACTIVATION VOLTAGE) Close to 0.2
HI)RDO1-16 Link Connector)
MULTIFUNCTION DLC1-1
RADIO
GAUGE RESULT DLC
CONNECTOR
CONNECTOR (CAN LO) (Diagnostic
Close to 0.2
Close to RDO1-17 Link Connector)
RDO1-33 CL-22 DLC1-2
0.1

If the continuity test passes and all the left hand If the test is not within specification, check and
multifunction switch functions operate beside ra- repair the wire as necessary.
dio control, replace the radio.
Radio Removal
If the continuity test passes and none of the left
hand multifunction switch functions operate, re- 1. Refer to BODY subsection and remove the fol-
place the multifunction gauge. lowing:
– Right middle side panel
If continuity test fails, repair defective circuit.
– Right top side panel
Radio Ground Circuit Test – Right rear side panel.
Verify the radio ground with multimeter between 2. Remove right radio control panel and switch as-
the radio connector and chassis ground as per the sembly.
following table. 3. Remove rear panel to access antenna connec-
tor.
4. Disconnect antenna connector (behind rear
light assembly).

rmr2014-030 23
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

SPEAKERS
Speaker Resistance Test
1. Refer to BODY subsection and remove the fol-
lowing:
– Right middle side panel
– Right top side panel
– Right rear side panel.
2. Remove right radio control panel and switch as-
sembly.
3. Disconnect radio connector.
rmr2010-030-019 4. Test the Passenger speaker resistance at the
radio connector as per following table:
5. Disconnect radio connector.
SPEAKER TESTING (AT RADIO CONNECTOR)
RADIO
SPEAKER OHMS ( )
CONNECTOR
Front left RDO1-3
3.2 to 4.3
speaker PRC-2
Front right RDO1-10
3.2 to 4.3
speaker RDO1-1
Right rear RDO1-26
3.2 to 4.3
speaker RDO1-18
Left rear RDO1-5
3.2 to 4.3
speaker RDO1-4

If the resistance values of the speakers is within

rmr2010-030-021
6. Remove the four screws securing the radio.
specification, perform the SPEAKER INPUT VOLT-
AGE TEST.
If the resistance of one speaker is bad, check the
resistance at the speaker terminals:
– If good, check the continuity of the wires to the
radio connector and repair as necessary.
– If bad, replace the speaker.

Speaker Input Voltage Test

rmr2010-030-020_a
1. Screws
Radio Installation
Reinstall the radio in the reverse order of removal.
NOTICE Make sure to add dielectric grease in
the antenna connector and make it point down-
ward to prevent water infiltration.
1. Access the correct speaker terminals. Refer to
the appropriate speaker removal procedure.
2. Test the speaker with the connectors con-
nected to the speaker with a multimeter set to
Vac as per the following chart and illustration.
NOTE: The voltage reading at half volume should
be pulsing and will vary with the radio station and
volume intensity.

24 rmr2014-030
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

REAR STORAGE COMPARTMENT SWITCH

TEST (AT GAUGE CONNECTOR)
GAUGE REAR STORAGE
RESULTS
CONNECTOR COMPARTMENTS
Pin 20 to chassis
All closed OL
ground
Pin 20 to chassis Any compartment Close to
ground opened 1.5 k

If the preceding test at the gauge connector is

within specification, replace the multifunction
gauge.
If the reading is OL in all positions:
rmr2010-030-043_a
– Check circuit continuity between the ACS
TESTING VAC AT THE SPEAKER TERMINALS
switch and storage compartment switches.
SPEAKER INPUT VOLTAGE TEST – Test ACS switch, refer to REAR SUSPENSION.
TEST ONE HALF If the reading is 1.5 k with all the compartments
NO VOLUME closed, perform the REAR STORAGE COMPART-
PROBES VOLUME
MENT SWITCH TEST (AT SWITCH CONNECTOR)
Speaker .300 Vac to at each switch.
.000 Vac
Terminals 1.3 Vac
Rear Storage Compartment Switch
If the AC voltage test is good at the speaker ter-
minals, replace the speaker.
Test (at Switch Connector)
1. Remove the left, right or rear panel as applica-
If the AC voltage reading at the speaker is not
ble to access the a ppropriate switch as deter-
within specification, replace the radio.
mined in the previous test. Refer to BODY sub-
section.
REAR STORAGE COMPARTMENT 2. Set multimeter to and test as follows.
SWITCHES
REAR STORAGE COMPARTMENT SWITCH
Rear Storage Compartment Switch TEST (AT SWITCH CONNECTOR)
Test (at Gauge Connector) STORAGE STORAGE
SWITCH
1. Remove the multifunction gauge to access the COMPARTMENT COMPARTMENT
CONNECTOR
gauge connector, refer to MULTIFUNCTION CLOSED OPEN
GAUGE REMOVAL in this subsection. Pin 1 to pin 2 OL Close to 1
2. Set multimeter to and test as follows.
If the test is not within specification, replace the
switch.

FRONT STORAGE
COMPARTMENT LIGHT
Front Storage Compartment Light
Voltage Test
1. Remove the front storage compartment.
2. Set multimeter to Vdc and test as follows.
rmr2010-030-014_a

MULTIFUNCTION GAUGE CONNECTOR (PIN-OUT)

rmr2014-030 25
Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

FRONT STORAGE COMPARTMENT LIGHT

VOLTAGE TEST
RESULT
TEST PROBES (IGNITION
SWITCH ON)
Light connector
Chassis Close to battery
pin 1
ground voltage
(vehicle side)

If result is not as per specification, check the conti-

nuity between pin 1 of the storage light connector
and fuse 7 of the LH fuse box.
If result is as per specification, carry out FRONT
rmr2010-030-055_a
STORAGE COMPARTMENT LIGHT GROUND PBS CONNECTOR (PIN-OUT)
TEST.
Test condition:
Front Storage Compartment Light – Ignition switch ON.
Ground Test
PBS SWITCH SWITCH FUNCTIONAL TEST
1. Remove the front storage compartment.
SWITCH
2. Set multimeter to and test as follows. TEST PROBES RESULTS
POSITION
FRONT STORAGE COMPARTMENT LIGHT
PBS connector
GROUND TEST Close to
pin 5 to Chassis Any
battery voltage
COVER ground
TEST PROBES RESULT
POSITION
PBS connector
Switch Close to
Light Close to pin 4 to Chassis
Open activated battery voltage
connector 0 ground
pin 2 Chassis
(storage ground If there is NO voltage at pin 5, check the continuity
Closed compartment OL between pin 5 of the PBS connector and:
side) – Main relay R3 (LFB)
If close to 0 regardless of the cover position, If there is voltage at pin 5 but no voltage to pin 4
carry out FSS RESISTANCE TEST (FOR STORAGE with the switch activated, replace the PBS switch.
COMPARTMENT LIGHT). If the test is to specification, check the continuity
If OL regardless of the cover position, check from pin 4 of the PBS switch to pin 2 of the FSS
circuit continuity and carry out FSS RESISTANCE connector and repair the wire as necessary. The
TEST (FOR STORAGE COMPARTMENT LIGHT). front storage actuator must be activated when
testing from PBS-4 toFSS-2.
If result is as per specification, replace light.

PBS SWITCH (HOOD ACTUATOR CENTRAL PANEL SWITCHES

FUNCTION) Central Panel Switches Illumination
Power Test
PBS Switch Functional Test
1. Remove the central panel. Refer to the BODY
1. Remove the central panel. Refer to BODY sub- subsection.
section.
2. Turn ignition ON.
3. Probe at the back of the connector for the
switch to be tested and test according to the
following illustration and table using a multime-
ter set to Vdc.

26 rmr2014-030
 Subsection 07 (LIGHTS, GAUGE AND ACCESSORIES)

CENTRAL PANEL SWITCHES ILLUMINATION

POWER TEST
TEST PROBES RESULT
Chassis Close to battery
Pin 8
ground voltage

If the test is not within specification, check the

wire continuity between the tested switch main
relay 3 and repair as necessary.
If the test is to specification, continue with the
CENTRAL PANEL SWITCHES ILLUMINATION
GROUND TEST.
Central Panel Switches Illumination
Ground Test
1. Turn ignition to OFF position.
2. Probe at the back of the connector for the
switch to be tested and test according to the
following table using a multimeter set to ohms.
CENTRAL PANEL SWITCHES ILLUMINATION
GROUND TEST
PROBES POSITION RESULT
Chassis Close to
Pin 7
ground 8.25 k

If the test is within specification, replace the de-

fective central panel switch. Refer to BODY sub-
section.
If the test is not within specification, repair ground
circuit as necessary.

rmr2014-030 27
 Subsection 08 (ELECTRONIC SHIFT SYSTEM (SE6))

ELECTRONIC SHIFT SYSTEM (SE6)

SERVICE TOOLS
Description Part Number Page
ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 4–5
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 8–9

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
FLUKE RIGID BACK PROBES ....................................................... TP88 ......................................... 8–9

GENERAL Clutch Sync State

Clutch sync state is defined as the state while the
clutch is transmitting torque without slipping. This
state is analogous to a released clutch lever on a
manual transmission.
SYSTEM DESCRIPTION
This state is active:
(Clutch Open Condition) – After vehicle/clutch takeoff.
This condition ensures full clutch separation, guar- – Until the vehicle is stopped or slows to a very
anteeing no transmitted torque. low speed.
This state is active when:
– Gearbox is in Neutral. Clutch Pressure Setpoint
– Engine started and immobilization required (re- The initial values are programmed with offsets
turn to neutral failed). to make sure no unwanted torque transmission
– A vehicle reaction requiring vehicle immobiliza- happens on first vehicle usage. Then, TCM will
tion was triggered by a monitoring or diagnostic learn the correct pressure for each temperature
detection. window and the vehicle will behave as it should.

Actual Engagement Point Freewheel Function

The actual engagement point is learnt by the
TCM. It prepares the clutch system to perform
an engagement when the throttle will be turned
open. Being near the engagement point when
beginning clutch engagement is important to
perform a smooth transition between stationary
state and takeoff.
This state is active when:
– Gearbox is in gear (not N)
– Vehicle is stopped
– Throttle (handlebar) is at closed position
The TCM will learn new actual engagement points
as the clutch wears.
Clutch Takeoff / Slip State
The clutch slip state is when the clutch transmits
torque but is slipping. This state occurs during ve-
hicle takeoff.
When the vehicle is in 1st gear on a grade and the
brake pedal is released, the vehicle can accelerate
by itself. The clutch will engage gradually when
the vehicle attains a predetermined speed. This
ensures a smooth transition between prelaunch
and sync states. Engine braking will limit vehicle
speed.
Vehicle Startup / Auto Neutral
If the transmission is in any gear other than Neu-
tral, brake pedal has to be depressed to start the
engine.
Once the engine is started, the transmission will
shift back to Neutral gear by itself.
If the transmission does not succeed to shift to
Neutral automatically (defective shift linkage), the
vehicle will be able to take off only after a shift
button (+ / -) is pressed.

rmr2014-031 1
Subsection 08 (ELECTRONIC SHIFT SYSTEM (SE6))
Auto Neutral
When engine is started and running, the gearbox
is automatically set to the neutral position.
Shift from Neutral
The following conditions must be met so that a
gearshift can take place:
– Engine RPM is lower than 1500 RPM.
– Vehicle speed is lower than 3 km/h (2 MPH).
Upshift
When the gearshift selector is pushed (upshift)
and the vehicle is stopped, the TCM will immedi-
ately signal the corresponding solenoid valves on
the HCM to shift the gearbox up one gear if the
gearbox is in neutral or reverse.
When the vehicle is moving and the gearbox is
in 1st gear or above, a minimum RPM and speed
must be met to permit an upshift to take place.
Otherwise, no upshift is allowed until the required
RPM is reached.
If desired, the gearbox can remain in this gear until
engine reaches its rev-limited RPM.
If the gearbox is in 6th gear and the gearshift se-
lector is pushed (upshift), nothing will happen.
Downshift
When the gearshift selector is pulled (downshift),
the TCM will signal the corresponding solenoid
valves on the HCM to shift the gearbox down
one gear as long as it does not cause the engine
RPM to exceed preset parameters.
Downshifting from 1st goes to NEUTRAL if re-
verse gearshift selector is not pulled.
Downshifting from 1st goes to REVERSE if reverse
gearshift selector is pulled.
Downshifts are prohibited if next gear brings the
engine to a speed higher than redline.
Reverse
To shift into reverse gear:
– Engine must be running.
– Vehicle must not be moving.
– Push the reverse button.
– Pull the gearshift selector (downshift).
– Brake pedal is depressed.
If gearbox is in reverse gear and the gearshift se-
lector is pulled (downshift), nothing will happen.
To shift into neutral from reverse, the user must
shift into 1st then downshift into neutral.
2 rmr2014-031
Auto Downshift
When the following conditions are met, a down-
shift will automatically take place:
– Vehicle decelerates.
– A predetermined RPM is reached.
– A predetermined vehicle speed is reached.
RPM Increase on Downshift
When a downshift is commanded, the TCM will
transmit a downshift signal through the CAN BUS
that is used by the engine control module (ECM)
to command the electric throttle actuator (ETA) to
momentarily "slightly" open the throttle plates to
increase engine RPM. This assists the synchro-
nization of engine RPM and rear wheel speed
without any required action by the operator.
Vehicle Stop
When coming to a complete stop, after the gear-
box has shifted into first gear, the clutch will auto-
matically disengage the engine from the gearbox.
This prevents stalling and leaves the vehicle ready
for its next acceleration event.
Reverse Interlock
The reverse interlock is a mechanical lock in the
gearbox to prevent unwanted selection of the re-
verse gear. Also, the reverse interlock is used to
reach neutral gear. Here is the principle of the in-
terlock:
– When the lever is pulled (deployed) it permits
selection of reverse gear from 1st gear or Neu-
tral.
– When the lever is pulled (deployed) while up-
shifting from Reverse, the shifter stops at Neu-
tral position
 Subsection 08 (ELECTRONIC SHIFT SYSTEM (SE6))

rmr2014-031-007_a

HCM CONNECTOR (MCC2) ON CLUTCH COVER

RESISTANCE
HCM CONNECTOR
SOLENOID AT 20°C
PIN
(68°F)

rmr2014-031-001_a
Upshift (Y4) MCC2-F MCC2-G 10 - 11.5
REVERSE INTERLOCK PATTERN Downshift
A. Retracted MCC2-D MCC2-E 10 - 11.5
B. Deployed (Y3)
Clutch
INSPECTION pressure MCC2-H MCC2-M 4.1 - 4.9
(Y2)
SOLENOIDS Line
pressure MCC2-B MCC2-K 4.1 - 4.9
Solenoid Resistance (Y1)
Set multimeter to .
If the resistance measured is not within the spec-
Measure the resistance between the following ification, replace faulty parts.
pins.
NOTE: Replacing solenoids may require replacing
the HCM.

Power Circuit
Refer to WIRING DIAGRAM.
Refer to SOLENOID RESISTANCE test for MCC2
connector pinout.
Set multimeter to Vdc.
Probe female HCM connector (MCC2).

HCM CONNECTOR (MCC2) ON CLUTCH COVER

1. Nut
2. HCM connector (MCC2)

rmr2014-019-009_b

1. Female HCM connector (MCC2).

2. Clutch pressure sensor connector
3. Clutch cover

rmr2014-031 3
Subsection 08 (ELECTRONIC SHIFT SYSTEM (SE6))

WIRING
HARNESS
SWITCH HCM VOLTAGE
CONNECTOR
PIN
MCC2-F and
No voltage
battery ground
Upshift (Y4)
MCC2-G and
Battery voltage
battery ground
MCC2-D and 529036166
No voltage
battery ground
Downshift (Y3)
MCC2-E and
Battery voltage
battery ground
MCC2-M and
No Voltage
Clutch pressure battery ground
(Y2) MCC2-H and
Battery voltage
battery ground
MCC2-K and
No voltage
Line pressure battery ground
(Y1) MCC2-B and
Battery voltage
battery ground

If a solenoid test failed, check fuses. If good,

check wiring and connectors between TCM and rmr2014-031-008_a

battery. OTS RESISTANCE CURVE

OTS SIGNAL RESISTANCE SPECIFICATIONS

SENSORS
TEST CONDITION SENSOR RESISTANCE
Oil Temperature Sensor (OTS)
20°C (68°F) 2812
Refer to appropriate WIRING DIAGRAM.
80°C (176°F) 283
Refer to SOLENOID RESISTANCE test for MCC2
connector pinout. If the resistance is not within specification, repeat
OTS TERMINALS test at MCC2 connector on clutch cover housing.
OTS-1 5Vdc reference If the resistance is not within specification, re-
place OTS. Refer to HYDRAULIC CONTROL
Refer to OTS MODULE (SE6) subsection for removal proce-
OTS-2 SIGNAL VOLTAGE dure.
SPECIFICATIONS

OTS SIGNAL VOLTAGE SPECIFICATIONS

TEST CONDITION SIGNAL VOLTAGE
20°C (68°F) 2.09 Vdc
80°C (176°F) 0.337 Vdc

The oil temperature sensor is installed in the inlet

port of the HCM pump (inside clutch cover). The
sensor resistance is verified for asserting proper
sensor function.
Test OTS sensor resistance at TCMB connector
using ECM ADAPTER TOOL (P/N 529 036 166).

4 rmr2014-031
 Subsection 08 (ELECTRONIC SHIFT SYSTEM (SE6))

Oil Pressure Sensor (OPS) MULTIMETER PROBE

RESISTANCE
@ 20°C
POSITIONS
(68°F)
OPS connector (pin 2) and ECM
adapter tool on ECM B (pin B2)

Below 1

If resistance is out of specification, check wires

and connector pins. Repair and reset fault codes.
If resistance is good, replace the OPS and reset
fault codes. Refer to HYDRAULIC CONTROL
1. OPS connector MODULE (SE6) subsection for removal proce-
2. Clutch cover
dure.
Refer to appropriate WIRING DIAGRAM.
The oil pressure sensor is installed on the clutch TROUBLESHOOTING
cover. The sensor signal is verified for asserting Refer to POWER DISTRIBUTION AND GROUNDS
proper sensor function. for fuses and relay information.
OPS TERMINAL
MULTIMETER Always refer to the WIRING DIAGRAM when
READING troubleshooting an electrical circuit.
OPS-1 Ground Install a battery charger on battery terminals for
Refer to OPS PRESSURE
any tests that involve a prolonged "key ON" period.
OPS-2 If battery voltage gets too low, test results can be
SPECIFICATION table
altered.
OPS-3 5Vdc reference
NOTICE Never force a multimeter probe into
OPS PRESSURE SPECIFICATION an electrical terminal.
OPS PRESSURE
TEST CONDITION SPECIFICATION IN SYMPTOM BASED
B.U.D.S. TROUBLESHOOTING
3 bar ± 1 bar For any problem, start troubleshooting by:
Idle in 1stgear
(43.51 PSI ± 14.5 PSI)
– Checking fault codes using B.U.D.S.
If the OPS pressure specification in B.U.D.S. is not – Checking oil level and condition. Engine and
within specifications: HCM share the same oil. Oil type, level and
condition are very important.
Unplug “B” connector from ECM (ECMB) and
connect it to ECM ADAPTER TOOL (P/N 529 036 NOTE: In doubt of the oil condition or type,
166). change oil and filters before further diagnosis.
The format is presented as:

EXAMPLE SYMPTOM
1. Possible Cause(s)
- What to do.

GEARBOX DOES NOT SHIFT INTO GEAR

(UP OR DOWN)
1. No gear shift signal from switch.
- Perform GEAR SHIFTING SWITCHES TEST.

rmr2014-031 5
Subsection 08 (ELECTRONIC SHIFT SYSTEM (SE6))
2. No pressure is built by pump.
- Perform CHECK LINE PRESSURE ERROR test
ERRATIC OR HARSH SHIFTING
1. Problem with learnt clutch engagement point
coefficient.
- RESET CLUTCH ENGAGEMENT POINT
- LEARN ENGAGEMENT POINT
GEARBOX DOES NOT SHIFT INTO
REVERSE
1. No signal from reverse button.
- REVERSE BUTTON TEST .
2. Reverse interlock actuator problem.
- Inspect reverse interlock actuator
UNEXPECTED CLUTCH SLIP
1. Clutch pressure control is out of tolerance.
- Perform CHECK CLUTCH PRESSURE ERROR
test.
2. Sticking clutch valve.
- Perform CHECK CLUTCH PRESSURE HYSTERE-
SIS test.
3. An error at the clutch engagement point.
- RESET CLUTCH ENGAGEMENT POINT
- LEARN ENGAGEMENT POINT
VEHICLE STALLS WHEN BROUGHT TO A
STOP
1. Clutch valve might be stuck.
- Perform CHECK CLUTCH PRESSURE HYSTERE-
SIS test.
2. CAN communication is lost.
- TCM Test for CAN Communication
AUTOMATIC DOWNSHIFT IS DISABLED
1. Invalid vehicle speed signal
- Inspect sensor and signal. Refer to VEHICLE
STABILITY SYSTEM subsection.
2. Invalid gear position signal
- Inspect sensor and signal. Refer to GEARBOX
subsection.
6 rmr2014-031
ON THROTTLE RELEASE CLUTCH
OPENS INSTEAD OF BEING KEPT
SYNCHRONIZED
1. Invalid vehicle speed signal
- Inspect sensor and signal. Refer to VEHICLE
STABILITY SYSTEM subsection.
2. Invalid gear position signal
- Inspect sensor and signal. Refer to GEARBOX
subsection.
ROUGH VEHICLE TAKEOFF AND
UNDESIREABLE CLUTCH SLIP
1. Sticking clutch valve.
- Perform CHECK CLUTCH PRESSURE HYSTERE-
SIS test.
2. Faulty oil temperature sensor
- Inspect sensor and signal
ENGINE SPEED IS LIMITED DURING
TAKEOFF BY REV LIMITER AND REDUCED
ENGINE TORQUE
1. Faulty oil temperature sensor
- Inspect sensor and signal
2. Faulty clutch pressure sensor
- Inspect sensor and signal
VEHICLE WILL NOT MOVE
1. CAN communication is lost.
- TCM Test for CAN Communication
2. Clutch valve is stuck.
- Inpsect, replace HCM if determined defective
UNEXPECTED SHIFT
1. Internal HCM problem.
- Inspect, replace HCM if determined defective
TROUBLESHOOTING WITH
B.U.D.S.
Connect the latest version of B.U.D.S. and logon.
Make sure TCM is operational. Refer to TCM STA-
TUS VALIDATION in this subsection.
Activation section allows the activation of the dif-
ferent TCM and HCM self-tests.
 Subsection 08 (ELECTRONIC SHIFT SYSTEM (SE6))
Monitoring section allows the user to confirm var-
ious commands have reached the TCM and to see
the current status of the TCM and its monitored
components.
Settings section allows the user to erase, reset
and perform initialization procedures for the TCM.
Gear Shifting Switches Test
Select the Monitoring and TCM tabs.
If TCM SHIFTING LED is active there is a shifting
problem. Refer to WIRING DIAGRAM to check
wiring and switch continuity.
Refer to GEARBOX subsection for more informa-
tion.
Reverse Button Test
NOTE: Reverse light in cluster should activate
when reverse button is pushed.
If Reverse light in cluster DOES NOT turn on, Re-
fer to LIGHTS, GAUGE AND ACCESSORIES and
test left multifuction switch (MSL).
If Reverse light in cluster DOES turn on, Refer to
GEARBOX and test reverse actuator.
TCM Status Validation
Turn ignition key to ON.
Ensure that fuel pump turns ON a few seconds.
Otherwise, check ECM power supply.
Connect vehicle to B.U.D.S.
In the tool bar at the top of screen, click on Mod-
ule. TCM should be visible in the menu.
rmr2008-078-024_a
1. TCM is visible
If not, the module is either not powered, defective
or unable to communicate via CAN.
If TCM module is visible, check B.U.D.S. for tou-
ble codes.
rmr2014-031
Check Shifting Hydraulics
The hydraulic shift system test validates:
– Shift solenoids
– Spool valve
– Shift linkage
– Reverse interlock
– Shift drum
– Shift forks
– Gear Dogs
Check Clutch Pressure Hysteresis
The pressure hysteresis test checks if the clutch
pressures are commanded with the required pre-
cision. This test is useful to diagnose a sticking
spool valve.
If test fails, perform VALVE CLEARING CYCLE
TEST.
Check Line Pressure Hysteresis
The pressure hysteresis test checks if the line
pressures are commanded with the required pre-
cision. This test is useful to diagnose a sticking
spool valve.
If test fails, perform VALVE CLEARING CYCLE
TEST.
Check Clutch Pressure Step Response
The pressure step response test checks if the dy-
namic response of the hydraulic system is within
the required specifications to provide the correct
transmission behavior.
If test fails, perform VALVE CLEARING CYCLE
TEST.
Check Line Pressure Step Response
The pressure line response test checks if the dy-
namic response of the hydraulic system is within
the required specifications to provide the correct
transmission behavior.
If test fails, perform VALVE CLEARING CYCLE
TEST.
Clutch Pressure Ripple Measurement
The pressure ripple measurement test checks if
the pressure ripple is within required targets for
proper transmission operation.
Line Pressure Ripple Measurement
The pressure ripple measurement test checks if
the pressure ripple is within required targets for
proper transmission operation.
7
Subsection 08 (ELECTRONIC SHIFT SYSTEM (SE6))

Clutch Pressure Error Check The clutch pressure at the beginning of the en-
This test checks that the pressure valves deliver gine RPM drop is saved as the engagement point
the required pressure within the error tolerance. value.

Line Pressure Error Check TRANSMISSION CONTROL

This test checks that the line pressure valves de- MODULE (TCM) TESTS
liver the required pressure within the error toler-
Refer to appropriate WIRING DIAGRAM.
ance.

HCM Ventilation TCM Input Voltage Test

Check circuit fuses.
This function actuates the HCM valves to purge
the system of any trapped air. This test should be Remove body panels as required to access TCM
used upon HCM reassembly. (RH side). Refer to BODY subsection.
Disconnect TCM connector.
Valve Clearing Cycle Test
This function makes both clutch and line pressure
valves shuttle between their end positions multi-
ple times per second to get rid of a sticking valve
condition.
This procedure should be executed if:
– The hysteresis test fails
– Vehicle takeoff behavior is oscillating / harsh
– Any (clutch or line) ripple measurement test(s)
fails
– Any (clutch or line) pressure step response
test(s) fails.
rmr2014-031-003_a

PROCEDURES TCM LOCATION AND TCMB IDENTIFICATION

1. TCMB connector

RESET CLUTCH ENGAGEMENT Use the FLUKE 115 MULTIMETER (P/N 529 035 868)
POINT and FLUKE RIGID BACK PROBES (P/N TP88).
If the clutch pack is replaced or there is a doubt Set multimeter to Vdc.
on the validity of the adapted clutch engagement Read voltage as follows.
point value, this function lets the dealer force
NOTICE To avoid damaging the connector,
the default clutch engagement point value in the
TCM. probe only the terminal tip.
To reset the learned clutch engagement point: TCM TEST
BATTERY VDC
CONNECTOR CONDITION
1. Connect B.U.D.S. and select the Activations
and TCM tabs. TCMB-M4 Ground At all times
Battery
Voltage
2. Apply parking brake and vehicle brakes.
3. Click on Reset engagement point. Battery
TCBM-L3 Ground At all times
Voltage
Perform LEARN ENGAGEMENT POINT proce-
dure. Battery
TCMB-A2 Ground Key on
Voltage

LEARN ENGAGEMENT POINT If voltage is not as specified, check wiring and

1. Connect B.U.D.S. and select the Activations connectors between TCM and main relay. Refer
and TCM tabs. to WIRING DIAGRAM.
2. Apply parking brake and vehicle brakes. If voltage is good, carry out a TCM GROUND
TEST.
3. Click on Learn engagement point.
Clear fault codes.
8 rmr2014-031
 Subsection 08 (ELECTRONIC SHIFT SYSTEM (SE6))

TCM Ground Test TCM REPLACEMENT

Use the FLUKE 115 MULTIMETER (P/N 529 035 868) TCM Access
and FLUKE RIGID BACK PROBES (P/N TP88).
Remove body panels as required to access TCM
Set multimeter to VDC. under the RH lateral frame support. Refer to
Check ground as follows: BODY subsection.
1. Connect multimeter RED probe to a positive
source such as the battery terminal of the
starter solenoid.
2. Probe TCM connector pins with the BLACK
(COM) probe of the multimeter as follows.
NOTICE To avoid damaging the connector,
probe only the terminal tip.
TCM
BATTERY RESULT
CONNECTOR
TCMB-M2
Positive source Battery voltage rmr2014-031-004_a
TCMB-L1
TCM LOCATION ON VEHICLE - SOME COMPONENTS
REMOVED FOR CLARITY
If ground circuits are not as specified, check 1. TCM
wiring and connections between TCM and bat-
tery ground. TCM Removal
If ground circuits are as specified, try a new TCM. CAUTION Use an anti-static bracelet to
Clear fault codes. avoid damaging TCM during manipulations.
1. Disconnect electrical connectors.
TCM CAN Circuit Test
2. Remove retaining screws.
1. Check for CAN fault codes using B.U.D.S.
2. Carry out TCM STATUS VALIDATION in this
subsection.
If TCM is powered but not visible in B.U.D.S.,
carry out the TCM CAN CIRCUIT TEST.
3. Disconnect TCM connector.
4. Locate the diagnostic link connector (DLC).
Check CAN circuit continuity as per following ta-
ble:
TCM CAN CIRCUIT TEST
TEST PROBES RESULT
rmr2014-031-005_a
Close to TCM REMOVAL
CAN High: DLC pin 1 TCMB-C1
0
Close to TCM Installation
CAN Low: DLC pin 2 TCMB-C2
0 Reverse installation procedure.
If result is not as specified, repair wiring or con- TIGHTENING TORQUE
nector. 2.5 N•m ± 0.5 N•m
TCM Retaining Screws
(22 lbf•in ± 4 lbf•in)

New TCM Initialization

Perform RESETTING ENGAGEMENT POINT pro-
cedure.
rmr2014-031 9
Subsection 08 (ELECTRONIC SHIFT SYSTEM (SE6))

Then, perform LEARN ENGAGEMENT POINT pro-

cedure.

HYDRAULIC CONTROL MODULE

(HCM) REPLACEMENT
The HCM is part of the clutch cover assembly.
Refer to CLUTCH (SE6) for clutch cover removal
and installation procedures.

SHIFT LINKAGE
The shift linkage is part of the clutch cover assem-
bly.
Refer to CLUTCH (SE6) for clutch cover removal
and installation procedures.

10 rmr2014-031
 Subsection 01 (DRIVE BELT AND REAR WHEEL)

DRIVE BELT AND REAR WHEEL

SERVICE TOOLS
Description Part Number Page
BELT TENSION METER ................................................................ 529 036 115 ............................................. 1
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ............................................. 4
REAR WHEEL BEARING PUSHER ............................................... 529 036 246 ......................................... 4–5

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
SNAP-ON SEAL PULLER .............................................................. YA105 ............................................. 4

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ............................................. 3
XPS 4-STROKE SYNTH. BLEND OIL (SUMMER) ......................... 293 600 121 ............................................. 3
XPS SYNTHETIC GREASE............................................................. 293 550 010 ......................................... 3, 5

PROCEDURES
DRIVE BELT
Drive Belt Tension Verification
NOTICE Always verify drive belt tension
with all parts at room temperature and the
rear wheel lifted of the ground.
1. Place vehicle on a level surface.
NOTE: The area must be protected against wind rmr2008-030-009

and must have a low background noise. TYPICAL - LIFT BY THE FRAME

2. Set transmission to NEUTRAL. 4. To check the drive belt tension use the BELT
3. Lift rear of vehicle by the frame until rear wheel TENSION METER (P/N 529 036 115).
is off the ground.
NOTICE Do not lift under rear shock ab-
sorber. Always lift by the frame. Refer to
illustration.

529036115

5. Enter the following specifications to program

the meter.
MASS WIDTH SPAN
008.0 g/m 28.0 mm/R 0980 mm

rmr2014-032 1
Subsection 01 (DRIVE BELT AND REAR WHEEL)
rmr2014-032-001_a
SONIC TENSION METER DISPLAY
NOTE: Refer to the manufacturer's instructions
to set the informations into the device.
6. Turn rear wheel to align a wheel spoke with the
swing arm.
rmr2008-031-003
TYPICAL - SWING ARM ALIGNED WITH A SPOKE
7. Position the sensor under the LH passenger
footrest and hold the sonic tension meter sen-
sor approximately 1 cm (1/2 in) from belt or
closer without touching the belt.
rbs2010-006-001
8. Tap the belt to make the belt vibrate and note
the measurement.
9. Repeat step 8.
2 rmr2014-032
NOTE: The second value should be within ± 25 N.
If not, repeat measurements until tolerance is
met.
10. Repeat steps 6 to 9 for the 2 remaining wheel
spokes.
The average of the 3 obtained values (at the 3
spokes) must be within the following range:
DRIVE BELT TENSION
(PARTS AT ROOM TEMPERATURE AND
REAR OF VEHICLE LIFTED)
1050 N ± 150 N
If the tension of drive belt is out of specification,
adjust drive belt as per DRIVE BELT TENSION AD-
JUSTMENT.
Drive Belt Tension Adjustment
Lift rear of vehicle using a floor jack until rear
wheel is off the ground.
NOTICE Place floor jack underneath frame
only.
rmr2008-030-009
TYPICAL
Remove both rear axle caps.
From RH side of vehicle, remove and discard cot-
ter pin locking the rear axle nut.
 Subsection 01 (DRIVE BELT AND REAR WHEEL)

REAR AXLE NUT TIGHTENING TORQUE

225 N•m (166 lbf•ft)

Install a NEW cotter pin and both axle caps.

WARNING
Always install a NEW cotter pin on rear axle.

WHEEL HUB BEARING

NEW 48 N•m
(35 lbf•ft)

rmr2013-032-001_a NEW

TYPICAL - REAR RH SIDE OF VEHICLE NEW

1. Cotter pin 48 N•m
(35 lbf•ft)
2. Rear axle nut 20 N•m
(15 lbf•ft)

Using a 36 mm socket, loosen rear axle nut.

Adjust tensioner screws as following: NEW
NEW
– Tighten screws 1/4 turn to increase belt ten-
sion.
– Loosen screws 1/4 turn to decrease belt ten- rmr2014-032-002_a

sion. XPS 4-STROKE SYNTH. BLEND OIL

NOTE: Always turn both tensioner screws evenly (SUMMER) (P/N 293 600 121)
to keep drive belt aligned.
XPS SYNTHETIC GREASE (P/N 293 550 010)

LOCTITE 243 (BLUE) (P/N 293 800 060)

Component must be replaced when

removed.

Bearing Removal
Remove the wheel hub inner spacer.

rmr2013-032-002_a

TYPICAL
1. Rear axle tensioner
2. Tensioner screw

Tighten rear axle nut enough to avoid rear axle

movement.
Adjust drive belt tension as per specification, refer
rmr2008-067-002_a
to DRIVE BELT TENSION VERIFICATION. 1. Inner spacer
When recommended tension is obtained, torque 2. Wheel hub
rear axle nut. Remove the outer spacer.

rmr2014-032 3
Subsection 01 (DRIVE BELT AND REAR WHEEL)

rmr2008-067-005
rmr2013-032-009_a

1. Outer spacer
2. Wheel hub
Using a seal puller such as the SNAP-ON SEAL
PULLER (P/N YA105) or a screwdriver, drive the
seal out of the wheel hub.
Bearing Installation
NOTICE Strictly adhere to this installation
procedure to avoid bearing damage.
1. Press the LH bearing in the wheel.
REQUIRED TOOL

REAR WHEEL BEARING

PUSHER (P/N 529 036 246)

rmr2013-032-010_a

1. Seal
2. Wheel hub

Using the BLIND HOLE BEARING PULLER SET

(P/N 529 036 117), remove and discard sprocket rbs2012-008-001_a

bearing.
2. Install the wheel hub on the wheel.

529036117

rbs2012-008-002

3. Tighten as follows.

4 rmr2014-032
 Subsection 01 (DRIVE BELT AND REAR WHEEL)

TIGHTENING TORQUE
Wheel hub bolts 48 N•m (35 lbf•ft)

rbs2012-008-005_a
rbs2012-008-003_a
CUTAWAY VIEW
HUB BOLTS TIGHTENING SEQUENCE 1. Bearing pusher pushing on the RH bearing (in hub)
2. RH bearing
4. Insert the spacer in the hub until it contacts the 3. Spacer
4. Hub
bearing inner race. 5. LH bearing (in wheel)
6. Bearing pusher supporting the LH bearing

NOTICE Bearing pushers must be in good

condition and remain in contact with outer and
inner bearing races while pressing.

rbs2012-008-004_a

5. Press the RH bearing in the hub.

5.1 Apply a thin layer of XPS SYNTHETIC
GREASE (P/N 293 550 010) all around the
bearing outer race.
5.2 Install the assembly on the press as
shown
5.3 Push bearing until the spacer comes in
contact with each bearing inner race.
REQUIRED TOOLS
REAR WHEEL BEARING
PUSHER (P/N 529 036 246)
(Both required)

rmr2014-032 5
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

VEHICLE STABILITY SYSTEM (VSS)

SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ..................... 8, 10–12, 14–15

SERVICE TOOLS – OTHER SUPPLIER

Description Part Number Page
FLUKE RIGID BACK PROBES ....................................................... TP88 ........................... 8, 12, 14–15

SERVICE PRODUCTS
Description Part Number Page
BRP HEAVY DUTY CLEANER ....................................................... 293 110 001 ........................................... 16

WARNING SUBSYSTEM FUNCTION

Torque wrench tightening specifications Prevents the loss of steering
must be strictly adhered to. control in normal riding
Locking devices must be replaced with new SCS conditions as well as in
ones when removed (e.g.: locking tabs, elas- (Stability emergency avoidance maneuvers.
tic stop nuts, cotter pins, etc.). Control It applies braking power to the
System) appropriate wheel.
It may also reduce engine torque
NOTICE Hoses, cables or locking ties re- as necessary.
moved during the procedure must be rein- Prevents the wheels to lock while
ABS
stalled as per factory standard. (Antilock
braking.
It reduces braking power to the
Braking
appropriate wheel by modulating
GENERAL System)
brake pressure as necessary.

SYSTEM DESCRIPTION EBD

Allows the distribution between
(Electronic
(FEATURES) Brake
front and rear brakes to be adjusted
according to conditions.
Distribution)
The VSS maintains vehicle control in normal riding
conditions as well as in emergency avoidance ma- Optimizes rear wheel traction to
neuvers. TCS
help keeping the vehicle on its
intended trajectory.
The VSS uses the following subsystems to (Traction
It reduces engine torque as
achieve its goals. Control
necessary.
System)
It may also apply brake on rear
wheel if necessary.

The VSS coordinates the SCS, ABS, EBD and TCS

to work together to allow maximum vehicle con-
trol while accelerating, decelerating, turning and
braking.

rmr2013-033 1
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

VSS SYSTEM DESCRIPTION

(Vehicle Stability
System) (COMPONENTS)
Vehicle Control Module (VCM)
VCM The Vehicle Control Module (VCM) is the heart
of the vehicle stability system (VSS). It contains
2 microprocessors, 2 hydraulic pumps, sev-
SCS ABS EBD TCS
(Stability (Antilock (Electronic (Traction
eral solenoids and passageways to the 3 brake
Control Braking Brake Control calipers.
System) System) Distribution) System)

rmr2008-019-018_en

Stability Control System (SCS)

The SCS helps to maintain control in normal riding
conditions as well as in emergency avoidance ma-
neuvers by modulating the brake fluid pressure to
the brake calipers. There are several possibilities
for braking modulation. It can, as needed, prevent
a front wheel from lifting by applying the brake on
the opposite wheel and reduce the engine torque
if necessary.

Anti-Lock Braking System (ABS)

The ABS prevents the wheels to lock while brak-
ing. The vehicle configuration allows a single
rmr2013-033-002_a
brake point at the right foot, to provide the op-
1. Electronic module (2 microprocessors)
timal amount of hydraulic brake pressure on all 2. Hydraulic pump motor
three wheel's brake discs, under a multitude of 3. Solenoids and passageways
braking and road conditions. The result is maxi-
The VCM receives inputs from several sensors
mizing vehicle control while allowing the wheels
and performs calculations to cycle the pump and
to remain available to generate steering control
solenoids to apply or relieve hydraulic pressure to
force in response to the rider’s input.
or from the vehicle brake calipers. In addition the
Electronic Brake Distribution (EBD) VCM has the ability to send a signal to the ECM
to reduce engine torque if necessary.
The EBD allows the distribution between front
and rear brakes to be adjusted according to condi-
SAS
tions. Based on inputs from the various sensors, VSS 1 VSS 2
it achieves an efficient braking by reacting to ve-
hicle weigh transfer by reducing the rear braking
pressure as needed. VCM

LPS
Traction Control System (TCS)
The TCS optimizes rear wheel traction to help YRS
keep the vehicle on its intended course. It can
reduce engine torque if necessary. It may also BLS
apply brake on rear caliper if necessary.
The TCS will limit rear wheel spin and is throttle ECM
dependant. PRS
At WOT (throttle opening above 90%), TCS will OLS 1
allow rear wheel slip speed up to redline in first OLS 2
gear.
At lower throttle opening, TCS will manage rear VSS 4
wheel slip to allow maximum acceleration and rmr2011-082-002_a
control.
2 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

VSS Sensors

rmr2013-033-003_a

TYPICAL
1. Wheel speed sensor (rear)
2. Wheel speed sensors (front)
3. Vehicle control module (VCM)
4. Steering angle sensor (SAS)
5. Yaw rate sensor (YRS)
6. Pillion rider sensor (PRS)
7. Oil level sensors (BFS)
8. Brake light switch (BLS) and low pressure switch (LPS)

rmr2013-033 3
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

SENSOR VSS INPUTS/OUTPUTS

DESCRIPTION FUNCTION
ACRONYM
INPUT USAGE OUTPUT
Determines the
Wheel speed YRS
VSS1 speed of the LH
sensor # 1
front wheel. Longitudinal
Determines the acceleration
Wheel speed
VSS2 speed of the RH Lateral
sensor # 2 These sensor
front wheel. acceleration signals (or
– Modulate
Wheel speed VSS (3) parameters)
Determines the brake fluid
sensor # 3 are used by the
VSS3 speed of the rear Front brake VSS to perform pressure to
(bottom rear
wheel. pressure proper caliper.
sensor) computations
(inside and to then act – Engine torque
Determines the VCM) by providing the reduction.
Steering angle angle of the front proper output(s).
SAS SAS
sensor wheels in relation to
the vehicle. PRS
Measures lateral BLS thru
and longitudinal ECM
Yaw rate
YRS accelerations, as
sensor
rotation speed (yaw LPS These sensors
rate). are used to
monitor proper
Signals the VCM VSS system
when the PRS operation. They – Fault codes.
switch is depressed. OLS (2)
are not used
the VCM applies to perform
Pillion rider changes to the computations.
PRS
switch control parameters,
mainly to reduce
The YRS and SAS are input sensors that, in addi-
maximum allowed
lateral acceleration tion to monitoring, broadcast their values to the
and yaw. CAN bus to be used by other electronic modules.
Signals the ECM Yaw Rate Sensor (YRS)
that the vehicle The YRS is located on top of the frame, at the front
has begun braking. of vehicle.
Brake light
BLS The ECM then
switch
broadcasts the
signal to the VCM
via CAN bus.
Signals the VCM
in case of a low
Low pressure
LPS pressure situation in
switch
the braking hydraulic
system.
Signals the VCM
in the event of a
Brake fluid level low brake fluid level
OLS1
sensor # 1 in rear half of the
dual reservoir (front
brakes).
Will signal the VCM
in the event of a rmr2013-033-005_a

Brake fluid level low brake fluid level TYPICAL

OLS2 1. Yaw rate sensor (YRS)
sensor # 2 in front half of the
dual reservoir (rear
brakes).

4 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

The YRS measures lateral and longitudinal accel- Pillion Rider (Passenger) Switch (PRS)
eration as well as vehicle rotation rate.

Longitudinal
Acceleration
X axis

Vehicle rotation
YRS Lateral
Acceleration
Y axis

rmr2013-033-006_a

TYPICAL - BOTTOM VIEW OF SEAT, REAR LH SIDE

1. Pillion rider switch (PRS)
rmr2008-019-022_aen

The Pillion Rider Switch (PRS), located under the

This VCM input helps to determine the direction seat, detects the presence of a passenger and in-
and velocity in which the vehicle mass is actually forms the VCM.
traveling.
The center of gravity and weight is much affected
The VCM calculates the acceleration, deceleration by the presence of a passenger therefore, the VSS
and rotation of the vehicle. It determines the ve- behavior will change based on the addition of the
locity and direction, calculates the force (weight) second rider.
and adjusts the VCM parameters accordingly.
Wheel Speed Sensor (VSS)
Steering Angle Sensor (SAS)
The SAS is attached to the bottom of the steering
column shaft under the DPS.

rmr2013-033-007_a

FRONT WHEEL SPEED SENSOR

rmr2013-033-004_a

1. Steering angle sensor (SAS)

The SAS informs the VCM of the handlebar posi-

tion in relation to the chassis.
NOTE: To test, replace and reset the steering an-
gle sensor (SAS), refer to STEERING (DPS) AND
FRONT WHEELS subsection.
rmr2013-033 5
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

Brake Fluid Level Sensor (OLS)

rmr2013-033-001_a

1. Rear wheel speed sensor

There are 3 wheel speed sensors on the vehicle,
one on each wheel. The wheel speed sensors are
hall effect type sensors that send a digital signal to
the VCM.
As the wheel rotates, the teeth on the encoder
wheel pass in front of the sensor. The output fre-
quency of the sensor is proportional to the wheel
rotation speed.
rmr2013-033-009_a
1. Brake fluid reservoir
2. Brake fluid level sensor (front brakes)
3. Brake fluid level sensor (rear brakes)
The brake fluid level in the dual reservoir is mon-
itored on each section individually. The front
switch monitors the rear brake and the rear
switch monitors the front brakes.
The switches inform the VCM in the event of a
low fluid level in any section of the dual reservoir
or an open circuit or short circuit in the brake fluid
level sensor (OLS) connections.
Brake Light Switch (BLS)
The brake light switch (BLS) is located close to the
master cylinder. It is activated by the brake pedal.

rmr2013-033-008_a

1. Extrusions on encoder wheel

2. Wheel speed sensor

The inputs to the VCM from the wheel speed sen-

sors are major inputs to the initiation of ABS, EBD
and TCS.

rmr2013-033-010_a

1. Brake light switch

2. Low pressure switch

6 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))
The BLS turns on the brake lights and supplies
the ECM a signal that the operator is applying the
brakes. The ECM sends the message to the VCM
via CAN. This input is used notably to enable the
ABS and deactivate cruise control.
Low Pressure Switch (LPS)
The low pressure switch (LPS) is located close
to the master cylinder (see previous illustration in
Brake Light Switch (BLS)). It is also activated by
the brake pedal.
Under normal operation during a light to medium
braking, the brake lever does not activate the LPS
switch.
The switch is positioned so that it will be activated
only when a predefined stroke is reached. At this
point, the VSS checks the pressure in the system
and reacts accordingly.
If there is a loss of pressure (leak or air in the sys-
tem), the pedal would travel further than the pre-
defined stroke and activate the LPS switch. This
will inform the VCM of the low pressure condition.
There is also a internal brake pressure sensor for
the front brake circuit in the VCM. Its pressure sig-
nal output can be viewed in B.U.D.S.
rmr2008-039-012
MONITORING TAB, VCM MODULE
TROUBLESHOOTING
Refer to POWER DISTRIBUTION AND GROUNDS
for fuses and relays information.
Always refer to the WIRING DIAGRAM when
troubleshooting an electrical circuit.
Install a battery charger on battery terminals (un-
der seat) for any tests that involve a prolonged
"key ON" period. If battery voltage gets too low,
the VSS shuts off, some accessories are shut off
by the ECM and test results can be altered.
NOTICE Never force a multimeter probe into
an electrical terminal.
rmr2013-033
TROUBLESHOOTING TIPS
If the vehicle is in limp home mode and the appli-
cable indicator lights remain ON in the multifunc-
tion gauge, the VSS does not work.
Start troubleshooting by checking fault codes us-
ing B.U.D.S. Make sure fuses 6 and 8 in rear fuse
box are good; follow the service actions in the
fault codes section. Refer to DIAGNOSTIC AND
FAULT CODES.
In B.U.D.S., the VCM will not show up in the
Module menu (top of screen) if the VCM does
not communicate through CAN bus. Refer to
VCM CAN RESISTOR TEST in this subsection.
Carry out the tests in this subsection according to
the fault codes informations. Refer to DIAGNOS-
TIC AND FAULT CODES subsection.
PROCEDURES
WARNING
The recommended tire pressure is critical
for optimal VSS operation. Use only recom-
mended tire dimensions and type.
YAW RATE SENSOR (YRS)
YRS Connector Access
To access the YRS connector, refer to BODY sub-
section and carry out the following;
– Open the seat.
– Remove console module.
rmr2013-033-005_a
TYPICAL
1. Yaw rate sensor (YRS)
YRS Input Voltage Test
1. Disconnect the YRS connector.
7
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

2. Use the FLUKE 115 MULTIMETER (P/N 529

035 868) and the FLUKE RIGID BACK PROBES
(P/N TP88).
3. Set multimeter to Vdc.
4. Turn ignition switch to ON.
5. Read voltage as follows.
YRS INPUT VOLTAGE TEST
rmr2013-033-011_b
PROBES RESULT
YRS connector If ground circuit is not good, check wiring from
Ground Battery voltage YRS connector to battery ground. Refer to
pin 4
WIRING DIAGRAM.
If continuity is good, check the CAN lines.

YRS CAN Line Test

1. Open front storage compartment cover.
2. Remove service cover.
3. Disconnect diagnostic link connector (DLC).
4. Read wiring resistance between diagnostic link
connector and YRS.
rmr2013-033-011_a

YRS CAN LINE TEST

If voltage is not good, check wiring and connec-
tors from battery through ignition switch to YRS CAN* PROBES RESULT
connector. Refer to WIRING DIAGRAM. Diagnostic
YRS
If voltage is good, carry out the YRS GROUND link
High connector
connector
CIRCUIT TEST that follows. pin 3
pin 1 Close
to 0
YRS Ground Circuit Test YRS
Diagnostic (continuity)
link
1. Use the FLUKE 115 MULTIMETER (P/N 529 Low connector
connector
035 868) and the FLUKE RIGID BACK PROBES pin 2
pin 2
(P/N TP88).
* CAN: Serial data communication
2. Set multimeter to Vdc.
3. Connect multimeter RED probe to a positive If continuity is not good, check wiring and connec-
source such as the battery terminal of the tors from diagnostic link connector (DLC) to YRS
starter solenoid. connector. Refer to WIRING DIAGRAM.
4. Probe pin 1 of the YRS connector with the If everything tested good, try a new YRS.
BLACK (COM) probe of the multimeter.
YRS GROUND CIRCUIT TEST
YRS Removal
1. Refer to BODY subsection and remove the fol-
PROBES RESULT lowing:
YRS connector – LH and RH upper side panels
Positive source Battery voltage
pin 1 – LH and RH acoustic panels.
2. Remove LH and RH fuel tank covers. Refer to
FUEL TANK AND FUEL PUMP subsection.
3. Remove YRS from frame.

8 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

YRS Installation PILLION RIDER (PASSENGER)

NOTICE The YRS is very fragile. Do not drop SWITCH (PRS)
or hit. Handle with care. Replace if dropped or PRS Location
damaged.
The PRS is located under the rear portion of the
Reverse removal procedure. However, pay atten- seat.
tion to the following. To access it, open the seat.
Position YRS as illustrated.

rmr2013-033-006_a

rmr2013-033-012_a TYPICAL - PRS UNDER SEAT

TYPICAL 1. Pillion rider switch (PRS)
1. YRS flange against frame
2. Connector towards rear
PRS Connector Access
Reset the YRS. 1. Open seat.
2. Remove battery access panel, refer to CHARG-
YRS Reset ING SYSTEM subsection.
1. Place vehicle on a flat level surface.
2. Connect vehicle to applicable B.U.D.S. version.
3. In B.U.D.S., select the following:
– Setting page tab
– VCM page.
4. Have someone sit on the vehicle seat.
5. Click on the Reset Longitudinal Offset button
in the Yaw Rate Sensor field.

rmr2013-033-013_a

1. PRS connector
rmr2008-033-012_b

SETTING, VCM PRS Test with B.U.D.S.

1. Reset Longitudinal Offset button
1. Connect vehicle to applicable B.U.D.S. version.

rmr2013-033 9
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

2. In B.U.D.S., select the following:

– Monitoring page tab
– VCM page.
3. Have someone sit on the rear portion of the
seat (passenger position).
NOTE: The Pillion Rider switch light should
come ON in B.U.D.S.

rmr2008-033-016_a
rmr2008-033-015_b

MONITORING, VCM If voltage is not good, check wiring and connec-

1. Pillion Rider switch light
tors from battery through ignition switch to PRS
If the pillion rider switch light in B.U.D.S. does connector. Refer to WIRING DIAGRAM.
not come on as specified, carry out a PRS INPUT If voltage is good, carry out a PRS GROUND CIR-
VOLTAGE TEST. CUIT TEST.
4. Have the person leave the seat.
PRS Ground Circuit Test
NOTE: The pillion rider switch light should turn
OFF in B.U.D.S. 1. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and set it to Vdc.
PRS Input Voltage Test 2. Connect multimeter RED probe to a positive
1. Open seat. source such as the battery terminal of the
starter solenoid.
2. Disconnect PRS connector, refer to PRS CON-
NECTOR ACCESS. 3. Probe pin C of the PRS connector with the
BLACK (COM) probe of the multimeter.
3. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and set it to Vdc. PRS GROUND CIRCUIT TEST
4. Turn ignition switch to ON. PROBES RESULT
5. Read voltage as follows. PRS connector
Positive source Battery voltage
pin C
PRS INPUT VOLTAGE TEST
PROBES RESULT
PRS connector
Ground Battery voltage
pin A

rmr2008-033-016_d

10 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

If ground circuit is not good, check wiring from
PRS connector to VCM,refer to WIRING DIA-
GRAM. If no problem is found, carry out the VCM
GROUND CIRCUIT TEST, refer to VEHICLE CON-
TROL MODULE (VCM) in this subsection.
If ground circuit is good, carry out the PRS OUT-
PUT SIGNAL TEST that follows.
2. Disconnect the seat stay cylinder from the seat.
3. Open seat until a resistance is felt and support
in position.
4. Disconnect PRS connector. Access connector
through the hole in the battery cover.
5. Remove PRS retaining screws.

PRS Output Signal Test

1. Reconnect PRS connector and rotated it to the
horizontal position.
2. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and set it to Vdc.
3. Carefully insert the back probes in the PRS con-
nector as specified in the following table.
4. Turn ignition key to ON and read voltage as fol-
lows.
PRS OUTPUT SIGNAL TEST
PROBES CONDITION RESULT
No passenger
2.5 to
seated on rear
PRS PRS 4.14 Vdc rmr2013-033-006_b
position 1. PRS retaining screws
connector connector
pin B pin C Passenger
0.9 to PRS Installation
seated on rear
1.84 Vdc
position Reverse removal procedure.

WHEEL SPEED SENSOR (VSS)

rmr2011-082-004_a

TYPICAL - PRS OUTPUT SIGNAL TEST

1. PRS connector
2. Back probes

If voltage output is not good, replace PRS. rmr2013-033-007_a

If voltage output is good, carry out a CONTINUITY FRONT WHEEL SPEED SENSOR
TEST OF PRS SIGNAL WIRES to check wiring and
connectors between PRS sensor and VCM. Refer
to WIRING DIAGRAM for circuit details.

PRS Removal
1. Open seat.

rmr2013-033 11
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

If one of the sensor gauges does not respond to

wheel rotation, refer to VSS WIRING CONTINU-
ITY TEST.
VSS Wiring Continuity Test
1. Disconnect the wheel speed sensor connector
to be tested.
2. Disconnect VCM connector, refer to VCM CON-
NECTOR ACCESS in this subsection.
3. Use the FLUKE 115 MULTIMETER (P/N 529
035 868) and the FLUKE RIGID BACK PROBES
(P/N TP88).
4. Set multimeter to .
rmr2013-033-001_a 5. Measure wiring resistance as follows.
1. Rear wheel speed sensor
NOTICE To avoid damaging the connector,
Make sure that: probe only the terminal tip.
– Wheel sensors are securely fastened and un- VCM
damaged. SENSOR
SENSOR CONNECTOR MEASUREMENT
– Rear wheel speed sensor is properly adjusted. TERMINAL
PIN
– Front wheel sensor gap is the same (within 1 8
0.6 mm (.024 in) at 4 different places, 90° Front LH
apart. Otherwise, inspect components for 2 19
straightness and ensure wheels are properly 1 4
tightened. Close to 0
Front RH
2 16 (continuity)
VSS Test with B.U.D.S.
1 17
1. Connect vehicle to applicable B.U.D.S. ver- Rear
sion, refer to COMMUNICATION TOOLS AND 2 29
B.U.D.S. subsection.
If continuity test failed, repair wiring or
2. In B.U.D.S., select the following: connectors.
– Read Data button
If continuity test succeeded, try a new sensor.
– Monitoring page tab
If problem persists, try a new VCM.
– VCM page.
3. Lift each wheel one at a time and manually ro- VSS Adjustment (Rear Only)
tate wheel. 1. Lift rear of vehicle and support safely.
4. Look in B.U.D.S. to see if the corresponding 2. Rotate wheel to align a tooth of the encoder
sensor needle moves. wheel with the sensor.
3. Use a feeler gauge and measure the gap be-
tween the tooth and sensor.

rmr2011-082-001

Otherwise, perform the electrical tests.

12 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))
rmr2013-033-014_a
A. Gap
ENCODER WHEEL/SENSOR GAP
1.30 - 1.80 mm (.051 - .075 in)
Rotate wheel and repeat measurement at 4 differ-
ent places spaced of approximately 90° apart.
If measurement is out of specification, carry out
theVSS ADJUSTMENT PROCEDURE that fol-
lows.
NOTE: If gap measurement varies significantly
with wheel rotation, it may indicate a warped disc
brake or an improperly seated encoder wheel or
disc brake. If measurement is way out of specifi-
cation, it may indicate a bent mounting bracket.
VSS Adjustment Procedure
NOTE: Adjustment is performed by removing or
adding shims between the sensor and mounting
bracket.
1. Remove sensor retaining screw.
2. Remove sensor with spacer and shims.
3. Add or remove shims to obtain gap specifica-
tion.
4. Reinstall sensor and ensure the spacer is
against the sensor followed by the shim(s).
5. Tighten sensor retaining screw as specified.
WHEEL SPEED SENSOR
RETAINING SCREW TORQUE
10 N•m (89 lbf•in)
6. Lower vehicle to the ground.
7. Clear fault codes using B.U.D.S. as necessary.
rmr2013-033
VEHICLE CONTROL MODULE
(VCM)
rmr2013-033-015
TYPICAL
VCM Troubleshooting
A VCM failure is not likely to occur. These mod-
ules have proven to be very reliable. Prior to re-
placing a suspected VCM, take the following into
account.
The problem can be related to a hydraulic function,
check the following:
– Brake fluid level
– Brake line leaking, bent or pinched
– Brake caliper
– Master cylinder (including piston rod position).
The problem can be related to an electric function,
check the following:
– Fault codes
– VCM electrical connector. Refer to WIRING
HARNESS AND CONNECTORS subsection for
detailed information on the VCM connector
– Wiring harness condition.
NOTE: If pins or terminals are not clean, check
VCM harness connector seal condition and ensure
connector mechanism properly locks connector
seal against VCM.
Try disconnecting and reconnecting the VCM con-
nector to see if it “cures” the problem.
As a final test, try a new VCM without discon-
necting brake lines from the old VCM. Proceed as
follows:
IMPORTANT: Disconnecting brake lines would re-
quire the system bleeding.
1. Connect VCM connector to a new VCM.
13
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

2. Turn ignition switch ON. VCM Power Supply Pinout

NOTE: It is normal that some fault codes appear VCM CONNECTOR
at this time. FUNCTION
TERMINAL
3. If problem persists, the trouble is elsewhere. Power from ignition
28
4. If problem is now solved, the VCM in the vehi- switch
cle is faulty. Install the new VCM in the vehicle. Hydraulic pump power 1

WARNING Hydraulic valves power 25

Never ride a vehicle with a VCM temporarily Grounds 13 and 38
installed. Can high 26

VCM Connector Access Can low 14

WARNING
The VCM motor and valves are powered from
the battery when the key is to the ON posi-
tion. Always disconnect the battery prior to
disconnecting VCM connector.

Connector can be accessed from the front LH side

as illustrated.

rmr2013-033-017_a

VCM HARNESS CONNECTOR PINOUT

VCM Input Voltage Test

rmr2013-033-016_a
LH SIDE
1. VCM connector
2. Lower suspension arm
Refer to WIRING HARNESS AND CONNECTORS
subsection for procedures on how to disconnect
and reconnect the VCM connector.
NOTICE Follow procedures to avoid damage
to the connector housing and lock lever.
1. Refer to WIRING HARNESS AND CONNEC-
TORS subsection and disconnect VCM con-
nector.
2. Disconnect SAS connector.
3. Open the reusable locking tie that secure har-
ness to the chassis.
4. Gently pull VCM connector out of the chassis to
ease probing.
5. Use the FLUKE 115 MULTIMETER (P/N 529
035 868) and the FLUKE RIGID BACK PROBES
(P/N TP88).
6. Set multimeter to Vdc.
7. Turn ignition switch ON.
8. Test for input voltage as follows.
NOTICE To avoid damaging the connector,
probe only the tip of the terminal.
NOTE: Refer to VCM POWER SUPPLY PINOUT in
this subsection for pin identification.

14 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

VCM VCM
BATTERY VOLTAGE BATTERY VOLTAGE
CONNECTOR CONNECTOR
Pin 28 Ground Battery voltage Pin 13 Positive source
Battery voltage
Pin 38 Positive source

rmr2013-033-019_a

If voltage is not good, check wiring/connectors rmr2013-033-019_b

from battery through ignition switch to VCM har-
ness connector. Refer to WIRING DIAGRAM.
If voltage is good, test for input voltage as follows.
NOTE: Ignition switch can be either ON or OFF.
VCM
CONNECTOR
BATTERY VOLTAGE
Pin 1 Ground
Battery voltage
Pin 25 Ground
If voltage is not good, check wiring/connectors
from battery to VCM harness connector. Refer to
WIRING DIAGRAM.
If voltage is good, carry out the VCM GROUND
CIRCUIT TEST in this subsection.
VCM Ground Circuit Test
1. Use the FLUKE 115 MULTIMETER (P/N 529
035 868) and the FLUKE RIGID BACK PROBES
(P/N TP88).
2. Set multimeter to Vdc.
3. Connect multimeter RED probe to a positive
source such as the battery terminal of the
starter solenoid.
4. Probe pins 13, then 38 VCM connector with the
BLACK (COM) probe of the multimeter.
NOTE: Refer to VCM POWER SUPPLY PINOUT in
this subsection for pin identification.
If ground circuits are not good, check wiring from
VCM harness connector to chassis ground located
on the front part of the frame. Refer to WIRING
DIAGRAM.
If ground circuits are good, carry out the CAN LINE
RESISTOR TEST in this subsection.
VCM CAN Resistor Test
NOTE: The VCM contains a CAN line termination
resistor. If the resistor value is not correct, or the
resistor is open circuit, the VCM will not be able
to properly communicate with the other modules.
To check the CAN resistor within the VCM, carry
out the following steps.
1. Turn off ignition switch.
2. Open front storage compartment and remove
RH service cover.
3. Disconnect the ECM-B connector, refer to
ELECTRONIC FUEL INJECTION (EFI) subsec-
tion.
4. Measure VCM CAN resistor by probing at the
diagnostic link connector (DLC) as follows.
NOTICE To avoid damaging the connector,
probe only the terminal tip.

rmr2013-033 15
Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

VCM CAN RESISTOR TEST NOTE: Before replacing the VCM, make sure
electrical and hydraulic systems are in good
DLC CONNECTOR MEASUREMENT condition, see VCM REPLACEMENT in this sub-
Pin 1 Pin 2 55 - 65 section.
1. Disconnect battery. Refer to CHARGING SYS-
If the resistance value is as specified, VCM CAN TEM subsection.
resistor and CAN lines are good. Replace VCM.
2. Refer to BODY subsection and remove the bot-
If the resistance value is NOT as specified, carry tom rear side panel.
out the VCM CAN LINE CONTINUITY TEST in this
subsection. 3. Disconnect longitudinal engine mount tie-rod at
both ends, then move it out of the way. Do not
5. Reconnect ECM connector. loosen adjuster lock nuts.
VCM CAN Line Continuity Test
Read wiring resistance between diagnostic link
connector and VCM.
NOTE: Refer to VCM POWER SUPPLY PINOUT in
this subsection for pin identification.
NOTICE To avoid damaging the connector,
probe only the terminal tip.
VCM CAN LINE TEST
CAN* PROBES RESULT
Diagnostic
VCM
link
High connector
connector
pin 26 Close
pin 1
to 0 rmr2013-006-001_a
Diagnostic (continuity)
VCM 1. Front longitudinal engine mount tie-rod end
link
Low connector
connector 4. Disconnect both steering inner tie-rod ends.
pin 14
pin 2
5. Using compressed air, clean:
* CAN: Serial data communication – The VCM and brake line fittings
If continuity is not good, check wiring and con- – The area around the VCM.
nectors from diagnostic link connector (DLC) to 6. Use BRP HEAVY DUTY CLEANER (P/N 293 110
VCM connector. Refer to applicable WIRING DI- 001) to thoroughly clean the parts. Blow com-
AGRAM. pressed air again and thoroughly dry the parts.
If everything tested good and VCM does not work, NOTE: Disconnect brake lines from the old VCM
try a new VCM. only just prior to installing the new VCM. The
shorter the time the brake lines are open, the
VCM Removal lesser the possibility of brake system contamina-
tion.
WARNING
7. Disconnect VCM connector.
Cleanliness is critical when working with the
VCM and brake lines. All precautions must be 8. Disconnect brake lines.
taken to prevent any foreign particle from en- 9. Remove VCM from frame.
tering the brake system. 10. Pull assembly out of position to dislodge
grommet.

16 rmr2013-033
 Subsection XX (VEHICLE STABILITY SYSTEM (VSS))

5. Tighten steering tie-rod ends to 85 N•m

(63 lbf•ft).
6. Make sure the VCM connector is properly in-
stalled and locked.
7. Reset the YRS. Refer to YAW RATE SENSOR
(YRS) in this subsection.
8. Bleed the VCM, refer to VCM BLEEDING pro-
cedure that follows.

VCM Bleeding
WARNING
Brake bleeding must be performed to remove
any air trapped in the brake system. Refer to
rmr2013-033-020_a
BRAKES subsection.
TYPICAL

11. Pull grommet out of VCM support and pull out After bleeding, refer to DIAGNOSTIC AND FAULT
VCM towards the LH side of vehicle. Discard CODES and do the following:
grommet. – Check and clear fault codes.
– Clear LPS fault (if occurred).
VCM Installation – Reset SAS.
NOTE: Keep the protective plugs on new VCM – Reset VCM variant if VCM is used.
until brake line installation.
Reverse removal procedure. However, pay atten-
tion to the following:
Install NEW grommet.
1. Remove protective plugs from VCM brake line
ports.
2. Make sure to reinstall brake lines as illustrated.

rmr2013-033-021_a

1. To LH front brake caliper

2. To RH front brake caliper
3. To rear brake caliper

3. Tighten VCM mounting screws to 7 N•m

(62 lbf•in).
4. Tighten longitudinal engine mount tie-rod to
48 N•m (35 lbf•ft).
rmr2013-033 17
 Subsection 02 (STEERING, DPS AND FRONT WHEELS)

STEERING, DPS AND FRONT WHEELS

SERVICE TOOLS
Description Part Number Page
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ........................................... 3

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 4

rmr2014-033 1
Subsection 02 (STEERING, DPS AND FRONT WHEELS)

7 N•m
(62 lbf•in) 38 N•m
(28 lbf•ft)
7 N•m
(62 lbf•in)
10 N•m 2.5 N•m
(89 lbf•in) (22 lbf•in)

2 N•m
(18 lbf•in)
XPS synthetic grease 1 N•m
(9 lbf•in)
25 N•m
(18 lbf•ft)

NEW
XPS synthetic grease

XPS synthetic grease

43 N•m
(32 lbf•ft)
28 N•m
(21 lbf•ft) NEW
NEW 63 N•m
(46 lbf•ft)
NEW
Loctite 767
(antiseize lubricant)
NEW

7 N•m NEW
(62 lbf•in)
7 N•m
63 N•m (62 lbf•in)
(46 lbf•ft)

2.5 N•m
NEW = Component must be replaced when removed. (22 lbf•in)
rmr2014-033-100_a

2 rmr2014-033
 Subsection 02 (STEERING, DPS AND FRONT WHEELS)

PROCEDURES SAS CAN Communication Link (CAN)

STEERING ANGLE SENSOR
(SAS)
First, check for fault codes using the latest appli-
cable version of B.U.D.S. software.
Before replacing the SAS, check the following.
Continuity Test
1. Disconnect the vehicle diagnostic connector.
2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to selection and test SAS CAN bus wire
continuity as per following table.

SAS Input Voltage and Ground Test

Disconnect SAS connector.
Turn ignition switch ON.

529035868

MULTIMETER PROBE RESISTANCE @

POSITIONS 20°C (68°F)
SAS connector (pin 1) and
diagnostic connector (pin 2)

rmr2014-033-002_a

TYPICAL - BOTTOM OF DPS UNIT

1. SAS
2. SAS connector Less than 1
SAS connector (pin 4) and
MULTIMETER PROBE VOLTAGE diagnostic connector (pin 1)
POSITIONS (KEY ON)
SAS connector (pin 3) and
battery ground

Resistance is out of specification — Check wires

and connector pins. Repair and reset fault codes.
Battery voltage Resistance is good — Replace the steering angle
SAS connector (pin 6) and
battery + terminal
sensor and reset fault codes.

No voltage — Check wires and connector pins.
Replace or repair defective parts and reset fault
codes.
Battery voltage measured — Check SAS commu-
nication link (CAN).
SAS Removal
1. Remove the front storage compartment. Refer
to BODY subsection.
2. Disconnect and remove battery. Refer to
CHARGING SYSTEM.
3. Remove the SAS support from DPS.
4. Disconnect the SAS connector.

rmr2014-033 3
Subsection 02 (STEERING, DPS AND FRONT WHEELS)

NOTICE During insertion, be careful to avoid

damaging the SAS adaptor and create free
play.
4. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of sensor support screw threads or use
new screws.
NOTE: While torquing SAS support screws, en-
sure SAS is well centered.
TIGHTENING TORQUE
SAS support screws 7 N•m (62 lbf•in)
rmr2014-033-003_a

1. SAS support screw

2. SAS connector

5. Remove SAS from its support. Discard the SAS

adaptor.

rmr2014-033-005_a

1. DPS shaft
2. SAS support
3. New elastic stop nut (2x)
4. SAS support screw (2x)
5. SAS adaptor
6. SAS
7. SAS retaining screw (2x)

5. Install all other parts removed, refer to applica-

rmr2014-033-004_a
ble subsection.
1. SAS support 6. Using B.U.D.S., reset the SAS.
2. SAS adaptor
3. SAS

SAS Inspection
Inspect SAS support for cracks or other damages.
Replace if necessary.

SAS Installation
1. Install a new SAS adaptor on DPS shaft.
NOTICE The SAS adaptor MUST be replaced
each time the SAS is removed.
2. Secure the SAS on its support using NEW elas-
tic stop nuts.
TIGHTENING TORQUE
SAS retaining screws 2.5 N•m (22 lbf•in)

3. Install the SAS on the DPS by inserting the SAS

shaft in the SAS adaptor.

4 rmr2014-033
 Subsection XX (FRONT SUSPENSION)

FRONT SUSPENSION
SERVICE TOOLS
Description Part Number Page
BALL JOINT INSTALLER............................................................... 529 035 975 ............................................. 9
BALL JOINT REMOVER SUPPORT .............................................. 529 036 121 ......................................... 7, 9
REAR WHEEL BEARING PUSHER ............................................... 529 036 246 ............................................. 9
SPRING COMPRESSOR ............................................................... 529 036 184 ............................................. 4

SERVICE PRODUCTS
Description Part Number Page
XPS SYNTHETIC GREASE............................................................. 293 550 010 ............................................. 3

rmr2013-041 1
Subsection XX (FRONT SUSPENSION)

Upper suspension arm Lower suspension arm

RH side RH side

3 N•m 3 N•m
(27 lbf•in) (27 lbf•in)
XPS synthetic grease XPS synthetic grease

64 N•m
(47 lbf•ft)
2.0 N•m
(18 lbf•in)

64 N•m
(47 lbf•ft)
2.0 N•m
(18 lbf•in)

RS-S 48 N•m RS, ST, RT 48 N•m

(35 lbf•ft) (35 lbf•ft)

48 N•m
(35 lbf•ft) 48 N•m 25 N•m
(35 lbf•ft) (18 lbf•ft)

7.5 N•m
(66 lbf•in)

NEW = Component must be replaced when removed.

rmr2013-041-100_a

2 rmr2013-041
 Subsection XX (FRONT SUSPENSION)

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.

WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced. rmo2012-001-001_a

SPYDER RS-S
1. Spring preload adjustment ring
2. Lock ring
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled 3. Lock the assembly by tightening the lock ring
as per factory standards. against the preload ring.
TORQUE
ADJUSTMENT
Lock ring 10 N•m (89 lbf•in)
SPRING PRELOAD ADJUSTMENT
(RS-S MODELS) MAINTENANCE
WARNING SUSPENSION LUBRICATION
Adjust both springs to the same load. Un-
Place vehicle on a level surface.
even adjustment can cause poor handling,
loss of stability and loss of control. Apply parking brake.
Loosen wheel lug nuts.
Verification conditions: Lift the front of the vehicle.
– Vehicle on a level surface
Secure vehicle on jack stands.
– Normal cargo load
Remove wheel.
– Rider and passenger taking place on the vehi-
cle. Lubricate suspension arms. There are two grease
fittings per arm.
Measure the distance between the upper and
lower shock absorber mounting bolts. SERVICE PRODUCT
RECOMMENDED PRELOAD XPS SYNTHETIC GREASE (P/N 293 550 010)
420 mm (16-17/32 in)
(rider+passenger+cargo)

To adjust:
1. Loosen the lock ring.
2. Bring the preload ring to the recommended set-
ting.

rmr2013-041 3
Subsection XX (FRONT SUSPENSION)

rmr2013-041-002_a rmr2013-041-005_a

UPPER ARM FRONT CARGO MODULE REMOVED FOR CLARITY

1. Grease fittings 1. Shock absorber bolts

Remove shock absorber from vehicle.

Shock Absorber Disassembly

Remove spring from the shock absorber.
REQUIRED TOOL
SPRING COMPRESSOR (P/N 529 036 184)

529036184

rmr2013-041-003_a

LOWER ARM
Position the shock absorber in the tool and install
1. Grease fittings the spring compressor hooks.

PROCEDURES
SHOCK ABSORBER
Shock Absorber Removal
Remove body parts as required to access to the
shock absorber. Refer to BODY subsection.
Lift the front of vehicle.
mmr2010-033-012_a

Unscrew shock absorber bolts. 1. Spring compressor hooks

Tighten the spring compressor tool screw until

the spring is sufficiently compressed to remove
spring stopper.
Release the spring compressor tool screw.
Remove spring from shock absorber.

4 rmr2013-041

Shock Absorber Inspection
Examine shock for leaks.
Extend and compress the piston at least 5 com-
plete strokes with its rod upward.
Check that rod moves smoothly and with uniform
resistance over its entire stroke.
NOTE: During compression motion, it is normal to
feel a small resistance only.
Pay attention to the following conditions that will
denote a defective shock:
– A very weak rebound.
– 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.
Check piston rod for excessive wear or pitting.
Inspect the spring for damage. Replace if neces-
sary.
On both ends, check the bushings for excessive
wear or other damages.
Replace shock absorber or spring if any faults are
present.
Shock Absorber Assembly and
Installation
For assembly and installation, reverse the disas-
sembly and removal procedures.
AIR DEFLECTOR (UPPER ARM)
Air Deflector Removal
Remove body parts as required to access to the
air deflector. Refer to BODY subsection.
Underneath suspension arm, remove air deflector
screws.
rmr2013-041-007_a
rmr2013-041
Subsection XX (FRONT SUSPENSION)
Remove the upper shock absorber bolt.
rmr2013-041-004_a
1. Upper shock absorber bolt
Detach flexible brake hose and speed sensor wire
from air deflector.
Remove the air deflector.
Air Deflector Installation
The installation is the reverse of the removal pro-
cedure.
UPPER SUSPENSION ARM
Upper Suspension Arm Inspection
Check upper suspension arms for bending or
other damage. Replace suspension arms if nec-
essary.
Move upper suspension arm from side to side and
up and down. There should be no noticeable play
in bushings.
If necessary, remove suspension arm and inspect
pivot bushings and sleeves for wear or damages.
Replace bushings and/or sleeves if necessary.
Upper Suspension Arm Removal
Place vehicle on a level surface.
Apply parking brake.
Remove front cargo module. Refer to BODY sub-
section.
Loosen wheel lug nuts.
Lift the front of the vehicle.
Secure vehicle on jack stands.
Remove wheel.
Remove brake disc and encoder wheel. Refer to
BRAKES subsection.
5
Subsection XX (FRONT SUSPENSION)

Remove screws securing the air deflector on up-

per suspension arm.

rmr2013-041-012_a

1. Upper suspension arm bolts

rmr2013-041-007_a
Remove the upper suspension arm without its air
Remove screws securing the upper ball joint sup- deflector.
port.
Upper Suspension Arm Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Perform STEERING ALIGNMENT. Refer to
STEERING (DPS) AND FRONT WHEELS.
Lubricate upper suspension arm. Refer to MAIN-
TENANCE in this subsection.

UPPER BALL JOINT

Upper Ball Joint Inspection
Inspect ball joint end for damage. Ensure it is
moving freely without play. Replace ball joints as
required.

rmr2013-041-008_d Upper Ball Joint Removal

1. Upper ball joint support screws
Remove upper screw retaining oil cooler air duct
(LH side) or radiator air duct (RH side).
Remove the UPPER SUSPENSION ARM, see pro-
cedure in this subsection.
Remove circlip securing ball joint to suspension
arm.

rmr2013-041-009_a

LH SIDE SHOWN
1. Oil cooler air duct
2. Screw to remove
rmr2008-029-015

Unscrew upper suspension arm bolts. Press ball joint out of the upper suspension arm.

6 rmr2013-041
 Subsection XX (FRONT SUSPENSION)

REQUIRED TOOL Move lower suspension arm from side to side and
up and down. There should be no noticeable play
BALL JOINT REMOVER SUPPORT in bushings.
(P/N 529 036 121)
If necessary, remove suspension arm and inspect
pivot bushings and sleeves for wear or damages.
Upper Ball Joint Installation Replace bushings and/or sleeves if necessary.
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. Lower Suspension Arm Removal
Press ball joint into the suspension arm. Place vehicle on a level surface.
BALL JOINT NUT TORQUE Apply parking brake.
48 N•m (35 lbf•ft) Remove front cargo module. Refer to BODY sub-
section.
Install circlip. Loosen wheel lug nuts.
Lift the front of the vehicle.
AIR DEFLECTOR (LOWER ARM) Remove wheel.
Air Deflector Removal Remove brake disc and encoder wheel. Refer to
Underneath suspension arm, remove air deflector BRAKES subsection.
screws. Unscrew ball joint nut.
Remove the lower shock absorber bolt.

rmr2013-041-006_a

UNDERNEATH LH LOWER SUSPENSION ARM

1. Air deflector screws rmr2013-041-008_b
2. Air deflector 1. Lower shock absorber bolt
3. Suspension arm

Remove the air deflector. Underneath lower suspension arm, remove stabi-
lizer bar bolt.
Air Deflector Installation
The installation is the reverse of the removal pro-
cedure.

LOWER SUSPENSION ARM

Lower Suspension Arm Inspection
Check lower suspension arms for bending or
other damage. Replace suspension arms if nec-
essary.
rmr2013-041-010_a

1. Lower suspension arm

2. Stabilizer bar

rmr2013-041 7
Subsection XX (FRONT SUSPENSION)

Unscrew lower suspension arm bolts.

rbg2013-003-001

rmr2013-041-003_a

1. Lower suspension arm bolts

Remove the lower suspension arm with its air de-

flector.
Turn suspension arm upside down and remove
the air deflector.

Lower Suspension Arm Installation

rbg2013-003-002
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. 3. Remove the RH front wheel.
Tighten ball joint nut to specification.
BALL JOINT NUT TORQUE
48 N•m (35 lbf•ft)

Perform STEERING ALIGNMENT. Refer to

STEERING (DPS) AND FRONT WHEELS.
Lubricate lower suspension arm. Refer to MAIN-
TENANCE in this subsection.

LOWER BALL JOINT

Lower Ball Joint Inspection rbg2013-003-003

Inspect ball joint end for damage. Ensure it is

moving freely without play. Replace ball joints as 4. Remove the lower ball joint retaining bolt and
required. discard elastic nut.

Lower Ball Joint Removal

1. Place the vehicle on a level surface and apply
parking brake.
2. Lift the front of vehicle.

8 rmr2013-041
 Subsection XX (FRONT SUSPENSION)

rbg2013-003-004_a

1. Ball joint retaining bolt location

rbg2013-003-006

5. Lift up the upper suspension arm. 6.3 Tighten C-clamp and press the ball joint out
of the suspension arm.

Lower Ball Joint Installation

1. Install the new lower ball joint.
1.1 Using electrical tape, secure a REAR
WHEEL BEARING PUSHER (P/N 529 036
246) to the top section of the BALL JOINT
INSTALLER (P/N 529 035 975).
1.2 Install the C-clamp, the ball joint installer,
the rear wheel bearing pusher and the
socket of 35 mm (1-3/8 in) as shown.

rbg2013-003-005

NOTE: Properly secure the suspension arm to

keep it out of the way during the procedure.
6. Remove the lower ball joint.
6.1 Using electrical tape, secure a REAR
WHEEL BEARING PUSHER (P/N 529 036
246) to the bottom of the BALL JOINT RE-
MOVER SUPPORT (P/N 529 036 121).
6.2 Install the C-clamp, the ball joint remover
support and the rear wheel bearing pusher
on lower ball joint as shown.
NOTE: Fixed portion of C-clamp must be in-
stalled on moving part of ball joint to stabilize
it during removal.

rbg2013-003-007

rmr2013-041 9
Subsection XX (FRONT SUSPENSION)

1.3 Tighten C-clamp and press the ball joint Pivot Bushings Installation
into lower suspension arm. The installation is the reverse of the removal pro-
NOTICE Always push on the ball joint edge, cedure.
never on center surface.
STABILIZER BAR
2. Lower upper suspension arm and secure
knuckle to lower suspension arm using a new Stabilizer Bar Removal
M10 elastic nut. Remove front cargo module. Refer to BODY sub-
TIGHTENING TORQUE section.
M10 elastic nut 48 N•m (35 lbf•ft) Unscrew stabilizer bar from link rods.

3. Reinstall wheel.
TIGHTENING TORQUE
Wheel lug nuts 105 N•m (77 lbf•ft)

PIVOT BUSHINGS
rmr2013-041-013_a
NOTE: The following procedure is the same for all
TYPICAL
suspension arms. 1. Stabilizer bar
2. Link rods
Pivot Bushings Removal
Turn stabilizer bar downward.
Remove appropriate suspension arm. Refer to
UPPER SUSPENSION ARM or LOWER SUSPEN- Remove stabilizer bar bushings.
SION ARM in this subsection.
Remove sleeve from pivot bushings.

rmr2008-029-027_a

1. Sleeve
2. Pivot bushings

Using a punch, remove pivot bushings.

rmr2013-041-014_a

TYPICAL
1. Stabilizer bar bushing
2. Remove these bolts
3. Stabilizer bar

Remove stabilizer bar from vehicle.

Stabilizer Bar Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
rmr2008-029-028_a

1. Pivot bushings Before installing stabilizer bar, verify if all ball joints
of link rods move smoothly and freely. Replace
link rod if necessary.

10 rmr2013-041
 Subsection XX (FRONT SUSPENSION)

Check stabilizer bar bushings for cracks or other

damages. Replace if necessary.
Install all other removed parts.

LINK ROD
Link Rod Removal
Lift the front of vehicle.
Remove the air deflector from lower suspension
arm.

rmr2013-041-015_a

TYPICAL - LH SIDE SHOWN

1. Air deflector

Unscrew the bolts securing link rods.

rmr2013-041-016_a

LH SIDE SHOWN
1. Link rod bolts
2. Lower suspension arm
3. Stabilizer bar

Link Rod Installation

The installation is the reverse of the removal pro-
cedure.

rmr2013-041 11
 Subsection XX (REAR SUSPENSION (RT SERIES))

REAR SUSPENSION (RT SERIES)

SERVICE TOOLS
Description Part Number Page
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ........................................... 23
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................................. 8, 13, 16
SPRING COMPRESSOR ............................................................... 529 036 184 ........................................... 19

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 24
LOCTITE 592 (PIPE SEALANT) ..................................................... 293 800 018 ........................................... 16
XPS SYNTHETIC GREASE............................................................. 293 550 010 ........................................... 23

rmr2013-035 1
Subsection XX (REAR SUSPENSION (RT SERIES))

System without Loctite 592

pipe sealant 48 N•m
compressor (35 lbf•ft)
13 N•m
(115 lbf•in)

Loctite 592
pipe sealant

7 N•m
(62 lbf•in)

5 N•m
(44 lbf•in)
7 N•m
(62 lbf•in) 7 N•m
(62 lbf•in)

7 N•m
(62 lbf•in)
NEW

55 N•m
(41 lbf•ft)

7 N•m
(62 lbf•in)
NEW
55 N•m
XPS synthetic (41 lbf•ft)
grease

NEW = Component must be replaced when removed.

rmr2013-035-100_a

2 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))
GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded view.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.
CAUTION The ACS suspension system
may be under high pressure (up to 7 bar
(100 PSI)). Release air pressure prior to work-
ing on the system. Refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING.
CAUTION Always wear safety goggles
when working with pressurized air system.
NOTICE Do not exceed 7 bar (100 PSI) in the
system. This might damage the air suspension
system.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
NOTE: Install a battery charger on battery termi-
nals (under seat) for any tests that involve a pro-
longed KEY ON period. If battery voltage gets too
low, some accessories are shut off by the ECM.
SYSTEM DESCRIPTION
ACS System Without Compressor
(Manual Adjustment)
The ACS suspension is manually adjustable using
a conventional air compressor and a pressure
gauge. This system is equipped with an air spring
mounted on the swing arm and located in front
of the shock absorber.
The air spring is connected directly to an air hose
with a pneumatic valve, as a result, adjusting the
air pressure is as easy as inflating a tire.
NOTE: When adjusting the pressure, do not put
your weight on the vehicle and do not load cargo
in the storage compartment.
rmr2013-035
ACS System with Compressor
(Remote Adjustment)
This system allows the suspension to be adjusted
electronically using a dedicated button. The sys-
tem can be adjusted on the fly to suit rider prefer-
ences and automatically keeps vehicle level con-
stant with changing rider weight or load applied.
To achieve this, an air spring is used in conjunction
with the following components:
– ACS air compressor
– ACS position sensor
– ACS solenoid valve
– ACS relay (R4)
– ACS switch.
When the suspension button is pressed, the re-
quested setting is sent to the multifunction gauge.
Depending on the rider adjustment, the multifunc-
tion gauge will request a pressure increase in the
air spring using the compressor or a pressure re-
lease using the solenoid valve. The position sen-
sor mounted on the swing arm monitors the vehi-
cle level to ensure proper ride height.
The highlighted bar on the multifunction gauge in-
dicates the actual setting. Pressing the switch will
move the bar up or down one at a time.
The multifunction gauge indicates suspension set-
ting as follows.
1
rmo2010-001-400_ben
1. Actual setting
To change the ACS setting, press ACS switch un-
til the requested setting is displayed in the multi-
function gauge.
3
Subsection XX (REAR SUSPENSION (RT SERIES))

3. Wait until the system is completely empty of

air.
NOTE: Make sure to wait enough time in order to
let the system expel the air. (no more pressurized
air sound from the valve).

INSPECTION
ACS SYSTEM LEAK TEST
rmo2010-001-038_i
1. Remove the rear side panels. Refer to BODY
1. Press here to stiffen subsection.
2. Press here to soften
2. Locate the ACS pneumatic valve.
ACS Suspension Settings
On both systems, the ACS suspension is ad-
justable from 0.7 bar (10 PSI) to 7 bar (100 PSI).
Refer to the table below to know the air pressure
setting relating to the recommended loading ca-
pacity of the vehicle.
System Without Compressor

WARNING
MINIMUM PRESSURE 10 PSI / 70 kPa
Do not exceed recommended pressure by 10 PSI / 70 kPa
PASSENGER + CARGO (lb /kg)
LOAD
0 100/45 150/70 200/90 250/115
Lb/Kg PSI/kPa PSI/kPa PSI/kPa PSI/kPa PSI/kPa
DRIVER

150/70 20/135 40/275 50/345 60/415 70/485 rmo2010-001-056_a

200/90 30/205 50/345 60/415 70/485 80/555 TYPICAL

250/115 40/275 60/415 70/485 80/555 90/625 1. Pneumatic valve
704902072
3. Manually adjust air suspension pressure to
System with Compressor specification.
ACS SUSPENSION SETTINGS ACS SYSTEM LEAK TEST PRESSURE
SETTING BAR RIDING POSITION 275 kPa (40 PSI)
1 (top) Lowest
4. Spray the following areas with soapy water:
2 Low – Pneumatic valve
3 Factory setting (Middle) – Air spring
4 High – Pneumatic hose fittings
– ACS air compressor output (if applicable)
5 (bottom) Highest
– ACS solenoid valve (if applicable)
– ACS manifold (if applicable).
Releasing Air Pressure in System for
Servicing
Before working on the air system, always release
air pressure as follows.
1. Open seat.
2. Push and hold pneumatic valve plunger using a
small screwdriver.

4 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

rbs2010-017-002_a
rbs2010-017-001_a
SYSTEM WITHOUT COMPRESSOR
SYSTEM WITH COMPRESSOR
1. Spray soapy water in these areas
1. Spray soapy water in these areas

NOTE: It may be necessary to wait 5 minutes for

bubbles to appear.
5. Repair any leak.

Pneumatic Fitting Leak

To repair a leak coming from a pneumatic fitting,
proceed as follows:
1. Push the fitting ring away from hose.
2. Hold ring in place.
3. Pull hose out of the fitting.
4. Cut end of hose straight approximately
1 mm - 2 mm (.039 in - .079 in).
5. Push the fitting ring in, insert hose and pull ring
back into position.
6. Check for leaks again.

Air Spring Leak

To repair a leak coming from the air spring or its
90° fitting, order the following repair kit.
AIR SUSPENSION REPAIR KIT
(P/N 219 800 175)

rmr2013-035 5
Subsection XX (REAR SUSPENSION (RT SERIES))
NOTE: This kit includes the air spring and the 90°
fitting.
TROUBLESHOOTING
DIAGNOSTIC TIPS
Before any troubleshooting operations on ACS
system, it is important to check the fault codes
using B.U.D.S. to properly diagnose the problem.
Refer to DIAGNOSTIC AND FAULT CODES sub-
section.
ACS Does Not Work and No Fault
Code Is Set
If the ACS system (system with compressor) is
not working, make sure the required option is se-
lected in B.U.D.S. Otherwise, the ACS system will
not work and no fault code will be set.
1. Connect and start B.U.D.S. to check the Ad-
justable Controlled Suspension option.
rmr2011-085-001_a
SETTING AND ACC TABS
1. Adjustable Controlled Suspension
2. With/Without ACS option
NOTE: If the option is checked in B.U.D.S. and
the vehicle is not equipped with the ACS system,
false fault code(s) will be set.
Error Code "MANUAL" Displayed in
Gauge
The error code MANUAL can appear on the mul-
tifunction gauge for different reasons that are not
necessarily related to a failure of the ACS system.
rmo2011-001-004_a
TYPICAL
1. Error code MANUAL
6 rmr2013-035
If the Error Code Appears Momentarily
If the error code appears momentarily on the mul-
tifunction gauge, it indicates a disparity between
the requested and the actual suspension settings.
To deactivate the error code, turn the ignition key
to OFF position then wait a few seconds.
NOTE: Ensure that vehicle maximal load capacity
is not exceeded.
If the Error Code Remains Active
If the error code remains active each time that the
ACS switch is pressed, refer to TROUBLESHOOT-
ING GUIDELINES.
TROUBLESHOOTING
GUIDELINES
ERROR CODE "MANUAL" REMAINS
ACTIVE IN GAUGE
1. Leak in the ACS system.
- Check ACS system to detect leak, refer to ACS
SYSTEM LEAK TEST.
2. Faulty ACS position sensor or wiring. (Refer to
ACS POSITION SENSOR for testing).
- Check ACS position sensor signal circuit continu-
ity.
- Check ACS position sensor input voltage.
- Check ACS position sensor ground circuit conti-
nuity.
- Perform the ACS position sensor reset with
B.U.D.S.
3. Damaged position sensor.
- Check ACS position sensor for damage, refer to
ACS POSITION SENSOR INSPECTION.
REQUESTED SETTING DISPLAY DOES
NOT CHANGE IN GAUGE
1. Faulty ACS Switch (CSS) or wiring.
- Check ACS switch continuity, refer to ACS
SWITCH.
- Check ACS switch control circuit, refer to ACS
SWITCH.
SUSPENSION SETTING CAN NOT BE
CHANGED ON VEHICLE
1. Make sure the following requirements are met:
- Engine is started.
- Parking brake is released.
- Gearbox in gear (first or reverse).
- Rear storage compartments are closed.
 Subsection XX (REAR SUSPENSION (RT SERIES))

2. Damaged fuse.
- Check F5 fuse in RH fuse box (RFB), refer to
POWER DISTRIBUTION AND GROUNDS sub-
section.
3. Damaged relay.
- Check R3 relay (load shedding relay), refer to
POWER DISTRIBUTION AND GROUNDS sub-
section.
- Check R4 relay (ACS relay), refer to ACS RELAY
(R4).
4. Faulty multifunction gauge control circuits.
- Check multifunction gauge control circuit continu-
ity to ACS relay (R4) to (PIN-19).
- Check multifunction gauge control circuit continu-
ity to ACS solenoid valve (PIN-18).
5. Faulty ACS compressor or wiring.
- Carry out an ACS COMPRESSOR OPERATION rmr2011-085-002_a
TEST. Step 1: Select Monitoring
Step 2: Select ACC
6. Faulty ACS solenoid valve or wiring.
- Carry out an ACS SOLENOID VALVE OPERATION 4. Start engine and release parking brake.
TEST. 5. Let vehicle run at idle in 1st gear.
6. Press ACS adjustment switch on vehicle.
TROUBLESHOOTING WITH
B.U.D.S.
ACS Position Sensor Monitoring
To monitor the position sensor during trou-
bleshooting operation, proceed as follows:
1. Connect vehicle to B.U.D.S. Refer to COMMU-
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection.
2. Select Monitoring page.
3. Select ACC folder.
rmo2010-001-038_i

ACS ADJUSTMENT SWITCH

1. Press here to stiffen
2. Press here to soften

7. Check proper operation in B.U.D.S.

PROCEDURES
NOTE: Refer to the exploded view for service
product, torque and assembly details.

ACS POSITION SENSOR

The ACS position sensor is identified SPS in the
WIRING DIAGRAM.

rmr2013-035 7
Subsection XX (REAR SUSPENSION (RT SERIES))

ACS Position Sensor Location ACS Position Sensor Input Voltage

The ACS position sensor is located on the LH side Test
of the vehicle near the shock absorber. 1. Remove rear cargo module. Refer to BODY
subsection.
2. Disconnect position sensor connector.

rmr2010-036-004_a

SOME PARTS REMOVED FOR CLARITY PURPOSE

1. ACS position sensor

ACS Position Sensor Signal Circuit rmr2010-036-009_a

Continuity Test 1. Position sensor connector

1. Remove rear cargo module. Refer to BODY 3. Set the FLUKE 115 MULTIMETER (P/N 529 035
subsection. 868) to Vdc.
2. Disconnect position sensor connector. 4. Start engine and release parking brake.
5. Let vehicle run at idle in 1st gear.
6. Measure voltage as per the following table.
TEST PROBES VOLTAGE
Pin 5 (YL/WH)
Battery voltage (± 5 Vdc)
Battery negative (-) post

ACS Position Sensor Ground Circuit

Continuity Test
1. Remove rear cargo module. Refer to BODY
rmr2010-036-009_a
subsection.
1. Position sensor connector 2. Disconnect position sensor connector.
3. Remove multifunction gauge from vehicle. Re-
fer to LIGHTS, GAUGE AND ACCESSORIES
subsection.
4. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
5. Measure resistance as per the following table.
TEST PROBES RESISTANCE
Gauge connector
pin 13 (LT BU/YL)
Close to 0
Position sensor connector
pin 4 (LT BU/YL) rmr2010-036-009_a

1. Position sensor connector

3. Set the FLUKE 115 MULTIMETER (P/N 529 035

868) to Vdc.

8 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

4. Start engine and release parking brake. NOTE: Check battery voltage before performing
5. Let vehicle run at idle in 1st gear. this procedure. Battery must be fully charged or
use a power pack to ensure adequate power for
6. Measure voltage as per the following table. the entire procedure.
TEST PROBES VOLTAGE Resetting Procedure
Pin 1 (BK) Battery voltage 1. From LH side of vehicle, insert the short block
Battery positive (+) post (± 12 Vdc) in front of the curved portion of frame as
shown.
ACS Position Sensor Reset with NOTE: Make sure block does not touch other
B.U.D.S. parts of vehicle.
Required Tools
REQUIRED TOOLS
2 blocks of wood (typically 10 x 10 cm (4 x 4 in))
Short block: 110 mm (4-7/16 in)
Long block: 150 mm (5-7/8 in)

Vehicle Preparation
1. Park vehicle on a level surface.
2. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection. rbg2010-007-008_a

LH SIDE OF THE VEHICLE SHOWN

3. Inflate rear tire to 193 kPa (28 PSI).
4. Safely lift the vehicle.
5. Turn ignition key to ON.
6. Connect vehicle to B.U.D.S. Refer to COMMU-
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection.
7. Click the Setting tab.
8. Click the ACC tab at the bottom of the screen.
NOTE: Ensure the check box With/Without ACS
is checked.
1. Front of vehicle
2. Catalytic converter
2. Lower vehicle until it rests on block.
3. Place approximately 95 kg (210 lb) on passen-
ger seat.
4. Manually lift or push down the rear of vehicle
until rear screw of the footrest support is at the
specified distance from the ground.
DISTANCE FROM THE GROUND FOR
LOW POSITION RESET
355 mm ± 3 mm (14 in ± 1/8 in)

rbg2010-007-007_c

LOW POSITION FOR SENSOR RESET

1. Short block
A. See table
rbg2011-011-001_a

1. Setting tab 5. Hold vehicle in this position.

2. ACC tab
3. Checked box 6. Click Reset button of ACS LOW Position in
B.U.D.S.

rmr2013-035 9
Subsection XX (REAR SUSPENSION (RT SERIES))

rbg2011-011-001_c rbg2011-011-001_b

1. Click here 1. Click here

NOTICE ALWAYS use provided measure- 11. Save new settings in the vehicle ECU by click-
ments to reset the ACS position sensor. ing the Write Data button in B.U.D.S.
– The ACS position values indicated in
B.U.D.S. are specific to each sensor and
do not match with the suspension height
measurement.
– These values must NEVER be used to adjust
or confirm the position of the ACS position
sensor.
– Do not try to match these values on other
vehicles.
7. Replace the short block with the long block.
8. Manually lift or push down the rear of vehicle vmr2006-012-100_ben

until rear screw of the footrest support is at the

specified distance from the ground.
DISTANCE FROM THE GROUND FOR
HIGH POSITION RESET
400 mm ± 3 mm (15-25/32 in ± 1/8 in)
12. Remove weight and wood block from vehicle.
13. Lower vehicle to the ground.
14. Turn the ignition key to OFF position then wait
a few seconds.
15. Start engine and release parking brake.
16. Let vehicle run at idle in 1st gear.
17. Activate the suspension switch up and down
to ensure the ACS suspension works properly.

ACS Position Sensor Inspection

Check ACS position sensor lever for straightness
or other damage.
Check ACS position sensor lever for proper orien-
rbg2010-007-007_d
tation.
HIGH POSITION FOR SENSOR RESET
1. Long block
A. See table

9. Hold vehicle in this position.

10. Click Reset button of ACS HIGH Position in
B.U.D.S.

10 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

4. Detach link rod from position sensor by remov-

ing upper bolt and nut.

rbs2010-012-001

CORRECT ORIENTATION

rmr2010-036-010_a

1. Link rod upper bolt

5. Move position sensor arm to access to retain-

ing screws.
6. Remove position sensor retaining screws.

rbs2010-012-002_a

INCORRECT ORIENTATION

Check ACS link rod for straightness or other dam-

age.
Replace any damaged parts.

ACS Position Sensor Replacement

1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove body parts as required to access to the rmr2010-036-011_a

position sensor. Refer to BODY subsection. 1. Position sensor retaining screws

3. Disconnect position sensor connector. 7. Remove position sensor from vehicle.

8. Install a new position sensor on vehicle as the
reverse of removal.
9. Perform the initialization of the position sensor,
refer to ACS POSITION SENSOR RESET (WITH
B.U.D.S.).

ACS SOLENOID VALVE

The ACS solenoid valve is identified SRS in the
WIRING DIAGRAM.
ACS Solenoid Valve Location
rmr2010-036-009_a
The ACS solenoid valve is located on the RH side
1. Position sensor connector
of the vehicle near the shock absorber.
rmr2013-035 11
Subsection XX (REAR SUSPENSION (RT SERIES))
rmr2013-035-001_a
SOME PARTS REMOVED FOR CLARITY PURPOSE
1. ACS solenoid valve
ACS Solenoid Valve Operation Test
1. Manually adjust air suspension pressure to
6 bar (87 PSI).
2. Remove body parts as required to access to the
ACS solenoid valve. Refer to BODY subsection.
3. Disconnect solenoid valve connector.
rmr2013-035-002_a
1. Solenoid valve connector
NOTICE Be careful not to power the gauge by
the solenoid valve connector in order to avoid
permanent damage to gauge.
4. Connect solenoid valve connector pin 1 (LT
BU/RD wire) to a 20 A suitable fuse jumper and
then directly to the positive battery post.
5. Connect solenoid valve connector pin 2 (BK
wire) directly to the negative battery post.
6. Verify that air exits from side port to confirm
proper solenoid operation.
12
rmr2013-035-001_a
SOME PARTS REMOVED FOR CLARITY PURPOSE
1. Side port
If air exits from side port:
– Check input voltage at solenoid valve (PIN-1),
refer to the WIRING DIAGRAM.
– Check ground circuit continuity at solenoid
valve (PIN-2), refer to the WIRING DIAGRAM.
– Check connector and terminal condition.
If no air exits from side port:
– Replace ACS solenoid valve.
ACS Solenoid Valve Replacement
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove body parts as required to access to the
ACS solenoid valve. Refer to BODY subsection.
3. Disconnect solenoid valve connector.
rmr2013-035-002_a
1. Solenoid valve connector
rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

4. Disconnect pneumatic hoses from air fittings as

follows:
4.1 Push fitting ring toward ACS manifold.
4.2 Hold ring in place.
4.3 Pull air hose.

rmr2013-035-012_b

FRONT FUSES BLOCK

1. ACS suspension relay (R4)
2. Fuse F5

ACS Relay Continuity Test

1. Remove relay (R4), refer toACS RELAY LOCA-
rmr2013-035-003_a TION.
1. Air fittings 2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
5. Remove ACS manifold retaining screws.
3. Measure resistance as per the following table.
TEST PROBES RESISTANCE
Terminal 30
Open (OL)
Terminal 87

4. Apply 12 volts on terminals 86 and 85.

5. Measure resistance again as per the following
table.
TEST PROBES RESISTANCE
Terminal 30
Close to 0
rmr2010-036-014_a Terminal 87
1. ACS manifold retaining screws
If results are not as per the previous tables, re-
6. Remove ACS manifold from vehicle. place relay.
7. Unscrew ACS solenoid valve from ACS mani-
fold. ACS Relay Input Voltage Test
8. Install a new solenoid valve as the reverse of 1. Remove relay (R4), refer to ACS RELAY LOCA-
removal procedure. TION.
9. Check the air system for leakage, refer to ACS 2. Set the FLUKE 115 MULTIMETER (P/N 529 035
SYSTEM LEAK TEST. 868) to Vdc.
3. Start engine and release parking brake.
ACS RELAY (R4) 4. Let vehicle run at idle in 1st gear.
ACS Relay and Fuse Location 5. Measure voltage as per the following tables.
ACS relay (R4) and fuse F5 are located in the RH
fuse block (RFB), inside the front storage compart-
ment.
rmr2013-035 13
Subsection XX (REAR SUSPENSION (RT SERIES))

TEST PROBES VOLTAGE ACS Compressor Operation Test

Fuse box pin C7 NOTICE Do not power the compressor di-
(LIGHT GN/GY) Battery voltage rectly with the battery for more than 10 sec-
(± 12 Vdc) onds. Apply voltage quickly to ensure that
Battery negative (-) post
the compressor will not over pressurize the
TEST PROBES VOLTAGE ACS system. Respect a 1 minute cool down
between tests.
Fuse box pin C8
(LIGHT GN/GY) Battery voltage 1. Release air pressure, refer to RELEASING AIR
(± 12 Vdc) PRESSURE IN SYSTEM FOR SERVICING in this
Battery negative (-) post
subsection.
If voltage is not as specified: 2. Remove body parts as required to access to the
– Check fuse F5, refer to POWER DISTRIBU- compressor. Refer to BODY subsection.
TION AND GROUNDS. 3. Disconnect compressor connector.
– Check relay R3 (load shedding relay), refer to
POWER DISTRIBUTION AND GROUNDS.
– Check wiring continuity, refer to the WIRING
DIAGRAM.
– Check connector and terminal condition.

ACS COMPRESSOR
ACS Compressor Location
The ACS compressor is located on the RH side of
the vehicle near the shock absorber.

rmr2010-036-015_a

1. Compressor connector

4. Connect compressor connector pin 2 (ORANGE

wire) to a 20 A suitable fuse jumper and then
directly to the positive battery post.
5. Connect compressor connector pin 1 (BLACK
wire) directly to the negative battery post.
6. Verify if compressor works properly.
If compressor does not work:
– Replace compressor.
If compressor works:
– Check relay R4, refer to ACS RELAY (R4) in this
rmr2013-035-004_a
subsection.
SOME PARTS REMOVED FOR CLARITY PURPOSE
1. ACS compressor If the fault is not found after having carried out the
previous tests:
– Check input voltage at compressor (PIN-2), re-
fer to the WIRING DIAGRAM.
– Check ground circuit continuity at compressor
(PIN-1), refer to the WIRING DIAGRAM.
– Check connector and terminal condition.

14 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

ACS Compressor Removal

1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove body parts as required to access to the
compressor. Refer to BODY subsection.
3. Disconnect compressor connector.

rmr2013-035-011_a

1. Retaining collar
2. Bolts

6. Open retaining collar then remove compressor.

7. Remove compressor rubber.

rmr2010-036-015_a

1. Compressor connector

4. Disconnect compressor pneumatic hose from

manifold as follows:
4.1 Push fitting ring toward ACS manifold.
4.2 Hold ring in place.
4.3 Pull air hose.

rmr2010-036-018_a

1. Compressor rubber

8. Unscrew check valve and fitting from compres-

sor.

rmr2013-035-005_a

1. Compressor pneumatic hose

5. Remove bolts and nuts from compressor retain-

ing collar.
rmr2011-085-003_a

1. Check valve
2. Fitting

rmr2013-035 15
Subsection XX (REAR SUSPENSION (RT SERIES))

ACS Compressor Installation If switch does not work to UP and DWN position,
The installation procedure is the reverse of re- check control circuit continuity as follows.
moval procedure, however pay attention to the ACS SWITCH COMMON CONTROL CIRCUIT
following.
TEST PROBES RESISTANCE
Apply LOCTITE 592 (PIPE SEALANT) (P/N 293 800
018) on check valve and fitting threads. Multifunction gauge
pin-20 Close to 0
Check the air system for leakage, refer to ACS
SYSTEM LEAK TEST. ACS switch pin-6

ACS SWITCH COMMON CONTROL CIRCUIT

ACS SWITCH
TEST PROBES RESISTANCE
The ACS switch is identified CSS in the wiring di-
agram. Multifunction gauge
pin-20 Close to 0
ACS Switch Access ACS switch pin-2
Remove central panel. Refer to BODY subsec-
tion. If switch does not work to UP position only, check
control circuit continuity as follows.
ACS SWITCH UP POSITION CONTROL CIRCUIT
TEST PROBES RESISTANCE
ACS switch pin-5
Close to 825
Main ground

If switch does not work to DWN position only,

check control circuit continuity as follows.
ACS SWITCH DOWN POSITION CONTROL
rmr2010-036-102_a
CIRCUIT
1. ACS switch TEST PROBES RESISTANCE
2. ACS switch connector
3. Central panel ACS switch pin-1
Close to 18.2 K
ACS Switch Continuity Test Main ground
Set the FLUKE 115 MULTIMETER (P/N 529 035 868)
to . ACS Switch Replacement
Check ACS switch continuity as follows. Remove central panel. Refer to BODY subsec-
tion.
ACS SWITCH
PIN RESISTANCE Remove ACS switch from console by pushing re-
POSITION
taining tabs.
Firmly pushed to UP 2 5
Released (FREE) 2 3 Close to 0
Firmly pushed to DWN 2 1

If switch is defective, replace it with a new one.

If switch is correct, carry out the ACS SWITCH
CONTROL CIRCUIT TEST.
ACS Switch Control Circuit Test
Set the FLUKE 115 MULTIMETER (P/N 529 035 868)
to . rmr2010-036-102_a

Check ACS switch control circuits as follows. 1. ACS switch

2. ACS switch connector
3. Central panel

16 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

Install a NEW switch on console.

Re-install central panel as the reverse of removal
procedure.

ACS AIR SPRING

ACS Air Spring Location
The ACS air spring is located on the swing arm in
front of the shock absorber.

rmr2010-036-010_a

1. Link rod upper bolt

4. Disconnect pneumatic hose from air spring as

follows:
4.1 Push fitting ring toward air spring.
4.2 Hold ring in place.
4.3 Pull air hose.

rmr2013-035-006_a

SOME PARTS REMOVED FOR CLARITY PURPOSE

1. ACS air spring

ACS Air Spring Removal

NOTICE Always detach link rod from position
sensor before servicing the rear suspension
(on applicable models).
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove body parts as required to access to the
ACS air spring. Refer to BODY subsection. rmr2013-035-006_b

1. Air spring hose

3. Detach link rod from position sensor by remov-
ing upper bolt and nut (on applicable models). 5. Install a jack under the rear portion of frame.
6. Slightly lift the vehicle to extend the air spring.

rmr2013-035 17
Subsection XX (REAR SUSPENSION (RT SERIES))

rmr2008-030-009

TYPICAL

7. From underneath swing arm, remove air spring rmr2010-036-024_a

lower retaining screw. 10. Remove the following components from air
spring:
– ACS position sensor
– Pneumatic fitting
– Air spring plate retaining nut
– Air spring plate.

rmr2010-036-022_a

1. Lower retaining screw

8. Remove air spring upper retaining screws on

both side.

rmr2010-036-025_a

1. ACS position sensor

2. Pneumatic fitting
3. Air spring plate retaining nut
4. Air spring plate

ACS Air Spring Installation

The installation procedure is the reverse of re-
moval procedure, however pay attention to the
following.
Tighten air spring retaining screws to specifica-
tion.
AIR SPRING SCREWS TORQUE
rmr2010-036-023_a
7 N•m (62 lbf•in)
1. Upper retaining screw
Tighten air spring retaining nut to specification.
9. Carefully push down air spring then remove it
from vehicle frame. AIR SPRING RETAINING NUT
7 N•m (62 lbf•in)

18 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

Check the air system for leakage, refer to ACS

SYSTEM LEAK TEST.

SHOCK ABSORBER
Shock Absorber Removal
NOTICE Always detach link rod from position
sensor before servicing the rear suspension
(on applicable models).
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this rmr2008-030-010_a

subsection.
2. Remove body parts as required to access to the
shock absorber. Refer to BODY subsection.
3. Detach link rod from position sensor by remov-
ing upper bolt and nut (on applicable models).
TYPICAL
1. Shock absorber
2. Upper bracket
7. Remove the shock absorber lower bolt.
8. Remove rear shock absorber from vehicle.
Shock Absorber Disassembly
Remove spring from the shock absorber.
REQUIRED TOOL
SPRING COMPRESSOR (P/N 529 036 184)

529036184

Position the shock absorber in the tool and install

rmr2010-036-010_a the spring compressor hooks.
1. Link rod upper bolt

4. Remove the shock absorber upper bolt.

5. Install a jack under the rear portion of frame.

mmr2010-033-012_a

1. Spring compressor hooks

Tighten the spring compressor tool screw until

the spring is sufficiently compressed to remove
spring stopper.
Release the spring compressor tool screw.
rmr2008-030-009 Remove spring from shock absorber.
TYPICAL

6. Lift the vehicle until the shock absorber can be

removed from upper bracket.

rmr2013-035 19
Subsection XX (REAR SUSPENSION (RT SERIES))

Shock Absorber Inspection

Shock Absorber Removed from Vehicle
Examine shock for leaks.
Extend and compress the piston at least 5 com-
plete strokes with its rod upward.
Check that rod moves smoothly and with uniform
resistance over its entire stroke.
NOTE: During compression motion, it is normal to
feel a small resistance only.
Pay attention to the following conditions that will
rmr2008-030-014_a
denote a defective shock:
TYPICAL
– A very weak rebound. 1. Stopper opening
2. Cap opening
– A skip or a hang back when reversing stroke at
mid travel. Shock Absorber Installation
– Seizing or binding condition except at extreme
end of either stroke. The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
– Oil leakage.
– A gurgling noise, after completing one full com- ACS System with Compressor
pression and extension stroke. NOTICE In order to avoid damaging ACS po-
Replace if any faults are present. sition sensor:
Shock Absorber Installed on Vehicle – Ensure that the air pressure is released into
ACS system.
Manually adjust air suspension pressure to
2 bar ± 0.2 bar (30 PSI ± 3 PSI). – Do not lift the rear of vehicle too high.
From the rear, press down the vehicle as much Carefully lift the rear of vehicle and monitor the
as possible and release it to let suspension return alignment of the bottom of the shock absorber
upward. (anchoring hole) with the bottom of the lower
If the suspension bounces freely or returns too brackets.
quickly:
– Remove and inspect shock absorber.

Shock Absorber Assembly

The assembly is the reverse of the disassembly
procedure. However, pay attention to the follow-
ing.
When installing spring stopper and cap, make
sure to install opening at 180°.

rbs2010-012-010_a

TYPICAL
1. Lower bracket hole
2. Anchoring hole

20 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

SHOCK ABSORBER BOLTS TORQUE

48 N•m (35 lbf•ft)

SWING ARM
Swing Arm Removal
NOTICE Always detach link rod from position
sensor before servicing the rear suspension
(on applicable models).
rbs2010-012-004_a

INCORRECT SHOCK ABSORBER ALIGNMENT

1. Lower bracket hole
Prior to installing ACS position sensor, ensure that
sensor lever orientation is correct.
1. Release air pressure, refer to RELEASING AIR
PRESSURE IN SYSTEM FOR SERVICING in this
subsection.
2. Remove rear cargo module. Refer to BODY
subsection.
3. Remove belt guard from swing arm.

rbs2010-012-001

CORRECT ORIENTATION

rmr2010-036-026_a

1. Belt guard

4. Remove muffler from swing arm.

rbs2010-012-002_a

INCORRECT ORIENTATION

Tighten link rod on position sensor to specifica-

tion.
LINK ROD RETAINING NUT TORQUE
7 N•m (62 lbf•in)

Tighten shock absorber retaining bolts to specifi-

cation. rmr2013-008-213_a

1. Muffler

rmr2013-035 21
Subsection XX (REAR SUSPENSION (RT SERIES))

5. Detach ACS position sensor link rod from swing

arm by removing lower bolt and nut (on applica-
ble models).

rmr2013-035-013_a

1. Caliper screws

9. From underneath swing arm, remove air spring

rmr2010-036-028_a
lower retaining screw.
1. Link rod lower bolt

6. Remove cables protector from swing arm.

rmr2010-036-032_a

rmr2013-035-014_a TYPICAL
1. Lower retaining screw
1. Cables protector
2. Cables protector retaining screws
10. Place vehicle on a level surface.
7. From underneath swing arm, remove parking 11. Lift the rear of the vehicle.
brake cable fastener.
12. Install a jack stand under frame.
13. Remove rear wheel. Refer to DRIVE BELT
AND REAR WHEEL subsection.
14. Unscrew shock absorber lower bolt.

rmr2013-035-015_a

1. Parking brake cable fasteners

8. Remove and discard both caliper screws.

rmr2008-030-024_a

1. Shock absorber lower bolt

22 rmr2013-035
 Subsection XX (REAR SUSPENSION (RT SERIES))

15. Remove swing arm flange bolts.

rmr2013-035-010_a

CROSS SECTION OF FRAME AND SWING ARM (RIGHT SIDE)

1. Swing arm axle
rmr2013-035-008_a 2. Spacer
3. Frame
1. LH flange bolt 4. Swing arm bearings
2. Swing arm axle 5. Swing arm

17. Remove the swing arm.

Swing Arm Inspection

Check swing arm for cracks, bending or other
damages.
Check if bearings turn smoothly and freely.
Replace all damaged parts.

Swing Arm Disassembly

Using the BLIND HOLE BEARING PULLER SET
(P/N 529 036 117), remove swing arm bearings,
spacers and sleeves.

rmr2013-035-007_a

1. RH flange bolt

16. Using a longer bolt, position it in threads and

push to extract the swing arm axle.

529036117

Discard bearings and sleeves.

Swing Arm Assembly

1. Apply XPS SYNTHETIC GREASE (P/N 293 550 010)
on NEW sleeves.
2. Using a an appropriate bearing installer, install
NEW bearings, spacers and sleeves.

rmr2013-035 23
Subsection XX (REAR SUSPENSION (RT SERIES))

Swing Arm Installation
1. Position swing arm into place.
2. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of LH flange bolt.
3. Install LH flange bolt into swing arm axle.
8. Move swing arm up and down. The swing arm
must move freely and smoothly.
9. Install NEW caliper screws.
10. Install all other removed parts.

rmr2013-035-008_a

1. LH flange bolt
2. Swing arm axle

4. From the LH side, insert the swing arm axle

assembly into position.
5. Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of RH swing arm axle bolt.
6. Install RH flange bolt onto assembly.

rmr2013-035-007_a

1. RH flange bolt

7. Torque swing arm flange bolts to specification.

SWING ARM FLANGE BOLT TORQUE
55 N•m (41 lbf•ft)

24 rmr2013-035
 Subsection XX (BRAKES)

BRAKES
SERVICE TOOLS
Description Part Number Page
BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ........................................... 20
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ..................................... 32–33
MASTER CYLINDER ROD ADJUSTER ......................................... 529 036 119 ........................................... 24

SERVICE PRODUCTS
Description Part Number Page
BRAKE FLUID................................................................................ 293 600 131 ............................................. 5
LOCTITE 243 (BLUE)..................................................................... 293 800 060 ........................................... 16

FRONT AND REAR BRAKES

25 N•m
NEW (18 lbf•ft)
68 N•m
(50 lbf•ft)
NEW

7N•m 11 N•m
(62 lbf•in) (97 lbf•in) 11 N•m
16 N•m (97 lbf•in)
(142 lbf•in)
NEW
7N•m 16 N•m
(62 lbf•in) (142 lbf•in) 25 N•m
(18 lbf•ft)

NEW
NEW
16 N•m
(142 lbf•in)
See NEW
installation NEW 68 N•m
procedure 105 N•m (50 lbf•ft)
(77 lbf•ft) NEW 28.5 N•m
NEW
85 N•m 4.5 N•m 4.5 N•m NEW (21 lbf•ft)
(63 lbf•ft) (40 lbf•in) (44 lbf•in)
25 N•m
(18 lbf•ft)
25 N•m
(18 lbf•ft)
NEW
NEW
105 N•m
(77 lbf•ft)
NEW = Component must be replaced when removed.
rmr2013-036-102_a

rmr2013-036 1
Subsection XX (BRAKES)

BRAKE PEDAL

ST-S SE5 ST SE5

ST-LTD SE5 ST SM5
ST-S SM5

RT SE5
RT SM5
RS SE5 RT-S SM5
RS SM5
RS-S SE5
RS-S SM5

NEW
RT-S SE5
RT LTD SE5

48 N•m
(35 lbf•ft)

NEW
NEW = Component must be replaced when removed.
rmr2013-036-105_a

2 rmr2013-036
 Subsection XX (BRAKES)

FRONT PARKING BRAKE PULLEY

ST and RT Models

12 N•m
(106 lbf•in)

5.5 N•m
(49 lbf•in)

5.5 N•m
(49 lbf•in)

rmr2013-036-100_a

rmr2013-036 3
Subsection XX (BRAKES)

FOOTREST RELEASE MECHANISM

ST-S and ST-LTD SE5 NEW

8 N•m
(71 lbf•in)
NEW

NEW
35N•m
(26 lbf•ft)

34N•m
(25 lbf•ft)

RT-S and RT-LTD SE5

NEW
8 N•m
NEW (71 lbf•in)

NEW
35N•m
(26 lbf•ft)
34N•m
(25 lbf•ft)

NEW = Component must be replaced when removed.

rmr2013-036-104_a

4 rmr2013-036
 Subsection XX (BRAKES)

GENERAL TASK WHAT TO DO

This subsection covers the maintenance and pro- Any brake part
1. Check/clear fault codes
cedures related to the braking system mechani- replacement that
involved bleeding 2. Clear LPS fault
cal components. For ABS related components, re-
fer to VEHICLE STABILITY SYSTEM (VSS) subsec-
tion. MAINTENANCE
During assembly/installation, use the torque val-
ues and service products as in the exploded BRAKE FLUID
views.
Clean threads before applying a threadlocker. Re- Recommended Brake Fluid
fer to SELF-LOCKING FASTENERS and LOCTITE Always use brake fluid meeting the specification
APPLICATION at the beginning of this manual for DOT 4 only such as BRAKE FLUID (P/N 293 600 131).
complete procedure.
WARNING
WARNING To avoid serious damage to the brake system:
Torque wrench tightening specifications – Use only DOT 4 brake fluid from a sealed
must be strictly adhered to. container.
Locking devices when removed (e.g.: locking – Use only a clean funnel when filling brake
tabs, elastic stop nuts, cotter pins, etc.) must fluid reservoir.
be replaced.
– Do not use brake fluid taken from old or
already opened containers.
WARNING – Do not mix different fluids for topping off.
Never use thread sealant or Teflon tape on
brake fittings or bleeders. Brake system dam- Brake Fluid Level Verification
age and failure may occurs.
Park the vehicle on a firm level surface.
WARNING Unlatch and lift seat.
Avoid brake system contamination. If re- Check brake fluid level in each reservoir, near the
quired, clean components prior to removal. back of the seat. They should both be above the
MIN. mark.

NOTICE Avoid spilling brake fluid on plastic,

rubber or painted parts. Protect these parts
with a rag when servicing brake system.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
NOTE: Install a battery charger on battery termi-
nals (under seat) for any tests that involve a pro-
longed KEY ON period. If battery voltage gets too
low, some accessories are shut off by the ECM.

FAULT CODES
rmr2013-036-002_a
If any bleeding is performed on the braking sys- TYPICAL
tem, it is important to reset the fault codes. Refer 1. Brake fluid reservoir
to DIAGNOSTIC AND FAULT CODES subsection.
WARNING
NOTE: B.U.D.S. software is used to perform the
reset. Clean filler caps before removing.

Add fluid as required. Do not overfill.

rmr2013-036 5
Subsection XX (BRAKES)

vmr2008-033-062_a

TYPICAL
1. Correct position
2. Wrong position

Close seat and ensure it is fully latched.

rmo2010-001-091_a
1. Brake fluid MAX. level mark
2. Brake fluid MIN. level mark
Brake Fluid Replacement
To replace brake fluid, perform the complete
brake bleeding sequence. Refer to BRAKE FLUID
BLEEDING PROCEDURE (COMPLETE SYSTEM)
below.
NOTE: Dispose brake fluid as per your local envi-
ronmental regulations.

Brake Fluid Bleeding Procedure

(Complete System)
General Guidelines
This procedure is divided in multiple tasks that
rmo2010-001-092_a must be completed in a specific order according
A. Operating range to the following table.
Prior to installing brake fluid reservoir caps: STEP TASK
– Check that V slit is in good condition. Perform manual bleeding procedure (left
1
– Ensure diaphragm are properly positioned. caliper, right caliper, rear caliper and VCM)
Perform B.U.D.S. bleeding procedure (front
2
circuit and rear circuit)
3 Validate the system pressure

Requirements for Task Completion

DESCRIPTION QTY
RECOMMENDED BRAKE 1.75 L
FLUID (1.85 qt (U.S. liq.))
40 cm (16 in) clear hose (3/16) 3
80 cm (31 in) clear hose (3/16) 1
Small locking ties 4
rbg2008-003-002_a
Locking ties 4
TYPICAL
1. V slit
Use a computer with the latest version of
B.U.D.S. software, the MPI-2 and a diagnos-
tic cable.
NOTE: Assistance is required to accomplish
some actions.

6 rmr2013-036

Vehicle Preparation
NOTE: Vehicle battery must be fully charge prior
to bleed brake system.
Remove body parts as required to access to the
following components. Refer to BODY subsec-
tion.
– Front left and right calipers
– Rear caliper
– VCM
– Brake fluid reservoir.
NOTICE Protect plastic, rubber or painted
parts with rags when servicing brake system.
Place vehicle on a level surface.
Loosen front wheel lug nuts.
Lift the front of the vehicle.
Secure front of vehicle on jack stands.
Level the vehicle by using a jack underneath the
rear shock absorber.
NOTE: To ensure that the vehicle is level, use the
bottom vehicle frame as a reference.
Remove front wheels.
Open seat.
Detach lift cylinder from seat.
Lift seat and unplug the pillion rider (passenger)
switch connector.
Cut locking ties securing brake hoses between
reservoir and master cylinder.
Remove reservoir caps.
Install a 40 cm (16 in) long clear hose onto:
– Left caliper bleeder
– Right caliper bleeder
– Rear caliper bleeder.
Secure all clear hose with small locking ties.
Fill clear hoses with brake fluid using a funnel (ap-
proximately 60 mm (2-1/2 in) long).
Locate VCM at the front of vehicle.
Install 80 cm (31 in) long clear hose onto VCM
bleeder.
rmr2013-036
Subsection XX (BRAKES)
rmr2013-036-005_a
1. VCM bleeder
Secure VCM clear hose with small locking tie.
Fill VCM clear hose with brake fluid using a funnel
(approximately 60 mm (2-1/2 in) long).
Manual Bleeding Procedure (Preliminary
Bleeding)
NOTE: Brake fluid reservoir must be kept full to
prevent air from being pumped into the system. If
a sequence is interrupted or a lack of fluid occurs,
start the sequence again.
1. Start bleeding system with left front caliper.
2. Open bleeder and slowly depress then slowly
release brake pedal at least 25 times (full
stroke) until fluid freely flows out of the bleeder
without any air bubbles.
NOTE: It may be necessary to pump brake pedal
more than 25 times, as a result, it is important
to pump brake pedal until fluid flows out without
any air bubbles.
3. When there is no more air bubbles in clear
hose, close the bleeder while brake pedal is
depressed.
NOTE: Do not release brake pedal until bleeder
has been closed.
4. Pump up system pressure with brake pedal un-
til pedal resistance is felt.
5. Depress and hold brake pedal.
6. Re-open bleeder and then re-close it.
7. Release brake pedal slowly.
8. Repeat manual bleeding procedure for the
other bleeders in this order:
– Right front caliper
– Rear caliper
– VCM.
7
Subsection XX (BRAKES)
B.U.D.S. Bleeding Procedure (Final Bleeding)
NOTE: The bleeding procedure is accomplished
FIRST by completing the manual bleeding proce-
dure as explained above.
Brake bleeding is completed using B.U.D.S. soft-
ware. To properly bleed the complete braking sys-
tem, use the bleeding sequence according to this
table.
B.U.D.S. BLEEDING SEQUENCE
OPERATION BLEEDING CIRCUIT
Complete brake system Front circuit and rear
bleeding circuit
B.U.D.S. BLEEDING
BLEEDER LOCATION
CIRCUIT
1: Left front caliper
Front circuit
2: Right front caliper
3: Rear caliper
Rear circuit
4: VCM
NOTE: Each sequence must be carried out with-
out interruption. Furthermore, brake fluid reser-
voir must be kept full to prevent air from being
pumped into the system. If a sequence is inter-
rupted or a lack of fluid occurs, start the sequence
again.
1. Connect B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE.
2. In B.U.D.S., select Read Data.
3. Select Setting folder then the VCM page.
4. Read and understand the procedure on screen
before beginning it.
5. Perform FRONT CIRCUIT BLEEDING and
REAR CIRCUIT BLEEDING inclusively. Follow
the instruction in B.U.D.S.
Reinstall caliper. Refer to CALIPER in this subsec-
tion.
Reinstall wheels on vehicle. Refer to STEER-
ING/FRONT WHEELS subsection for procedure.
Carry out the BRAKE SYSTEM PRESSURE VALI-
DATION as detailed in this subsection.
NOTICE Do not pump up the brake pedal re-
peatedly before doing the validation.
Vehicle Reassembly
Reinstall brake fluid reservoir on vehicle with the
hoses at their original location.
Secure brake fluid reservoir to 7 N•m (62 lbf•in).
Secure hoses with locking ties.
8 rmr2013-036
Install all removed BODY parts as the reverse of
the removal procedure.
Ride the vehicle and apply the brake a few times
to ensure the normal behavior of the vehicle.
Brake Fluid Bleeding Procedure
(Rear Brake Only)
General Guidelines
This procedure is divided in multiple tasks that
must be completed in a specific order according
to the following table.
STEP TASK
Perform manual bleeding procedure
1
(rear caliper and VCM)
Perform B.U.D.S. bleeding procedure
2
(rear circuit)
3 Validate the system pressure
Requirements for Task Completion
Requirements are the same as for bleeding the
complete braking system. Refer to BRAKE FLUID
BLEEDING PROCEDURE (COMPLETE SYSTEM).
Vehicle Preparation
Remove body parts as required to access to the
following components. Refer to BODY subsec-
tion.
– Rear caliper
– VCM
– Brake fluid reservoir.
Level the vehicle.
NOTE: To ensure that the vehicle is level, use the
bottom vehicle frame as a reference.
Open seat.
Detach lift cylinder from seat.
Lift seat and unplug the pillion rider (passenger)
switch connector.
Remove reservoir caps.
Install a 40 cm (16 in) long clear hose onto rear
caliper bleeder.
Secure all clear hose with small locking ties.
Fill clear hoses with brake fluid using a funnel (ap-
proximately 60 mm (2-1/2 in) long).
Locate VCM at the front of vehicle.
Install 80 cm (31 in) long clear hose onto VCM
bleeder.

rmr2013-036-005_a
1. VCM bleeder
Secure VCM clear hose with small locking tie.
Fill VCM clear hose with brake fluid using a funnel
(approximately 60 mm (2-1/2 in) long).
Manual Bleeding Procedure (Preliminary
Bleeding)
NOTE: Brake fluid reservoir must be kept full to
prevent air from being pumped into the system. If
a sequence is interrupted or a lack of fluid occurs,
start the sequence again.
1. Start bleeding system with rear caliper.
2. Open bleeder and slowly depress then slowly
release brake pedal at least 25 times (full
stroke) until fluid freely flows out of the bleeder
without any air bubbles.
NOTE: It may be necessary to pump brake pedal
more than 25 times, as a result, it is important
to pump brake pedal until fluid flows out without
any air bubbles.
3. When there is no more air bubbles in clear
hose, close the bleeder while brake pedal is
depressed.
NOTE: Do not release brake pedal until bleeder
has been closed.
4. Pump up system pressure with brake pedal un-
til pedal resistance is felt.
5. Depress and hold brake pedal.
6. Re-open bleeder and then re-close it.
7. Release brake pedal slowly.
8. Repeat manual bleeding procedure for VCM
bleeder.
B.U.D.S. Bleeding Procedure (Final Bleeding)
NOTE: The bleeding procedure is accomplished
FIRST by completing the manual bleeding proce-
dure as explained above.
rmr2013-036
Subsection XX (BRAKES)
Brake bleeding is completed using B.U.D.S. soft-
ware. To properly bleed the complete braking sys-
tem, use the bleeding sequence according to this
table.
B.U.D.S. BLEEDING SEQUENCE
OPERATION BLEEDING CIRCUIT
Rear brake system
Rear circuit
bleeding
B.U.D.S. BLEEDING
BLEEDER LOCATION
CIRCUIT
3: Rear caliper
Rear circuit
4: VCM
NOTE: Each sequence must be carried out with-
out interruption. Furthermore, brake fluid reser-
voir must be kept full to prevent air from being
pumped into the system. If a sequence is inter-
rupted or a lack of fluid occurs, start the sequence
again.
1. Connect B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE.
2. In B.U.D.S., select Read Data.
3. Select Setting folder then the VCM page.
4. Read and understand the procedure on screen
before beginning it.
5. Perform REAR CIRCUIT BLEEDING. Follow
the instruction in B.U.D.S.
Carry out the BRAKE SYSTEM PRESSURE VALI-
DATION as detailed in this subsection.
NOTICE Do not pump up the brake pedal re-
peatedly before doing the validation.
Vehicle Reassembly
Reinstall brake fluid reservoir on vehicle with the
hoses at their original location.
Secure brake fluid reservoir to 7 N•m (62 lbf•in).
Secure hoses with locking ties.
Install all removed BODY parts as the reverse of
the removal procedure.
Ride the vehicle and apply the brake a few times
to ensure the normal behavior of the vehicle.
Brake Fluid Bleeding Procedure (Front
Brakes Only)
General Guidelines
This procedure is divided in multiple tasks that
must be completed in a specific order according
to the following table.
9
Subsection XX (BRAKES)
STEP TASK
Perform manual bleeding procedure
1 NOTE: Brake fluid reservoir must be kept full to
(left caliper and right caliper)
Perform B.U.D.S. bleeding procedure
2
(front circuit)
3 Validate the system pressure
Requirements for Task Completion
Requirements are the same as for bleeding the
complete braking system. Refer to BRAKE FLUID
BLEEDING PROCEDURE (COMPLETE SYSTEM).
Vehicle Preparation
Remove body parts as required to access to the
following components. Refer to BODY subsec-
tion.
– Front left and right calipers
– Brake fluid reservoir.
Place vehicle on a level surface.
Apply parking brake.
Loosen front wheel lug nuts.
Secure front of vehicle on jack stands.
Level the vehicle by using a jack underneath the
rear shock absorber.
NOTE: To ensure that the vehicle is level, use the
bottom vehicle frame as a reference.
Remove front wheels.
NOTICE Never use any type of impact
wrench for lug nut removal and installation.
The use of impact wrench could damage the
bolts threads and nuts.
Open seat.
Detach lift cylinder from seat.
Lift seat and unplug the pillion rider (passenger)
switch connector.
Remove reservoir caps.
Install a 40 cm (16 in) long clear hose onto:
– Left caliper bleeder
– Right caliper bleeder.
Secure all clear hose with small locking ties.
Fill clear hoses with brake fluid using a funnel (ap-
proximately 60 mm (2-1/2 in) long).
10
Manual Bleeding Procedure (Preliminary
Bleeding)
prevent air from being pumped into the system. If
a sequence is interrupted or a lack of fluid occurs,
start the sequence again.
1. Start bleeding system with:
– Left front caliper
– Right front caliper.
2. Open bleeder and slowly depress then slowly
release brake pedal at least 25 times (full
stroke) until fluid freely flows out of the bleeder
without any air bubbles.
NOTE: It may be necessary to pump brake pedal
more than 25 times, as a result, it is important
to pump brake pedal until fluid flows out without
any air bubbles.
3. When there is no more air bubbles in clear
hose, close the bleeder while brake pedal is
depressed.
NOTE: Do not release brake pedal until bleeder
has been closed.
4. Pump up system pressure with brake pedal un-
til pedal resistance is felt.
5. Depress and hold brake pedal.
6. Re-open bleeder and then re-close it.
7. Release brake pedal slowly.
B.U.D.S. Bleeding Procedure (Final Bleeding)
NOTE: The bleeding procedure is accomplished
FIRST by completing the manual bleeding proce-
dure as explained above.
Brake bleeding is completed using B.U.D.S. soft-
ware. To properly bleed the complete braking sys-
tem, use the bleeding sequence according to this
table.
B.U.D.S. BLEEDING SEQUENCE
OPERATION BLEEDING CIRCUIT
Front brake system
Front circuit
bleeding
B.U.D.S. BLEEDING
CIRCUIT
BLEEDER LOCATION
1: Left front caliper
Front circuit
2: Right front caliper
rmr2013-036

NOTE: Each sequence must be carried out with-
out interruption. Futhermore, brake fluid reser-
voir must be kept full to prevent air from being
pumped into the system. If a sequence is inter-
rupted or a lack of fluid occurs, start the sequence
again.
1. Connect B.U.D.S. Refer to COMMUNICATION
TOOLS AND B.U.D.S. SOFTWARE.
2. In B.U.D.S., select Read Data.
3. Select Setting folder then the VCM page.
4. Read and understand the procedure on screen
before beginning it.
5. Perform FRONT CIRCUIT BLEEDING. Follow
the instruction in B.U.D.S.
Reinstall caliper. Refer to CALIPER in this subsec-
tion.
Reinstall clip retaining hose on suspension arm
(one on each side).
Secure bolt to 11 N•m (97 lbf•in).
rmr2013-036-003_a
TYPICAL
1. Clip retaining hose
Reinstall wheels on vehicle. Refer to STEERING
(DPS) AND WHEELS for procedure.
Carry out the BRAKE SYSTEM PRESSURE VALI-
DATION as detailed in this subsection.
NOTICE Do not pump up the brake pedal re-
peatedly before doing the validation.
Vehicle Reassembly
Reinstall brake fluid reservoir on vehicle with the
hoses at their original location.
Secure brake fluid reservoir to 7 N•m (62 lbf•in).
Secure hoses with locking ties.
Install all removed BODY parts as the reverse of
the removal procedure.
rmr2013-036
Subsection XX (BRAKES)
Ride the vehicle and apply the brake a few times
to ensure the normal behavior of the vehicle.
INSPECTION
BRAKE SYSTEM PRESSURE
VALIDATION
NOTICE Do not pump up the brake pedal re-
peatedly before doing the validation.
In B.U.D.S., select Monitoring folder then the
VCM page.
Slowly depress the brake pedal (only once) until
you reach 3500 kPa (508 PSI) at the brake pres-
sure sensor.
Maintain the brake pedal in position.
Check the Low Pressure Switch button value on
the computer screen.
rmr2008-032-062_a
TYPICAL
1. Brake Pressure Sensor (PSI) value
2. Low Pressure Switch button
If Low Pressure Switch button is still off when
you reached the required pressure the validation
is successful.
If Low Pressure Switch button turns on before
reaching 3500 kPa (508 PSI), perform the follow-
ing additional steps:
Perform equivalent of 3 complete wheels rotation
(for the 3 wheels).
Slowly depress the brake pedal until Low Pres-
sure Switch button turns on.
Take note of the Brake Pressure Sensor (PSI)
value.
Perform equivalent of 3 complete wheels rotation
(for the 3 wheels).
Slowly depress the brake pedal until Low Pres-
sure Switch button turns on.
11
Subsection XX (BRAKES)

Take note of the Brake Pressure Sensor (PSI) PROCEDURES

value.
Perform equivalent of 3 complete wheels rotation CALIPER
(for the 3 wheels).
Caliper Removal
Slowly depress the brake pedal until Low Pres-
sure Switch button turns on. Front Caliper
Take note of the Brake Pressure Sensor (PSI) Place the vehicle on a level surface.
value. Apply parking brake.
Calculate the average of the 3 Brake Pressure Loosen wheel lug nuts.
Sensor (PSI) values previously noted.
Lift the front of vehicle.
If the average is EQUAL OR ABOVE 3500 kPa
(508 PSI), the brake system pressure is conform. Safely support the vehicle on jack stands.
Clear fault codes.
If the average is BELOW 3500 kPa (508 PSI), re-
peat BRAKE FLUID BLEEDING PROCEDURE with
the following deviation:
– Lift the rear of vehicle and adjust master cylin-
der on level.

TROUBLESHOOTING
TROUBLESHOOTING
GUIDELINES (PARKING BRAKE)
Before any troubleshooting operations on parking rmr2008-032-016

TYPICAL
brake system, it is important to check the fault
codes using B.U.D.S. to properly diagnose the Remove wheel.
problem. Refer to DIAGNOSTIC AND FAULT
CODES subsection. Remove and discard caliper screws.
NOTE: If the caliper is replaced, loosen brake
PARKING BRAKE DOES NOT WORK hose first. See procedure below. Otherwise,
1. Faulty WPM module or wiring.
omit the next steps concerning the brake hose.
- Check if windshield works properly.
- Carry out a WPM MODULE SIGNAL CIRCUIT
CONTINUITY TEST.
2. Faulty PBS switch or wiring.
- Carry out a PARKING BRAKE SWITCH TEST.
3. Faulty HBS switch or wiring.
- Carry out a PARKING BRAKE LIGHT SWITCH
TEST.
4. Faulty parking brake motor or wiring.
- Carry out a PARKING BRAKE MOTOR OPERA-
TION TEST.
5. Wrong parking brake cable adjustment.
- Carry out a PARKING BRAKE CABLE ADJUST-
MENT. rmr2013-036-009_b

TYPICAL
1. Caliper screws

NOTICE Do not let caliper hangs by the hose

and do not stretch or twist the hose.

12 rmr2013-036
 Subsection XX (BRAKES)

Install a drain pan under caliper to catch brake

fluid.
Loosen the Banjo fitting. Disconnect brake hose
and discard sealing washers.
Remove the caliper from the vehicle.
Rear Caliper
Place vehicle on a level surface.
Remove muffler from swing arm.
Remove parking brake cable from parking brake
support.
Remove retaining nut from parking brake ten-
sioner.
Remove parking brake cable tensioner and its rmr2013-036-011_a

spring. 1. Retaining clip

2. Retaining screw

Remove and discard caliper screws.

rmr2013-036-001_e

1. Parking brake cable

2. Parking brake support
3. Parking brake cable tensioner rmr2013-036-001_c

4. Parking brake tensioner retaining bolt 1. Caliper screws

5. Spring
NOTE: If the caliper is replaced, loosen brake
Remove parking brake support from caliper sup- hose first. See procedure below. Otherwise,
port plate. omit the next steps concerning the brake hose.
NOTICE Do not let caliper hang by the hose
and do not stretch or twist the hose.
Install a drain pan under caliper to catch brake
fluid.
Loosen the Banjo fitting. Disconnect brake hose
and discard sealing washers.

rmr2013-036 13
Subsection XX (BRAKES)

Tighten caliper screws to specification.

CALIPER SCREWS TORQUE
68 N•m (50 lbf•ft)

Rear Caliper
Tighten caliper screws to specification.
CALIPER SCREWS TORQUE
105 N•m (77 lbf•ft)

Check wheel speed sensor adjustment. Refer to

VEHICLE STABILITY SYSTEM subsection.
rmr2013-036-010_b
Adjust parking brake cable, refer to PARKING
1. Banjo fitting BRAKE CABLE ADJUSTMENT in this subsection.
2. Sealing washers

Remove caliper. BRAKE PAD

Caliper Inspection Brake Pad Inspection
Check piston(s) for scratches, rust or other dam- Measure brake pad lining thickness.
ages. If so, replace caliper.
BRAKE PAD THICKNESS
Caliper Installation SERVICE LIMIT 1 mm (.04 in)
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. NOTICE Brake pads must always be replaced
in pairs.
Install NEW caliper screws.
If hoses were disconnected: Front Brake Pad Replacement
– Install NEW sealing washers. Place the vehicle on a level surface.
– Tighten Banjo fitting to specification. Apply parking brake.
BANJO FITTING TORQUE Lift seat.
25 N•m (18 lbf•ft) Clean and remove the rear reservoir cap.

Front Caliper
NOTICE To ensure good clamping of calipers
screws, it is imperative to clean knuckle
threads using a metric tap M10 x 1.5.

rmr2013-036-002_b

TYPICAL
1. Remove this cap

Loosen wheel lug nuts.

rbg2008-002-107_a

TYPICAL
Lift the front of vehicle.
1. Knuckle threads Safely support the vehicle on jack stands.

14 rmr2013-036
 Subsection XX (BRAKES)

Remove brake pads.

Check the condition of pistons pins. Replace
caliper as required.
Install NEW brake pads.
Install caliper. Refer to CALIPER in this subsec-
tion.
Install wheel.
Ride the vehicle a few minutes to make sure the
repair is successful.

rmr2008-032-016 WARNING
TYPICAL
When installing new brake pads, always ob-
Remove wheel. serve a break-in period of 300 km (200 mi).
During this time, the brakes and the VSS
Remove and discard caliper screws. will not operate at their maximum efficiency.
Remove and discard brake pads retaining screw You could lose control and crash – use extra
and retaining clip. caution.

Rear Brake Pad Replacement

Place vehicle on a level surface.
Lift seat.
Clean and remove the front reservoir cap.

rmr2013-036-009_a

TYPICAL
1. Caliper screws
2. Retaining clip
3. Brake pad retaining screw

Using a flat screwdriver, depress pistons into their rmr2013-036-002_c

bores. TYPICAL
1. Remove this cap

Remove muffler from swing arm.

Remove cables protector and cables fastener
from swing arm.

rmr2008-032-018_a

TYPICAL

rmr2013-036 15
Subsection XX (BRAKES)

rmr2013-036-012_a rmr2013-036-063_a

1. Cables protector 1. Retaining clip

2. Cables fastener 2. Retaining screw

Remove parking brake cable, refer to PARKING
BRAKE CABLE subsection.
Remove and discard both caliper screws.
rmr2013-036-001_c
Check brake pad pins for wear, replace as re-
quired.
Rotate the parking brake lever on the caliper to pull
back piston.
Remove and discard brake pads.
Install NEW brake pads.
Apply LOCTITE 243 (BLUE) (P/N 293 800 060) on
threads of brake pad pin.
NOTE: If new brake pad pins are used, the
threads are coated with a self-locking product, do
not apply Loctite 243 on threads.
Install brake pad pins. Do not tighten yet.
Install NEW retaining clip.
Install caliper with NEW screws.
Tighten caliper screws to specification.
CALIPER SCREWS TORQUE

1. Caliper screws
Front caliper screws 68 N•m (50 lbf•ft)
Rear caliper screws 105 N•m (77 lbf•ft)
Remove and discard retaining clip securing brake
pad retaining screw. Tighten brake pad pins to specification.
Unscrew and remove brake pad retaining screw.
BRAKE PAD PINS TORQUE
46 N•m (34 lbf•ft)

Apply brake a few times.

Proceed with PARKING BRAKE CABLE TEN-
SIONER INSTALLATION. See procedure in this
subsection.
Check wheel speed sensor adjustment. Refer to
VEHICLE STABILITY SYSTEM subsection.
Ride the vehicle a few minutes to make sure the
repair is successful.

16 rmr2013-036
 Subsection XX (BRAKES)

WARNING MAXIMUM BRAKE DISC WARPAGE

When installing new brake pads, always ob- FRONT AND REAR 0.100 mm (.0039 in)
serve a break-in period of 300 km (200 mi).
During this time, the brakes and the VSS Brake Disc Removal
will not operate at their maximum efficiency.
You could lose control and crash – use extra Front Brake Disc
caution. Place vehicle on a level surface.
Loosen wheel lug nuts.
BRAKE DISC
Lift the front of vehicle.
Brake Disc Inspection Safely support the vehicle on jack stands.
Remove front wheels.
Measure front brake disc thickness.

rmr2008-032-016

TYPICAL

Remove wheel.
Remove caliper screws.
rmr2013-036-056

TYPICAL - FRONT BRAKE DISC

Measure rear brake disc thickness.

rmr2013-036-009_a

TYPICAL
1. Caliper screws

NOTICE Do not let caliper hang by the hose

rmr2013-036-057

REAR BRAKE DISC

and do not stretch or twist the hose.

MINIMUM BRAKE DISC THICKNESS Remove brake disc.

FRONT AND REAR 6.4 mm (.25 in)

Using a dial gauge, verify the brake disc warpage.

rmr2013-036 17
Subsection XX (BRAKES)

Rear Brake Disc

Remove rear wheel. Refer to DRIVE BELT AND
REAR WHEEL subsection.
Remove encoder wheel by unscrewing encoder
wheel screws. Discard screws.

rmr2008-032-034

Front Brake Disc

Install all other removed parts.
Rear Brake Disc
Install NEW brake disc screws.
Tighten brake disc screws to specification as per
tightening sequence.
rmr2013-036-013_a
BRAKE DISC SCREWS TORQUE
1. Encoder wheel screws 25 N•m (18 lbf•ft)
Remove and discard brake disc screws.

rmr2013-036-013_c

rmr2013-036-013_b TIGHTENING SEQUENCE

1. Brake disc screws
Install ENCODER WHEEL, see procedure further
Remove brake disc. in this subsection.
Install all other removed parts.
Brake Disc Installation
The installation is the reverse of the removal pro- ENCODER WHEEL
cedure. However, pay attention to the following.
Position the brake disk so that directional arrow Encoder Wheel Removal
points forward. Front Encoder Wheel
Remove front wheel.
Remove BRAKE DISC, see procedure in this sub-
section.
Remove encoder wheel retaining screws.

18 rmr2013-036
 Subsection XX (BRAKES)

rmr2013-036-059_a rmr2013-036-058_a

1. Encoder wheel retaining screws 1. Encoder wheel

Pull encoder wheel to remove it.
Rear Encoder Wheel
Remove rear wheel. Refer to DRIVE BELT AND
REAR WHEEL subsection.
Remove and discard encoder wheel screws.
Install all other removed parts.
Rear Encoder Wheel
Position the encoder wheel with the inscription
SENSOR SIDE facing outward.

rmr2013-036-013_a rmr2013-036-060_a

1. Encoder wheel screws 1. Sensor side location

Encoder Wheel Inspection Install NEW encoder wheel screws.

Check if encoder wheel teeth are bent or other- Tighten encoder wheel screws to specification as
wise damaged. Replace encoder wheel if neces- per tightening sequence.
sary. ENCODER WHEEL SCREWS TORQUE
Encoder Wheel Installation 5 N•m (44 lbf•in)

Front Encoder Wheels

Position the encoder wheel onto wheel hub.
Install retaining screws and torque to specifica-
tion.
ENCODER WHEEL RETAINING SCREW
7.5 N•m (66 lbf•in)

rmr2013-036 19
Subsection XX (BRAKES)

rmr2013-036-016_a

1. Brake pedal bolt

rmr2013-036-013_d 2. Tab
TIGHTENING SEQUENCE
Remove brake pedal and both washers.
Install rear wheel.

BRAKE PEDAL
Brake Pedal Removal
Remove body parts as required to access to the
following components. Refer to BODY subsec-
tion.
– Brake pedal
– Master cylinder.
Unhook connecting rod from brake pedal.
rmr2010-037-103_a

TYPICAL
1. Brake pedal
2. Both washers

Brake Pedal Disassembly

Remove and discard brake pedal bearings using
the BLIND HOLE BEARING PULLER SET (P/N 529 036
117).
Remove brake pedal sleeve.

rmr2013-036-015_a

1. Connecting rod
2. Brake pedal

From the LH side, underneath vehicle:

529036117
– Unfold tab
– Remove and discard brake pedal bolt.

20 rmr2013-036
 Subsection XX (BRAKES)

rmr2010-037-104_a

TYPICAL rmr2013-036-016_a
1. Brake pedal bearings
2. Brake pedal sleeve 1. Brake pedal bolt
2. Folded tab

Brake Pedal Assembly
Assembly is the reverse of the disassembly pro-
cedure.
NOTE: When assembly brake pedal, always use
NEW bearings.
Brake Pedal Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install brake pedal using a NEW brake pedal bolt.
Make sure to install washers as per the following
illustration.
Each time brake pedal is re-installed, the adjust-
ment of the master cylinder rod is necessary. Re-
fer to MASTER CYLINDER ROD.
All SE5 Models Equipped with Front Footrest
Following brake pedal installation, make sure the
footrest release mechanism is working properly.
Refer to FOOTREST RELEASE MECHANISM sub-
section.
FOOTREST RELEASE
MECHANISM
Footrest Release Mechanism Removal
ST-S and ST-LTD SE5 Only

rmr2013-036-027_a

TYPICAL
1. Brake pedal
2. Washers

Tighten brake pedal bolt to specification.

BRAKE PEDAL BOLT TORQUE rmr2013-036-028_a

PARTS REMOVED FOR CLARITY

48 N•m (35 lbf•ft) 1. Footrest mechanism stud
2. Footrest release mechanism retaining screw
3. Footrest release mechanism spring
Fold either tabs against a flat side of brake pedal 4. Spring retaining screw
bolt head. 5. Brake pedal
6. Footrest release mechanism latch

rmr2013-036 21
Subsection XX (BRAKES)

Remove retaining screw securing footrest release

mechanism spring and remove spring.
Remove retaining screw and both washer secur-
ing footrest release mechanism latch to footrest
support.

Footrest Release Mechanism

Disassembly
Remove footrest release mechanism from vehi-
cle. Refer to FOOTREST RELEASE MECHANISM
REMOVAL.
rmr2013-036-030_a
Remove retaining ring and bearing from latch.
1. Latch pin location
Remove latch pin and washer from footrest.
Remove brake pedal. Refer to BRAKE PEDAL RE-
MOVAL in this subsection.
Remove footrest support. Refer to FOOTREST
SUPPORT REMOVAL in BODY.
Remove retaining screw securing footrest release
mechanism spring and remove spring.
Remove retaining screw and both washers, secur-
ing footrest release mechanism latch to footrest
support.
RT-S and RT-LTD SE5 Only

rmr2013-036-033_a

1. Latch pin
2. Washer

Footrest Release Mechanism

Installation
Installation is the reverse of the removal for both
models however pay attention to the following.
TIGHTENING TORQUE
Latch pin 34 N•m (25 lbf•ft)
Footrest release
mechanism retaining 35 N•m (26 lbf•ft)
screw
rmr2013-036-031_a

RT MODEL SHOWN - PARTS REMOVED FOR CLARITY
1. Footrest mechanism stud
2. Footrest release mechanism retaining screw
3. Footrest release mechanism spring
4. Spring retaining screw
5. Footrest release mechanism latch
6. Brake pedal
7. Latch pin
Remove brake pedal. Refer to BRAKE PEDAL RE-
MOVAL in this subsection.
Remove footrest support. Refer to FOOTREST
SUPPORT REMOVAL in BODY.
Spring retaining screw 8 N•m (71 lbf•in)
Before installing footrest support assembly onto
vehicle verify proper functioning.
– Press on brake pedal far enough to activate
footrest release mechanism.
– Apply pressure on footrest to make sure it ro-
tates all the way down. Then let go of footrest
to make sure it rotates back to its starting posi-
tion.
Install footrest support assembly onto vehicle.

22 rmr2013-036
 Subsection XX (BRAKES)

BRAKE FLUID RESERVOIR Place a container under master cylinder to catch

Brake Fluid Reservoir Removal
Remove body parts as required to access to the
brake fluid reservoir. Refer to BODY subsection.
Unplug brake fluid level sensor connectors.
Remove reservoir screws.
brake fluid.
Loosen Banjo fittings retaining metal brake lines
to master cylinder.
Apply on brake pedal to empty the brake fluid
reservoir and the dual master cylinder.
Remove Banjo fittings and discard sealing wash-
ers.

rmr2008-032-040_a

TYPICAL
1. Sensors connector
2. Reservoir screws rmr2013-036-017_a

1. Banjo fittings
Remove reservoir caps.
Empty reservoir as much as possible. Remove and discard master cylinder screws.
Cut Oetiker clamps and disconnect hoses.

Brake Fluid Reservoir Installation

Connect hoses with NEW Oetiker clamps.
Install reservoir on frame.
Plug brake fluid level sensors.
Fill up reservoir with recommended brake fluid
and bleed brake system. Refer to BRAKE FLUID
in this subsection.
NOTE: Make sure reservoir is filled completly to
avoid low brake fluid error message.
NOTICE Do not overfill to avoid spill.
Install all other removed parts.
rmr2013-036-018_a

SOME PARTS REMOVED FOR CLARITY

DUAL MASTER CYLINDER 1. Master cylinder screws

Dual Master Cylinder Removal Unscrew brake fluid reservoir screws.

Remove body parts as required to access to the Unplug brake fluid level sensor connectors.
following components. Refer to BODY subsec- Remove master cylinder by moving it toward the
tion. front.
– Master cylinder
Cut Oetiker clamps and remove reservoir hoses
– Brake fluid reservoir. from master cylinder.
Cut locking ties securing brake fluid reservoir
hoses to frame.

rmr2013-036 23
Subsection XX (BRAKES)

Dual Master Cylinder Inspection MASTER CYLINDER ROD

Check bellows for cracks or other damages. Re-
place bellows as necessary.
Check if the master cylinder plunger is not stuck
by pushing it on. Replace master cylinder if nec-
essary.
Dual Master Cylinder Installation
NOTICE During installation, ensure all parts
are cleaned to avoid brake system contamina-
tion.
Install reservoir hoses with NEW Oetiker clamps.
Master Cylinder Rod Adjustment
WARNING
This adjustment is necessary to calibrate the
dual master cylinder and avoid braking sys-
tem malfunction.
The adjustment of master cylinder rod must be
performed when one of the following items is re-
placed or removed:
– Brake pedal
– Brake pedal stop
– RH footrest support
– Master cylinder rod
– Connecting rod.
Remove dual master cylinder. Refer to DUAL
MASTER CYLINDER in this subsection.
Unscrew the nut locking the master cylinder rod.
Tighten master cylinder rod into hook.

rmr2008-032-053_a

TYPICAL
1. From the front brake fluid reservoir
2. From the rear brake fluid reservoir

Install dual master cylinder using 2 NEW master

cylinder screws.
Tighten master cylinder screws to specification.
MASTER CYLINDER SCREWS TORQUE
25 N•m (18 lbf•ft)

Install metal brake lines on master cylinder with rmr2013-036-019_a

1. Locking nut
NEW sealing washers. 2. Hook
Tighten Banjo fitting to specification.
Install the MASTER CYLINDER ROD ADJUSTER
BANJO FITTING TORQUE (P/N 529 036 119) instead of dual master cylinder.
28 N•m (21 lbf•ft) Position the end of rod inside tool.

Install brake fluid reservoir.

Plug brake fluid level sensors.
Bleed complete brake system. Refer to BRAKE
FLUID BLEEDING PROCEDURE (COMPLETE
SYSTEM) at the beginning of this subsection.
Install all other removed parts.
529036119

24 rmr2013-036
 Subsection XX (BRAKES)

rmr2008-032-054_a

TYPICAL rmr2013-036-019_a
1. Master cylinder rod adjuster
1. Lock nut
2. Hook lock
Ensure brake pedal leans against its rubber stop.
Hold brake pedal in this position. Remove master cylinder rod from vehicle by mov-
Adjust the rod position until it just touches the in- ing it toward the rear.
side of the adjuster hole without compressing rub- Unscrew clevis from master cylinder rod.
ber stop.
Hold the master cylinder rod and tighten lock nut.
Ensure rod does not turn.

rmr2008-032-063_a

1. Master cylinder rod

2. Lock nut
3. Clevis

Master Cylinder Rod Installation

Completely screw the clevis on master cylinder
rmr2008-032-057
rod.
TYPICAL Secure clevis to brake pedal using the clevis lock.
Remove tool and install the dual master cylinder. Adjust master cylinder rod, refer to MASTER
Refer to DUAL MASTER CYLINDER in this sub- CYLINDER ROD ADJUSTMENT.
section.
Attach reservoir hoses with NEW locking ties. PARKING BRAKE FRONT PULLEY
Parking Brake Front Pulley Removal
Master Cylinder Rod Removal
Remove body parts as required to access to the
Remove body parts as required to access to the parking brake front pulley. Refer to BODY subsec-
master cylinder. Refer to BODY subsection. tion.
Loosen lock nut. Detach parking brake cable from pulleys as fol-
Remove hook lock. lows:
– Ensure parking brake is released.
– Unscrew nut securing parking brake cable on
parking brake support.
– Remove cable from parking brake support.
– Unhook cable from parking brake cable ten-
sioner.
– Unhook cable from front pulley.

rmr2013-036 25
Subsection XX (BRAKES)

Carefully pull front pulley toward the outside then

remove spacer.

rmr2013-036-001_d

1. Parking brake support

2. Nut securing cable to parking brake support
3. Parking brake cable tensioner rmr2010-037-111_a

TYPICAL
1. Front pulley
2. Spacer

Parking Brake Front Pulley Installation

Install spacer on front pulley retaining bolt.
Install front pulley with the lower pulley stopper
positioned toward driver footpeg, refer to illustra-
tion.

rmr2010-037-108_a

TYPICAL - FRONT PULLEY

1. Parking brake cable

Remove front pulley retaining nut.

rmr2010-037-118_a

TYPICAL
1. Front pulley
2. Lower pulley stopper
3. Driver footpeg

Install and tighten retaining nut to secure front pul-

rmr2010-037-110_a ley.
TYPICAL
1. Front pulley Connect vehicle to B.U.D.S. Refer to COMMUNI-
CATION TOOLS AND B.U.D.S. SOFTWARE sub-
section.

26 rmr2013-036
 Subsection XX (BRAKES)

Select Activation page.

Select WPM folder.
Press Park Brake Sequence button to set pulley
at its reference position.

rmr2013-036-001_d

1. Parking brake support

2. Nut securing cable to parking brake support
3. Parking brake cable tensioner

rmr2011-086-001_a

PARK BRAKE SEQUENCE BUTTON

Attach parking brake cable on front pulley.

Attach parking brake cable on parking brake cable
tensioner.
Adjust parking brake cable, refer to PARKING
BRAKE CABLE ADJUSTMENT in this subsection. rmr2010-037-108_a

Apply and release the parking brake a few times TYPICAL - FRONT PULLEY
1. Parking brake cable
to ensure normal operation of the mechanism.
Remove retaining nut from parking brake cable
PARKING BRAKE CABLE tensioner.
TENSIONER Remove parking brake cable tensioner and its
spring.
Parking Brake Cable Tensioner
Removal
Detach parking brake cable from pulleys as fol-
lows:
– Ensure parking brake is released.
– Unscrew nut securing parking brake cable on
parking brake support.
– Remove cable from parking brake support.
– Unhook cable from parking brake cable ten-
sioner.
– Unhook cable from front pulley.

rmr2013-036 27
Subsection XX (BRAKES)

rmr2013-036-061_c
rmr2013-036-001_b
1. Parking brake cable tensioner
1. Parking brake cable 2. Parking brake cable support
2. Parking brake support
3. Parking brake cable tensionerr
4. Parking brake tensioner bolt 5. Rotate parking brake cable adjustment nut
clockwise to rotate the lever clockwise up until
the distance (A) between parking brake cable
PARKING BRAKE CABLE tip and parking brake cable support is short-
Parking Brake Cable Adjustment ened by 6 mm (.24 in).
1. Loosen parking brake cable retaining nut.
2. Remove cable tip from the tensioner and cable
from the cable support.

rmr2013-036-061_b

A. Shorter by 6 mm (.24 in)

6. Rotate parking brake cable adjustment nut

rmr2013-036-061_d counterclockwise for 4 1/2 turns or 5.6 mm
1. Parking brake tensioner (.22 in).
2. Parking brake cable tip
3. Parking brake cable retaining nut 7. Finger tighten parking brake cable retaining nut.
4. Parking brake cable adjustment nut
5. Rubber part 8. Once adjusted properly, the minimum distance
6. Cable support between the parking brake cable retaining nut
and the rubber part should be 1 mm (.04 in).
3. Using parking brake cable tip, pull on cable to
remove slack.
4. Insert parking brake cable tip into parking brake
tensioner and parking brake cable into parking
brake cable support.

28 rmr2013-036
 Subsection XX (BRAKES)

rmr2013-036-064_a rmr2013-036-001_d

A. Minimum distance of 1 mm (.04 in) 1. Parking brake support

2. Nut securing cable to parking brake support
3. Parking brake tensioner
9. Tighten retaining nuts on the parking brake ca-
ble support to 12 N•m (106 lbf•in).
10. Apply and release the parking brake a few
times to ensure normal operation of the
mechanism.
If parking brake cable cannot be properly adjusted
using this procedure, replace cable. Refer to
PARKING BRAKE CABLE REMOVAL in this sub-
section.

Parking Brake Cable Removal

Remove body parts as required to access to the
parking brake cable. Refer to BODY subsection.
rmr2010-037-108_a
Detach parking brake cable from pulley and ten-
TYPICAL - FRONT PULLEY
sioner as follows: 1. Parking brake cable
– Ensure parking brake is released.
– Unscrew nut securing parking brake cable on From underneath swing arm, remove parking
parking brake support. brake cable fasteners.
– Remove cable from parking brake support.
– Unhook cable from parking brake cable ten-
sioner.
– Unhook cable from front pulley.

rmr2013-036-020_a

SOME PARTS REMOVED FOR CLARITY

1. Parking brake cable fastener behind passenger footrest
2. Parking brake cable fastener behind master cylinder

rmr2013-036 29
Subsection XX (BRAKES)

From RH side of vehicle, remove cable fastener PARKING BRAKE MOTOR

and locking tie securing parking brake cable.
Parking Brake Operation
To apply parking brake, press parking brake switch
(PBS) down.
To release parking brake, press PBS switch down
until brake indicator lamp turns OFF.
The parking brake cannot be activated while the
vehicle is moving faster than 10 km/h (6 MPH).

Parking Brake Motor Monitoring (with

B.U.D.S.)
To monitor parking brake motor during trou-
bleshooting operation, proceed as follows:
rmr2010-037-113_a
1. Connect vehicle to B.U.D.S. Refer to COMMU-
TYPICAL - SOME PARTS REMOVED FOR CLARITY NICATION TOOLS AND B.U.D.S. SOFTWARE
1. Parking brake cable fastener subsection.
2. Locking tie
2. Select Monitoring page.
Unscrew nut securing parking brake cable on the
3. Select WPM folder.
upper support.
Remove cable from the upper support by passing
it through the hole.

rmr2010-038-059_a

TYPICAL
Step 1: Select monitoring
Step 2: Select WPM
rmr2010-037-114_a
4. Press parking brake switch (PBS) on vehicle.
1. Nut securing cable to support
2. Hole to remove cable

Remove cable from vehicle.

Parking Brake Cable Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Align white lines on the cable with cable fasteners
on swing arm.
Adjust parking brake cable, refer to PARKING
BRAKE CABLE ADJUSTMENT in this subsection.
rmo2010-001-038_o

TYPICAL - PARKING BRAKE SWITCH (PBS)

5. Check proper operation in B.U.D.S.

30 rmr2013-036

Parking Brake Motor Operation Test
1. Connect vehicle to B.U.D.S. Refer to COMMU-
NICATION TOOLS AND B.U.D.S. SOFTWARE
subsection.
2. Select Activation page.
3. Select WPM folder.
4. Press Park Brake Sequence button.
rmr2011-086-001_a
PARK BRAKE SEQUENCE BUTTON
5. Verify if parking brake motor works properly to
apply and release parking brake.
If parking brake motor does not work:
– Check input voltage at motor (PIN-1), refer to
the WIRING DIAGRAM.
– Check ground circuit continuity at motor (PIN-
2), refer to the WIRING DIAGRAM.
– Check connector and terminal condition.
If the fault is not found after having carried out the
previous tests:
– Test motor operation by connecting it directly to
the battery posts.
• If motor works properly, test module, refer to
WINDSHIELD AND PARKING BRAKE MOD-
ULE (WPM) in this subsection.
• If motor does not work properly, replace mo-
tor.
NOTICE Do not power motor directly with the
battery for a long period. Apply voltage quickly
to ensure that the motor will not overheat at
the end of its stroke.
rmr2013-036
Subsection XX (BRAKES)
Parking Brake Motor Removal
Remove body parts as required to access to the
parking brake motor. Refer to BODY subsection.
Remove parking brake front pulley, refer to PARK-
ING BRAKE FRONT PULLEY REMOVAL in this
subsection.
Disconnect parking brake motor connectors.
rmr2013-036-021_a
1. Parking brake motor connectors
Remove retaining bolts and nuts of parking brake
motor.
rmr2010-037-112_a
TYPICAL
1. Motor retaining bolts
Remove motor from vehicle by pulling it upwards.
Parking Brake Motor Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Install parking brake front pulley, refer to PARK-
ING BRAKE FRONT PULLEY INSTALLATION in
this subsection.
Adjust parking brake cable, refer to PARKING
BRAKE CABLE ADJUSTMENT in this subsection.
31
Subsection XX (BRAKES)

PARKING BRAKE MODULE (PBM) TEST PROBES RESISTANCE

(ST MODELS) PBS switch connector
pin 2 (YL/LT GN)
PBM Module Signal Circuit Continuity Close to 0
Test WPM module connector
pin 10 (YL/LT GN)
1. Remove body parts as required to access to the
PBM module. TEST PROBES RESISTANCE
2. Remove retaining screws securing eyelet to ve-
PBS switch connector
hicle.
pin 3 (LT BU/GN)
Close to 0
WPM module connector
pin 1 (LT BU/GN)

TEST PROBES RESISTANCE

PBS switch connector
pin 1 (GY/OG)
Close to 0
WPM module connector
pin 12 (GY/OG)

If results are not as per the previous tables:

– Check connector and terminal condition.
– Repair open circuit in wiring.
If the fault is not found after having carried out the
previous operations:
rmr2013-036-025_a
– Test PBS switch, refer to PARKING BRAKE
1. Eyelets
SWITCH (PBS) in this subsection.
3. Remove the 4 retaining bolts securing PBM to – Check input voltage at WPM module (PIN-5),
PBM support. refer to the WIRING DIAGRAM.
– Check ground circuit continuity at WPM module
(PIN-7), refer to the WIRING DIAGRAM.
– Test HBS switch, refer to PARKING BRAKE
LIGHT SWITCH (HBS) in this subsection.
– Check wiring continuity between HBS switch
(PIN-1) and WPM module (PIN-3), refer to the
WIRING DIAGRAM.
If the fault is still not found:
– Replace PBM module.

rmr2013-036-026_a

1. Rear retaining bolts securing PBM to PBM support

4. Disconnect PBM module connector.
5. Disconnect parking brake switch (PBS) connec-
tor. Refer to PARKING BRAKE SWITCH (PBS)
in this subsection.
6. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
7. Measure resistance as per the following tables.
WINDSHIELD AND PARKING
BRAKE MODULE (WPM) (RT
MODELS)
NOTE: WPM module has 2 functions, it controls
windshield and parking brake. The WPM module
is integrated into the windshield base.
For troubleshooting and removal procedures relat-
ing to the WPM module, refer to WINDSHIELD
MODULE (WPM) in BODY (RT SERIES) subsec-
tion.

32 rmr2013-036
 Subsection XX (BRAKES)

TEST PROBES RESISTANCE

PBS switch connector
pin 1 (GY/OG)
Close to 0
WPM module connector
pin 12 (GY/OG)

If results are not as per the previous tables:

rmr2010-038-058
WPM MODULE AND WINDSHIELD BASE
WPM Module Signal Circuit Continuity
Test
1. Remove body parts as required to access to the
WPM module. Refer to WPM MODULE RE-
MOVAL in BODY subsection.
2. Disconnect WPM module connector.
– Check connector and terminal condition.
– Repair open circuit in wiring.
If the fault is not found after having carried out the
previous operations:
– Test PBS switch, refer to PARKING BRAKE
SWITCH (PBS) in this subsection.
– Check input voltage at WPM module (PIN-5),
refer to the WIRING DIAGRAM.
– Check ground circuit continuity at WPM module
(PIN-7), refer to the WIRING DIAGRAM.
– Test HBS switch, refer to PARKING BRAKE
LIGHT SWITCH (HBS) in this subsection.
– Check wiring continuity between HBS switch
(PIN-1) and WPM module (PIN-3), refer to the
WIRING DIAGRAM.
If the fault is still not found:
– Replace WPM module.

PARKING BRAKE SWITCH (PBS)

Parking Brake Switch Test
Remove central panel. Refer to BODY subsec-
tion.
rmr2010-038-053_a

1. WPM module connector

3. Disconnect parking brake switch (PBS) connec-

tor. Refer to PARKING BRAKE SWITCH (PBS)
in this subsection.
4. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
5. Measure resistance as per the following tables.
TEST PROBES RESISTANCE
PBS switch connector
pin 2 (YL/LT GN)
Close to 0
WPM module connector
pin 10 (YL/LT GN) rmr2010-037-006_a

1. Parking brake switch

TEST PROBES RESISTANCE 2. Parking brake switch connector

PBS switch connector Check switch operation as follows.

pin 3 (LT BU/GN)
Close to 0
WPM module connector
pin 1 (LT BU/GN)

rmr2013-036 33
Subsection XX (BRAKES)

PARKING BRAKE
PIN RESISTANCE
SWITCH POSITION
Firmly pushed Close to 0
2 3
Released (FREE) Infinite (OL)

PARKING BRAKE
PIN RESISTANCE
SWITCH POSITION
Firmly pushed Infinite (OL)
1 2
Released (FREE) Close to 0

If switch is defective, replace it with a new one.

Parking Brake Switch Replacement

Remove central panel. Refer to BODY subsec- rmr2013-036-021_b

tion. 1. Parking brake light switch

2. Parking brake light switch connector
Remove parking brake switch from central panel
by pushing tabs. Check switch operation as follows.
PARKING BRAKE RESISTANCE @
PIN
SWITCH POSITION 20°C (68°F)
Firmly pushed 0.2 max
1 3
Released Infinite (OL)

If switch is defective, replace it with a new one.

If the switch tests good, verify wire continuity
between harness connector and multifunction
gauge.
MULTIFUNCTION
GAUGE HARNESS RESISTANCE
CONNECTOR WIRES @ 20°C (68°F)
PIN
rmr2010-037-006_b
17 GREEN/WHITE Close to 0
1. Parking brake switch
2. Central panel

Install a NEW switch on console.

Parking Brake Light Switch Removal
Remove body parts as required to access to the
Re-install central panel as the reverse of removal
parking brake light switch. Refer to BODY subsec-
procedure.
tion.
PARKING BRAKE LIGHT SWITCH Unplug parking brake light switch connector.
(HBS)
Parking Brake Light Switch Test
Remove body parts as required to access to the
parking brake light switch. Refer to BODY subsec-
tion.
Unplug parking brake light switch connector.

34 rmr2013-036
 Subsection XX (BRAKES)

rmr2010-037-009_a

TYPICAL - RH SIDE OF VEHICLE

rmr2013-036-021_b
1. Brake light switch
1. Parking brake light switch 2. Brake light switch connector
2. Parking brake light switch connector
Check switch operation as follows.
Cut locking ties retaining the switch harness.
BRAKE LIGHT RESISTANCE @
Drill switch rivets. PIN
SWITCH POSITION 20°C (68°F)
Firmly pushed 0.2 max.
1 2
Released Infinite (OL)

If switch is defective, replace it with a new one.

If the switch tests good, verify wire continuity be-
tween harness connector and ECM-B connector.
ECM-B
HARNESS RESISTANCE
CONNECTOR
WIRES @ 20°C (68°F)
PIN
C3 WHITE Close to 0

Brake Light Switch Removal

Remove body parts as required to access to the
rmr2013-036-021_c brake light switch. Refer to BODY subsection.
1. HBS switch rivets
Cut locking ties retaining the switch harness.
Remove parking brake light switch. Drill brake light switch rivets.
Parking Brake Light Switch Installation
The installation is the reverse of the removal pro-
cedure.

BRAKE LIGHT SWITCH (BLS)

Brake Light Switch Test
Remove body parts as required to access to the
brake light switch. Refer to BODY subsection.
Unplug brake light switch connector.

rmr2013-036 35
Subsection XX (BRAKES)

LOW PRESSURE RESISTANCE @

PIN
SWITCH POSITION 20°C (68°F)
Firmly pushed Infinite (OL)
2 3
Released 0.2 max.

If switch is defective, replace it with a new one.

If the switch tests good, verify wire continuity be-
tween harness connector and VCM.
VCM
HARNESS RESISTANCE
CONNECTOR
WIRES @ 20°C (68°F)
PIN

rmr2010-037-009_b
8 WHITE/VIOLET Close to 0
TYPICAL - RH SIDE OF VEHICLE
1. BLS switch rivets
LPS Removal
Remove switch. Remove body parts as required to access to the
brake light switch. Refer to BODY subsection.
Brake Light Switch Installation
Drill LPS rivets.
The installation is the reverse of the removal pro-
cedure. Cut locking ties retaining the switch harness.

LOW PRESSURE SWITCH (LPS)

NOTE: After a low pressure switch (LPS) prob-
lem has been solved, it is necessary to clear the
occurred fault in the VCM. Refer to LPS FAULT
(BRAKING SYSTEM) below.
Low Pressure Switch Test
Remove body parts as required to access to the
brake light switch. Refer to BODY subsection.
Unplug LPS connector.

rmr2010-037-009_d

TYPICAL - RH SIDE OF VEHICLE

1. LPS switch rivets

Remove switch.

LPS Installation
The installation is the reverse of the removal pro-
cedure.

LPS Fault (Braking System)

After a low pressure switch (LPS) problem has
been solved, it is necessary to clear the occurred
rmr2010-037-009_c fault in the VCM as follows:
TYPICAL - RH SIDE OF VEHICLE 1. Turn ignition switch OFF.
1. LPS switch
2. LPS switch connector 2. Wait 30 seconds.
Check switch operation as follows. 3. Turn ignition switch ON.

36 rmr2013-036
 Subsection XX (BRAKES)

4. Firmly press brake pedal until you hear a “click”

from the LPS switch or until braking pressure
reaches 3 500 kPa (508 PSI).
NOTE: The 1st click will come from the brake light
switch. Continue to strongly press pedal to hear
a 2nd click. This one will come from the low pres-
sure switch.

rmr2008-039-011_a

TYPICAL

NOTE: Use B.U.D.S. to monitor brake pressure if

desired.

rmr2008-039-012

MONITORING TAB, VCM MODULE

5. Turn ignition switch OFF.

6. Wait 30 seconds.
7. Turn ignition switch ON.
8. Validate fault was cleared.

rmr2013-036 37
 Subsection 08 (BODY)

BODY
SERVICE PRODUCTS
Description Part Number Page
XPS ROADSTER WASH ................................................................ 219 701 703 ........................................... 13

BODY PARTS NOMENCLATURE (VEHICLE FRONT VIEW)

9
13

12
10
8

7
1 11

3 4 5 6

rmr2014-034-001_a

1. Front fascia
2. Front storage compartment cover
3. Bumper cover
4. Front panel
5. Air duct (or light trim)
6. Front fender
7. Passenger handle
8. Rear speaker grille (option package)
9. Passenger backrest
10. Seat
11. Lower wind deflector
12. Upper wind deflector
13. Windshield

rmr2014-034 1
Subsection 08 (BODY)

BODY PARTS NOMENCLATURE (VEHICLE REAR VIEW)

16
15 12
1

11
2
14
13
3

17

4 5 6 7 8 9 10

rmr2014-034-002_a

1. Front speaker grille (option package)

2. Mirror
3. Top side panel
4. Middle side panel
5. Bottom front side panel
6. Bottom rear side panel
7. Rear side panel
8. Footrest support
9. Side storage compartment cover
10. Rear fender
11. Rear panel
12. Top storage compartment cover
13. Glove box
14. Central panel
15. Ignition switch cover
16. Gauge trim
17. Grille

2 rmr2014-034
 Subsection 08 (BODY)

FRONT CARGO MODULE

Actuator

5.5 N•m H
(49 lbf•in)
4.5 N•m
(40 lbf•in)

4.5 N•m
(40 lbf•in) H
4.5 N•m
(40 lbf•in)

4.5 N•m
(40 lbf•in)

H
2.5 N•m
(22 lbf•in) H B
2.5 N•m 2.5 N•m
(22 lbf•in) (22 lbf•in)

I
2.5 N•m H
(22 lbf•in) 3.5 N•m
(31 lbf•in)

H
4.5 N•m A K50 X 16
(40 lbf•in)
B K50 X 20
H C M5 X 14
2.5 N•m D M5 X 25
(22 lbf•in) E M6 X 10
F M6 X 12
G M6 X 16
H M6 X 20
I K40 X 16

rmr2014-034-003_a

rmr2014-034 3
Subsection 08 (BODY)

CONSOLE MODULE

H C A K50 X 16
4.5 N•m 2.5 N•m B K50 X 20
(40 lbf•in) (22 lbf•in) C M5 X 14
D M5 X 25
STD E M6 X 10
F M6 X 12
G M6 X 16
H M6 X 20
I M6 X 25

D
2.5 N•m
(22 lbf•in)

NEW
H
4.5 N•m C
(40 lbf•in)
2.5 N•m
H
(22 lbf•in) 3.5 N•m
(31 lbf•in)

H
H H 3.5 N•m
3.0 N•m 4.5 N•m (31 lbf•in)
(27 lbf•in) (40 lbf•in)
H
4.5 N•m
(40 lbf•in)
A
H 2.0 N•m
3.5 N•m (18 lbf•in)
(31 lbf•in)

Windshield
motor

H
H 3.5 N•m
3.5 N•m (31 lbf•in)
(31 lbf•in)
NEW XPS
synthetic
grease

H
3.5 N•m 4.5 N•m
(31 lbf•in) (40 lbf•in)
See tightening
sequence
NEW
WPM
module

XPS
NEW = Component must be replaced when removed. synthetic grease
rmr2011-087-102_a

4 rmr2014-034
 Subsection 08 (BODY)

CONSOLE MODULE
A K50 X 16
B K50 X 20
C M5 X 14
D M5 X 25
E M6 X 10
F M6 X 12
G M6 X 16
H M6 X 20
I M6 X 25

4.5 N•m
(40 lbf•in)

7.5 N•m
(66 lbf•in)
4.5 N•m
(40 lbf•in)

4.5 N•m 7.5 N•m 4.5 N•m

(40 lbf•in) (66 lbf•in) (40 lbf•in)

NEW = Component must be replaced when removed.

rmr2011-087-101_a

rmr2014-034 5
Subsection 08 (BODY)

LATERAL BODY PARTS

H A K50 X 16
3.5 N•m B K50 X 20
(31 lbf•in) C M5 X 14
D M5 X 25
E M6 X 10
F M6 X 12
G M6 X 16
H M6 X 20
I M6 X 25

H
3.5 N•m
(31 lbf•in)

4.5 N•m
(40 lbf•in)

3.5 N•m
(31 lbf•in)
F
3.5 N•m
(31 lbf•in)
rmr2014-034-004_a

6 rmr2014-034
 Subsection 08 (BODY)

LATERAL BODY PARTS

A K50 X 16
B K50 X 20
C M5 X 14
D M5 X 25
E M6 X 10
F M6 X 12
G M6 X 16
H M6 X 20
I M6 X 25

3.5 N•m
(31 lbf•in)

35 N•m
(26 lbf•ft)

5 N•m
(44 lbf•in)

5.5 N•m
(49 lbf•in)

S and LTD
15.5 N•m models
(22 lbf•in)

27 N•m
(20 lbf•ft)

3.5 N•m
(31 lbf•in)

7 N•m
H (62 lbf•in)
5 N•m
(44 lbf•in) 48 N•m 2.5 N•m
(35 lbf•ft) (22 lbf•in)
rmr2014-034-005_a

rmr2014-034 7
Subsection 08 (BODY)

REAR CARGO MODULE (REAR VIEW)

2.5 N•m A K50 X 16

(22 lbf•in) B K50 X 20
S and LTD C M5 X 14
Models
D M5 X 25
E M6 X 10
F M6 X 12
A G M6 X 16
2.5 N•m H M6 X 20
(22 lbf•in) I M6 X 25

2.5 N•m
(22 lbf•in)

4.5 N•m A
(40 lbf•in) 2.5 N•m
F (22 lbf•in)
I 3.5 N•m
2.5 N•m (31 lbf•in)
(22 lbf•in) Base Model
F
3.5 N•m
(31 lbf•in)

9 N•m
G (80 lbf•in)
3.5 N•m
(31 lbf•in)

E
3.5 N•m
(31 lbf•in)
4.5 N•m
(40 lbf•in)

G
3.5 N•m
(31 lbf•in)

G H
3.5 N•m 5.5 N•m
(31 lbf•in) (49 lbf•in)
rmr2011-087-105_a

8 rmr2014-034
 Subsection 08 (BODY)

REAR CARGO MODULE (RH SIDE VIEW)

A K50 X 16
B K50 X 20
C M5 X 14 1.0 N•m
See tightening (9 lbf•in)
D M5 X 25
E M6 X 10 sequence
F M6 X 12 4.5 N•m
G M6 X 16 (40 lbf•in)
H M6 X 20
I M6 X 25

G
3.5 N•m
(31 lbf•in)
4.5 N•m
(40 lbf•in)
H
G 4.5 N•m
3.5 N•m (40 lbf•in)
(31 lbf•in) 1.0 N•m
(9 lbf•in)

G
3.5 N•m
(31 lbf•in)

4.5 N•m
(40 lbf•in)

E
3.5 N•m
(31 lbf•in)
See tightening
sequence G
4.5 N•m
(40 lbf•in)

rmr2011-087-106_a

rmr2014-034 9
Subsection 08 (BODY)

FRONT FENDER (BASE MODEL)

3.0 N•m
(27 lbf•in)

25.0 N•m
(18 lbf•ft)
NEW

7.0 N•m
(62 lbf•in)

NEW
25.0 N•m
(18 lbf•ft)
7.0 N•m
(62 lbf•in)

NEW = Component must be replaced when removed.

rmr2013-037-107_a

10 rmr2014-034
 Subsection 08 (BODY)

FRONT FENDER (RT-S AND RT LTD MODELS)

B
B

D
NEW

A
B

B
A 2.5 N•m (22 lbf•in)
B 1.0 N•m (9 lbf•in) C
C 4.5 N•m (40 lbf•in) C
D 25.0 N•m (18 lbf•ft)
D
NEW
NEW = Component must be replaced when removed.
rmr2013-037-106_a

rmr2014-034 11
Subsection 08 (BODY)

SEAT

2.5 N•m
A (22 lbf•in)

H
3.0 N•m
(40 lbf•in)

H
3.0 N•m
(27 lbf•in)

11 N•m
(97 lbf•in)
4.5 N•m
(40 lbf•in)

5.5 N•m
(49 lbf•in)

10 N•m
(89 lbf•in)

7 N•m
(62 lbf•in)
A K50 X 16
B K50 X 20
C M5 X 14
D M5 X 25
E M6 X 10
F M6 X 12
G M6 X 16
H M6 X 20
I M6 X 25
rmr2014-034-033_a

12 rmr2014-034
 Subsection 08 (BODY)

GENERAL WARNING
Do not apply a vinyl or plastic protector on
VEHICLE CARE the seat as the surface will become slippery
Vehicle Cleaning and the operator or the passenger may slip
off the vehicle.
To clean the vehicle, do not use high-pressure
washers (like the ones found in car washes) as
they may damage certain parts of the vehicle.
PROCEDURES
NOTICE Do not clean the windshield with al- FRONT CARGO MODULE
kaline or acid cleaner, gasoline or solvent to
avoid windshield damage.
NOTICE For Matte finishes, do not use wax,
detail spray, or other products used on regular
paint. Do not wash with abrasive materials. Do
not use mechanical cleaners or polishers, and
do not rub the surfaces vigorously.
To clean the vehicle:
1. Rinse the vehicle thoroughly with water to re-
move loose dirt.
2. Using a soft, clean cloth, wash the vehicle with
water mixed with a mild detergent, such as
soap specially formulated for motorcycles or
automobiles.
NOTE: Using warm water works well to remove rmr2014-034-025
bugs in the windshield and front panels. FRONT CARGO MODULE
NOTE: For Matte finishes, hand-wash with a soft
wash mitt and a mild cleaning product safe for Front Cargo Module Removal
matte paint. To remove foreign substances such 1. Remove mirrors. Refer to MIRRORS in this
as insects, use a soft applicator and a mild sol- subsection.
vent. Saturate and soak area before cleaning. Rub 2. Remove service covers. Refer to SERVICE
lightly. COVERS in this subsection.
3. While washing the vehicle, check for grease or 3. Remove middle side panels. Refer to MIDDLE
oil. You can use XPS ROADSTER WASH (P/N 219 SIDE PANELS in this subsection.
701 703) or a mild automotive degreaser. Thor-
oughly follow the manufacturer's instructions. 4. Remove top side panels. Refer to TOP SIDE
PANELS in this subsection.
4. Dry the vehicle with a chamois or a soft towel.
5. Remove front fascia. Refer to FRONT FASCIA
Vehicle Protection in this subsection.
Apply non-abrasive wax to plastic parts. 6. Remove front panel retaining screw on both
side.
NOTICE Do not wax or polish matte surfaces.
SURFACE PRODUCT/PRECAUTION
Glossy Apply only non-abrasive wax, safe
finishes for clear coat paints
Matte finishes Do not apply wax

NOTICE Do not polish windshield with any

plastic cleaner/polisher.

rmr2014-034 13
Subsection 08 (BODY)

rmr2010-038-025_a

SOME PARTS REMOVED FOR CLARITY PURPOSE

1. Upper retaining screws

rmr2014-034-026_a 10. From underneath bumper cover, remove

1. Front panel retaining screw lower retaining screws from cargo module.
7. On applicable models, remove nut securing
headlight adjustment cable (LB) on both side.

rmr2014-034-028_a

1. Lower retaining screws

rmr2014-034-027_a
11. Slightly pull cargo module toward front of ve-
ON APPLICABLE MODELS
hicle.
1. Headlight adjustment cable (LB) 12. Disconnect the following components from
8. Disconnect the following components from ve- vehicle (if equipped).
hicle (if equipped). – Air intake duct
– B.U.D.S. connector – AAPTS sensor connector
– Storage cover switch (FCS) connector – Low beam light connectors (CE)
– Storage cover actuator connector – Fog light connectors
– Storage cover cable. – Storage compartment light.
9. Remove upper retaining screws from cargo 13. Completely remove cargo module from vehi-
module. cle.

Front Cargo Module Disassembly

Sequence
To disassemble the front cargo module, carry out
the following steps in this specific order.
1. Remove front storage compartment cover.
1.1 Remove 4 screws at the front of cover.

14 rmr2014-034
 Subsection 08 (BODY)

rmr2014-034-030_a rmr2014-034-039_b

2. Remove skid plate. 3.2 Remove 6 screws at the rear.

2.1 Remove 6 screws underneath skid plate.

rmr2014-034-029_a

3.3 Remove 2 plastic rivets from inside air

rmr2014-034-039_a ducts on both sides.

3. Remove bumper cover air ducts.

3.1 Remove 4 screws underneath bumper
cover.

rmr2014-034-032_a

3.4 Remove 2 plastic rivets from underneath

bumper cover.

rmr2014-034 15
Subsection 08 (BODY)

rmr2014-034-031_a

3.5 Release snap inside the bumper cover on rmr2014-034-036_a

both sides.
4.2 Remove 6 plastic rivets on the top of front
panel.

rmr2014-034-037_a
rmr2014-034-034_a

5. Remove front bumper.

5.1 Remove a plastic rivet in the front of the
bin on both sides.

rmr2014-034-035_a

4. Remove front panels.

4.1 Remove 3 screws from inside front panel rmr2014-034-038_a

on both sides.

16 rmr2014-034
 Subsection 08 (BODY)

Front Cargo Module Assembly and

Installation
Assemble front cargo module as the reverse of
disassembly.
Install front cargo module as the reverse of re-
moval procedure, however, pay attention to the
following.
Adjust front storage compartment latch, refer to
FRONT STORAGE COMPARTMENT in this sub-
section.
Torque storage compartment screws to 4.5 N•m
(40 lbf•in).

rmr2014-034 17

GENERAL
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, cotter pins, etc.) must
be replaced.
NOTICE Hoses, cables and locking ties re-
moved during a procedure must be reinstalled
as per factory standards.
NOTICE Be careful when tightening plastic
panels. Any deformation on the panel around
the screw is an indication that it is too tight.
Do not over torque panels in order to avoid to
damage them.
NOTE: Install a battery charger on battery termi-
nals (under seat) for any tests that involve a pro-
longed KEY ON period. If battery voltage gets too
low, some accessories are shut off by the ECM.
VEHICLE CARE
Vehicle Cleaning
To clean the vehicle, do not use high-pressure
washers (like the ones found in car washes) as
they may damage certain parts of the vehicle.
NOTICE Do not clean the windshield with al-
kaline or acid cleaner, gasoline or solvent to
avoid windshield damage.
To clean the vehicle:
– Rinse the vehicle thoroughly with water to re-
move loose dirt.
– Using a soft, clean cloth, wash the vehicle with
water mixed with a mild detergent, such as
soap specially formulated for motorcycles or
automobiles.
18 rmr2013-044
Subsection XX (BODY (RT SERIES))
– While washing the vehicle, check for grease
or oil. You can use BRP HEAVY DUTY CLEANER
(P/N 293 110 001) or a mild automotive de-
greaser. Thoroughly follow the manufacturer's
instructions.
– Dry the vehicle with a chamois or a soft towel.
Vehicle Waxing
Apply only nonabrasive wax safe for clearcoat
paints on glossy finishes.
Avoid applying wax on matte surfaces.
NOTICE Do not polish windshield with any
plastic cleaner/polisher.
WARNING
Do not apply a vinyl or plastic protector on
the seat as the surface will become slippery
and the operator or the passenger may slip
off the vehicle.
TROUBLESHOOTING
TROUBLESHOOTING
GUIDELINES (WINDSHIELD)
Before any troubleshooting operations on wind-
shield, it is important to check the fault codes
using B.U.D.S. to properly diagnose the problem.
Refer to DIAGNOSTIC AND FAULT CODES sub-
section.
WINDSHIELD DOES NOT WORK
1. Faulty WPM module or wiring.
- Check if parking brake works properly.
- Carry out a WPM MODULE SIGNAL CIRCUIT
CONTINUITY TEST.
- Carry out a WPM MODULE CAN TEST.
2. Faulty windshield motor or wiring.
- Carry out a WINDSHIELD MOTOR OPERATION
TEST.
PROCEDURES
DECALS
Decal Removal
Using a heat gun (low heat setting) warm up one
end of decal for a few seconds until decal can roll
off when rubbing with your finger.
Pull decal slowly and when necessary apply more
heat to ease removal on the area that has to be
peeled off.
13
Subsection XX (BODY (RT SERIES))

If decal tears while pulling off, it has to be heated SERVICE COVERS

for a few seconds longer. If decal tends to stretch
while pulling off, stop heating and wait a few sec- NOTE: The procedures are the same for LH and
onds to let it cool, then peel it off. RH service covers.

Decal Installation Service Cover Removal

Using isopropyl alcohol, clean the surface and dry 1. Open the front storage compartment cover.
thoroughly. 2. Remove plastic rivet from service cover.
Apply a soapy water solution to new decal
and carefully position it. Using a sponge or a
squeegee, remove the air bubbles and water
working from the center toward the edges. Al-
low to air dry.
NOTICE Do not apply isopropyl alcohol or
solvent directly on decals.

MIRRORS
NOTE: The procedures are the same for LH and
RH mirrors. rmr2010-038-021_a

1. RH service cover
Mirror Removal 2. Plastic rivet

1. Hit with a sharp blow lower part of mirror to- 3. Pull down service cover using the recess to re-
ward the rear to unlock it. lease upper tabs from the front fascia.
2. Slide mirror upwards to unhook it from upper
slot.

rmr2010-038-061_a

4. Lift service cover to remove it.

rmr2011-087-009_a

Step 1: Hit with a sharp blow NOTICE For the RH service cover, pay at-
Step 2: Slide mirror upwards
tention not to damage the FCS switch (if
3. Disconnect turn signal connector. equipped).
NOTE: Be careful not to let the turn signal wires Service Cover Installation
fall inside body panels.
The installation is the reverse of the removal pro-
Mirror Installation cedure.
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. FRONT FASCIA
Hook mirror on the upper slot. Front Fascia Removal
Hit mirror with a sharp blow toward the vehicle to 1. Remove mirrors. Refer to MIRRORS in this
engage lower attachment. subsection.
19
14 rmr2013-044
 Subsection XX (BODY (RT SERIES))

2. Remove service covers. Refer to SERVICE

COVERS in this subsection.
3. Remove middle side panels. Refer to MIDDLE
SIDE PANELS in this subsection.
4. Remove top side panels. Refer to TOP SIDE
PANELS in this subsection.
5. Remove upper retaining screws and washers
from front fascia.

rmr2010-038-024_a

1. Lower retaining screw

8. Remove front fascia from vehicle.

Front Fascia Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Torque front fascia retaining screws to 3.5 N•m
(31 lbf•in).
rmr2010-038-022_a

1. Upper retaining screw

MIDDLE SIDE PANELS
NOTE: The procedures are the same for LH and
6. Remove middle retaining screws and washers
RH middle side panels.
from front fascia.
Middle Side Panel Removal
1. Remove middle side panel as follows:
1.1 Pull the rear of panel out of its grommet.
1.2 Slide down the top of the panel to free
panel hook.
1.3 Pull the bottom of the panel out of its
grommet.
1.4 Pull the front of the panel out of its grom-
met.
1.5 Slide the front of the panel to remove it.
2. Remove grille.
rmr2010-038-023_a

1. Middle retaining screw

7. Remove lower retaining screws and washers

from front fascia.

rmo2010-008-003_d

REMOVAL SEQUENCE

Middle Side Panel Installation

1. Install grille onto panel.

20 rmr2013-044 15
Subsection XX (BODY (RT SERIES))

2. Install middle side panel as follows:

2.1 Push the front of panel in its grommet.
2.2 Rotate the panel and clip it on the support.
2.3 Push the bottom of the panel in its grom-
met.
2.4 Push the rear of the panel in its grommet.
2.5 Push the top of the panel to fix the plastic
hook.

rmr2010-038-005_a

1. Upper retaining screws

7. Remove rear retaining screw from top side

panel.

rmo2010-008-003_e

INSTALLATION SEQUENCE

TOP SIDE PANELS

NOTE: The procedures are the same for LH and
RH top side panels.

Top Side Panel Removal

1. Lift seat.
2. Open front storage compartment. rmr2010-038-006_a

1. Rear retaining screw

3. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection. 8. Remove LH service cover. Refer to SERVICE
4. Remove retaining screws from lower wind de- COVERS in this subsection.
flector.

rmr2010-038-007_a
rmr2010-038-004_a
1. LH service cover
1. Retaining screws of wind deflector

5. Remove mirror. Refer to MIRRORS in this sub- 9. Remove front retaining screw from top side
section. panel.
6. Remove upper retaining screws from top side
panel.

16 rmr2013-044 21
 Subsection XX (BODY (RT SERIES))

REAR SIDE PANELS

NOTE: The procedures are the same for LH and
RH rear side panels.

Rear Side Panel Removal

1. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection.
2. Remove top side panel. Refer to TOP SIDE
PANELS in this subsection.
3. Remove front retaining screw of rear side
rmr2010-038-008_a panel.
1. Front retaining screw
4. Remove upper retaining screw and washer
10. Pull out lower part of top side panel to remove from rear side panel.
it from grommets.
NOTE: Do not remove lower screws from top
side panel.

rmr2010-038-010_a

1. Front retaining screw

2. Upper retaining screw

5. Remove front plastic rivet from rear side panel.

rbl2010-002-305

11. Remove top side panel by lifting it upwards.

rmr2010-038-011_a

1. Front plastic rivet

rmr2010-038-009_a
6. Open side storage compartment cover.
1. Top side panel 7. Remove rear retaining screws from rear side
panel.
Top Side Panel Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Torque top side panel retaining screws to 3.5 N•m
(31 lbf•in).

22 rmr2013-044 17
Subsection XX (BODY (RT SERIES))

GLOVE BOX
Glove Box Removal
1. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection.
2. Remove top side panel. Refer to TOP SIDE
PANELS in this subsection.
3. Remove lateral acoustic panels. Refer to
ACOUSTIC PANELS in this subsection.
rmr2010-038-012_a 4. Disconnect glove box cable from glove box.
1. Rear retaining screws
5. Remove locking ties securing glove box cable.
8. Remove top retaining screw of rear side panel.

rmr2010-038-013_a rmr2011-087-005_a
1. Top retaining screw
6. Remove locking ties securing central panel
9. Remove rear side panel from vehicle. switches harness.
NOTICE Be careful not to break lower tabs. 7. Disconnect central panel switches harness con-
nector.

rbl2010-002-356_a

LH REAR SIDE PANEL

1. Lower tabs

Rear Side Panel Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following. rmr2011-087-006_a

Torque rear side panel retaining screws to

8. Remove 3 plastic rivets from glove box on both
3.5 N•m (31 lbf•in).
side.
9. Remove 2 retaining screws from glove box on
both side.

18 rmr2013-044 23
 Subsection XX (BODY (RT SERIES))

rmr2010-038-030_a

1. Plastic rivets
2. Retaining screws rmr2010-038-500_a

TYPICAL - GLOVE BOX UNIT

10. Remove glove box as a unit with central panel 1. Plastic rivets
2. Top acoustic panel
by lifting it upwards. 3. Glove box
11. Remove locking tie securing switches harness
14. Remove plastic rivet securing central panel to
to glove box.
glove box.
15. Remove central panel from glove box.

rmr2011-087-007_a
rmr2010-038-502_a

12. Remove plastic rivets securing acoustic panel 1. Plastic rivet

2. Central panel
to glove box. 3. Glove box
13. Remove acoustic panel from glove box.
16. Remove all the remaining components from
glove box.

Glove Box Installation

The installation is the reverse of the removal pro-
cedure.

CENTRAL PANEL
Central Panel Removal
1. Remove glove box as a unit with central panel
from vehicle, refer to GLOVE BOX REMOVAL
in this subsection.
2. Remove plastic rivet securing central panel to
glove box.

24 rmr2013-044 19
Subsection XX (BODY (RT SERIES))

rmr2010-038-016_a
rmr2010-038-501_a
1. Lower plastic rivets
1. Plastic rivet
2. Central panel
3. Glove box
5. Remove bottom front side panel from vehicle.

3. Remove central panel from glove box.
Central Panel Installation
The installation is the reverse of the removal pro-
cedure.
BOTTOM FRONT SIDE PANELS
NOTE: The procedures are the same for LH and
RH bottom front side panels.
Bottom Front Side Panel Removal
1. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection.
2. Remove upper retaining screw from panel.
3. Remove upper plastic rivet from panel.
Bottom Front Side Panel Installation
The installation is the reverse of the removal pro-
cedure.
BOTTOM REAR SIDE PANELS
NOTE: The procedures are the same for LH and
RH bottom rear side panels.
Bottom Rear RH Side Panel Removal
1. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection.
2. Remove top side panel. Refer to TOP SIDE
PANELS in this subsection.
3. Remove rear side panel. Refer to REAR SIDE
PANELS in this subsection.
4. Remove bottom front side panel. Refer to BOT-
TOM FRONT SIDE PANELS in this subsection.
5. Remove front plastic rivet from bottom RH rear
side panel.

rmr2010-038-015_a

1. Upper retaining screw

2. Upper plastic rivet

4. From underneath panel, remove lower plastic

rivets. rmr2010-038-017_a

1. Front plastic rivet

6. Remove retaining screws from bottom rear RH

side panel.

20 rmr2013-044
25
 Subsection XX (BODY (RT SERIES))

ACOUSTIC PANELS
Acoustic Panel Replacement
Lateral
1. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection.
2. Remove top side panel. Refer to TOP SIDE
PANELS in this subsection.
3. Remove retaining screws from acoustic panel.

rmr2010-038-018_a

1. Retaining screws

7. Remove bottom rear RH side panel from vehi-

cle.

Removal of Bottom Rear LH Side

Panel
1. Remove middle side panel.
2. Remove top side panel.
3. Remove rear LH side panel.
rmr2010-038-019_a
4. Remove bottom front side panel. 1. Retaining screws
2. LH lateral acoustic panel
5. Remove bottom retaining screw from bottom
rear LH side panel. 4. Replace acoustic panel on vehicle.
5. Torque acoustic panel retaining screws to
6 N•m (53 lbf•in).
6. Reinstall all removed panels.
Top
1. Remove glove box as a unit with central panel
from vehicle. Refer to GLOVE BOX REMOVAL
rmo2013-005-010_a
in this subsection.
1. Bottom retaining screw 2. Remove plastic rivets securing acoustic panel
2. Upper retaining screw to glove box.
6. Loosen upper retaining screw.
NOTE: Upper retaining screw remains attached
to bottom panel.
7. Remove bottom rear side panel from vehicle by
pulling forward to release panel from bracket.
NOTE: The back of the panel is inserted between
the bracket and aluminium support.

Bottom Rear Side Panel Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Torque bottom side panel retaining screws to
2.5 N•m (22 lbf•in).
Torque bottom side panel retaining nut (located at
the rear) to 5.5 N•m (49 lbf•in).

26 rmr2013-044 21
Subsection XX (BODY (RT SERIES))

rmr2011-087-001_a

rmr2010-038-500_a 1. Front panel retaining screw

TYPICAL
1. Plastic rivets 7. On applicable models, remove nut securing
2. Top acoustic panel
3. Glove box headlight adjustment cable (LB) on both side.

3. Replace acoustic panel on glove box.

4. Reinstall all removed panels and components.

FRONT CARGO MODULE

rmr2010-038-027_b

ON APPLICABLE MODELS
1. Headlight adjustment cable (LB)

8. Disconnect the following components from ve-

hicle (if equipped).
– B.U.D.S. connector
rmr2010-038-020

FRONT CARGO MODULE – Storage cover switch (FCS) connector

– Storage cover actuator connector
Front Cargo Module Removal – Storage cover cable.
1. Remove mirrors. Refer to MIRRORS in this 9. Remove upper retaining screws from cargo
subsection. module.
2. Remove service covers. Refer to SERVICE
COVERS in this subsection.
3. Remove middle side panels. Refer to MIDDLE
SIDE PANELS in this subsection.
4. Remove top side panels. Refer to TOP SIDE
PANELS in this subsection.
5. Remove front fascia. Refer to FRONT FASCIA
in this subsection.
6. Remove front panel retaining screw on both
side.

22 rmr2013-044
27
 Subsection XX (BODY (RT SERIES))

2. Remove bumper cover air ducts.

2.1 Remove 2 screws at the rear on both side.
2.2 Remove 4 plastic rivets from inside air
ducts on both side.
2.3 Remove 2 plastic rivets from underneath
bumper cover on both side.
3. Remove front panels.
3.1 Remove 1 retaining washer from inside
front panel on both side.
rmr2010-038-025_a
3.2 Remove 3 screws from inside front panel
SOME PARTS REMOVED FOR CLARITY PURPOSE on both side.
1. Upper retaining screws
3.3 Remove 3 plastic rivets on the top of front
10. From underneath bumper cover, remove panel on both side.
lower retaining screws from cargo module. 4. Remove front bumper.

Front Cargo Module Assembly and

Installation
Assemble front cargo module as the reverse of
disassembly.
Install front cargo module as the reverse of re-
moval procedure, however, pay attention to the
following.
Adjust front storage compartment latch, refer to
FRONT STORAGE COMPARTMENT in this sub-
section.
Torque storage compartment screws to 4.5 N•m
rmr2010-038-026_a (40 lbf•in).
1. Lower retaining screws

11. Slightly pull cargo module toward front of ve- FRONT STORAGE
hicle. COMPARTMENT LATCH
12. Disconnect the following components from Front Storage Compartment Latch
vehicle (if equipped). Adjustment
– AAPTS sensor connector
1. Open front storage compartment cover.
– Horn connector
2. Loosen 4 retaining screws at the front of cover.
– Low beam light connectors (CE)
– Fog light connectors
– Storage compartment light.
13. Completely remove cargo module from vehi-
cle.

Front Cargo Module Disassembly

Sequence
To disassemble the front cargo module, carry out
the following steps in this specific order. Refer to
the exploded view at the beginning of this subsec-
tion for details.
1. Remove front storage compartment cover.
1.1 Remove 4 screws at the front of cover. rbg2010-008-006_a

1. Retaining screws

28 rmr2013-044 23
Subsection XX (BODY (RT SERIES))

3. Move cover upper section backward while

pulling lower section forward.
4. Tighten 4 retaining screws at the front of cover.

rbg2010-008-008_a

1. Retaining screws of cover hinge

2. Hinge housing wall
rmr2010-038-503_b
A. Hinge bracket parallel with housing wall
1. Upper section backward
2. Lower section forward
8. Tighten 2 retaining screws of cover hinge.
5. Loosen 2 retaining screws of cover hinge. 9. Carry out the FRONT STORAGE COMPART-
6. Completely move cover hinge toward the front. MENT SEAL VERIFICATION. See procedure in
this subsection.
Front Storage Compartment Seal Verification
NOTICE This test must be performed each
time the latch is adjusted in order to avoid
water intrusion into storage compartment.
1. Open front storage compartment cover.
2. Place a sheet of paper on storage compartment
seal.
3. Close front storage compartment cover.

rbg2010-008-008_b

1. Retaining screws of cover hinge

2. Moving cover hinge

7. Align hinge bracket with housing wall. They

must be parallel.

rbg2010-008-010_a

4. Check that cover is properly sealed by pulling

on the sheet of paper.
5. Repeat the previous steps for the other side.
FRONT STORAGE COMPARTMENT SEAL
VERIFICATION
PASS Sheet not easily removable
FAIL Sheet easily removable
29
24 rmr2013-044
 Subsection XX (BODY (RT SERIES))

6. If test fail, adjust front storage compartment
latch as follows:
6.1 Loosen latch nuts.
6.2 Adjust latch mechanism accordingly.
6. Remove top side panels. Refer to TOP SIDE
PANELS in this subsection.
7. Remove lateral acoustic panels. Refer to
ACOUSTIC PANELS in this subsection.
8. Remove front fascia. Refer to FRONT FASCIA
in this subsection.
9. Disconnect module harness connectors located
on the LH side of vehicle.

rbg2010-008-007_a

1. Latch nuts
2. Latch mechanism
rmr2010-038-029_a
7. Ensure cover height fits with front panels SOME PARTS REMOVED FOR CLARITY PURPOSE
height when cover is closed. 1. Module harness connectors

10. Remove nut securing headlight adjustment ca-

CONSOLE MODULE ble (HB) on both side.
11. Remove front retaining screws from console
module.

rmr2010-038-032
rmr2010-038-028_a
CONSOLE MODULE
SOME PARTS REMOVED FOR CLARITY PURPOSE
1. Front retaining screws
Console Module Removal
1. Lift seat. 12. Remove 3 plastic rivets from glove box on
both side.
2. Open front storage compartment.
13. Remove 2 retaining screws from glove box on
3. Remove mirrors. Refer to MIRRORS in this both side.
subsection.
4. Remove both service covers. Refer to SER-
VICE COVERS in this subsection.
5. Remove middle side panels. Refer to MIDDLE
SIDE PANELS in this subsection.

30 rmr2013-044 25
Subsection XX (BODY (RT SERIES))
rmr2010-038-030_a
1. Plastic rivets
2. Retaining screws
14. Slightly lift glove box upwards.
15. Remove side retaining screws from console
module.
rmr2010-038-031_a
1. Side retaining screw
16. Carefully pull console module toward front of
vehicle.
Console Module Disassembly
Sequence
To disassemble the console module, carry out the
following steps. Refer to the exploded view at the
beginning of this subsection for details.
1. Remove multifunction gauge.
1.1 Remove 4 screws securing gauge trim.
1.2 Pull down both upper tabs.
1.3 Move top of gauge toward rear.
1.4 Disconnect gauge connector.
2. Remove headlights.
2.1 Remove 4 retaining screws from head-
light.
2.2 Disconnect headlight connector.
26
3. Remove windshield. Refer to WINDSHIELD in
this subsection.
Console Module Installation
Assemble console module as the reverse of disas-
sembly, however, pay attention to the following.
Torque gauge trim screws to 2.5 N•m (22 lbf•in).
Install console module as the reverse of removal
procedure, however, pay attention to the follow-
ing.
Torque console module front retaining screws to
4.5 N•m (40 lbf•in).
Torque console module side retaining screws to
4.5 N•m (40 lbf•in).
REAR CARGO MODULE
rmr2010-038-033
REAR CARGO MODULE
Rear Cargo Module Removal
1. Remove middle side panel. Refer to MIDDLE
SIDE PANELS in this subsection.
2. Remove top side panel. Refer to TOP SIDE
PANELS in this subsection.
3. Remove rear side panel. Refer to REAR SIDE
PANELS in this subsection.
4. Remove seat from vehicle as follows:
4.1 Disconnect shock absorber from seat
base.
4.2 Unplug pillion rider (passenger) switch.
4.3 Remove seat base retaining bolts.
31
rmr2013-044
 Subsection XX (BODY (RT SERIES))

10. Remove audio player access panel from vehi-

cle.

rmr2010-038-034_a

1. Seat base retaining bolt

4.4 Remove spacer and caged nuts.

rmr2010-038-037_a

1. Audio player access panel

2. Rear retaining screw

11. Disconnect LH ground strap by unscrewing

each retaining screw.

rmr2010-038-035_a

1. Spacer
2. Caged nut

5. Remove rear retaining screw from battery ac-

cess panel (LH side).
6. Disconnect passenger heated grip switch.
rmr2010-038-038_a

7. Remove battery access panel from vehicle. 1. LH ground strap retaining screw

12. On the LH side of the vehicle near passenger

grab handle.
– Disconnect both cargo harness connectors.
– Disconnect accessories connector (if appli-
cable).

rmr2010-038-036_a

1. Battery access panel

2. Rear retaining screw

8. Remove rear retaining screw from audio player

access panel (RH side).
9. Disconnect passenger audio control switch (op-
tion package).
32 rmr2013-044 27
Subsection XX (BODY (RT SERIES))

15. With the assistance of a coworker, carefully

pull rear cargo module toward rear.
16. Install rear cargo module on an appropriate
support.

rmr2010-038-040_a

1. Cargo harness connectors

13. Remove lateral retaining screws and washers

(on both side) of rear cargo module.

rmr2011-087-008

TYPICAL - REAR CARGO MODULE SUPPORT

Rear Cargo Module Disassembly

Sequence
To disassemble the rear cargo module, carry out
the following steps in this specific order. Refer to
the exploded view at the beginning of this subsec-
tion for details.
rmr2010-038-041_a
1. Remove rear panel.
1. Lateral retaining screw
1.1 Open top and side storage compartment
14. Remove top retaining screws of rear cargo covers.
module. 1.2 Remove 2 screws on the top of each side
storage compartment.
1.3 Remove 4 screws on the rear of top stor-
age compartment.
2. Remove rear fender.
2.1 Remove 3 screws on the upper portion of
rear fender.
2.2 Remove 2 screws on the rear of each side
storage compartment.
2.3 Remove 1 screw on the back of each side
storage compartment.
rmr2010-038-042_a
2.4 Disconnect licence plate connector.
1. Top retaining screws 3. Remove passenger backrest.
NOTICE To avoid damaging the rear cargo 3.1 Remove 3 screws inside top storage com-
module: partment.
– Never lift rear cargo module by the passen- 3.2 Remove 2 screws on the top of passenger
ger grab handle. backrest.
– Always install rear cargo module on an ap- 4. Remove taillight.
propriate support. 4.1 Remove 3 screws on the taillight housing.
33
28 rmr2013-044
 Subsection XX (BODY (RT SERIES))

4.2 Disconnect taillight connector. Remove brake pedal. Refer to BRAKE PEDAL RE-
MOVAL in the BRAKES subsection.
Rear Cargo Module Installation Remove bolt retaining shifting link to shifting
Assemble cargo module as the reverse of disas- block.
sembly, however, pay attention to the following.
Torque taillight screws to 2.5 N•m (22 lbf•in).
Torque passenger backrest screws to 4.5 N•m
(40 lbf•in) for the ones inside storage compart-
ment and to 2.5 N•m (22 lbf•in) for upper screws.
Torque rear fender screws to 3.5 N•m (31 lbf•in)
as per the following sequence.

rmr2010-006-017_a

TYPICAL – SM5 ENGINE SHOWN

1. Shifting block
2. Shifting link

Remove retaining screws securing LH footrest

support to vehicle.

rmr2011-087-004_a

TIGHTENING SEQUENCE

Torque rear panel screws to 3.5 N•m (31 lbf•in).

Install cargo module as the reverse of removal
procedure, however, pay attention to the follow-
ing.
Torque rear cargo top retaining screws to 9 N•m rmr2013-044-301_a

(80 lbf•in). RETAINING SCREWS TO REMOVE

Torque rear cargo lateral retaining screws to

4.5 N•m (40 lbf•in).
Torque battery and audio player access panels re-
taining screws to 3.5 N•m (31 lbf•in).
Torque seat base retaining bolts to 4.5 N•m
(40 lbf•in).

FOOTREST SUPPORT AND

FOOTREST REMOVAL (ALL RT
MODELS)
Footrest Support
Footrest Support Removal
LH Footrest Support rmr2013-044-302_a

Remove the LOWER SIDE PANEL, see procedure RETAINING SCREWS SECURING FOOTREST SUPPORT TO
FRAME
above in this subsection.
Pull on footrest support to remove it.
34
rmr2013-044 29
Subsection XX (BODY (RT SERIES))

RH Footrest Support
Remove the LOWER SIDE PANEL, see procedure
above in this subsection.
Remove master cylinder screws.

rmr2013-044-304_a

RETAINING SCREWS SECURING FOOTREST SUPPORT TO

FRAME

Pull on footrest support to remove it.

Footrest Support Installation
rmr2013-044-303_a
The installation is the reverse of the removal pro-
MASTER CYLINDER SCREW TO REMOVE (SECOND SCREW cedure. However pay attention to the following.
NOT ILLUSTRATED)
Each time RH footrest support is re-installed, the
Remove screws retaining lateral support to adjustment of the master cylinder rod is nec-
footrest support. essary. Refer to MASTER CYLINDER ROD in
BRAKE.
Driver Footpeg and Driver Footrest
Driver Footpeg and Footrest Removal
On Models equipped with Footrest, remove
footrest release mechanism. Refer to FOOTREST
RELEASE MECHANISM in the BRAKES subsec-
tion.
LH Side
Remove the 3 retaining screws securing driver
rmr2013-044-305_a
footrest (2 for footpeg) to footrest support.
RETAINING SCREWS TO REMOVE

30 rmr2013-044
35
 Subsection XX (BODY (RT SERIES))

rmr2013-044-306_a rmr2013-044-312_a

RETAINING SCREWS TO REMOVE 1. Retaining bolt

2. Bushing
3. Sleeve
RH Side 4. Sleeve
Remove retaining screw and retaining bolt secur- 5. Rubber suppport
6. Footpeg
ing footpeg/footrest to footrest support. 7. Washer
8. Retaining nut

Remove footpeg/footrest from vehicle.

Driver Footpeg Installation
The installation is the reverse of the removal pro-
cedure.

Passenger Footrest
Passenger Footrest Removal
Remove retaining screw securing passenger
footrest to footrest support

rmr2013-044-307_a

rmr2013-044-310_a

RETAINING SCREW SECURING PASSENGER FOOTREST TO

FOOTREST SUPPORT

Remove passenger footrest from vehicle.

36 rmr2013-044 31
Subsection XX (BODY (RT SERIES))

Passenger Footrest Installation

The installation is the reverse of the removal pro-
cedure.

WINDSHIELD
Windshield Removal
1. From inside windshield, remove retaining
screws from windshield trim panels.

rmr2010-038-044_a

1. Windshield trim panels

4. Remove windshield retaining screws and

sleeves from support.

rmr2010-038-043_a

1. Windshield trim panels retaining screws

2. Place a sheet of paper on windshield to protect

it, refer to illustration.
NOTICE If this precaution is not taken,
scratch on the windshield may occur.

rmr2010-038-045_a

1. Windshield retaining screws

5. Carefully remove windshield from vehicle.

Windshield Installation
The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
NOTICE Prior to installing windshield trim
panel, place a sheet of paper on windshield to
rbl2010-002-028 protect it.

3. Remove windshield trim panels from vehicle.

32 rmr2013-044
37
 Subsection XX (BODY (RT SERIES))

rmr2010-038-047_a
rbl2010-002-028
1. Center arm
SHEET OF PAPER POSITIONING 2. C-clip

Torque windshield retaining screws to 4.5 N•m 6. Remove center arm pin.
(40 lbf•in).
7. Remove windshield support from vehicle.
Torque windshield trim panels retaining screws to
2.5 N•m (22 lbf•in). Windshield Support Installation
The installation is the reverse of the removal pro-
WINDSHIELD SUPPORT cedure. However, pay attention to the following.
Windshield Support Removal Make sure that arm bushings are installed as per
the following illustration.
NOTE: To access directly to windshield motor, it
is not necessary to remove windshield from wind-
shield support (step 1).
1. Remove windshield. Refer to WINDSHIELD in
this subsection.
2. Remove C-clips from side arm pins.

rmr2010-038-048_a

1. Bushings

Install NEW C-clip on arm pins.

WINDSHIELD MOTOR
NOTICE Do not remove windshield motor
from windshield base. Both are calibrated at
the factory. If windshield motor needs to be
changed, replace windshield base with WPM
rmr2010-038-046_a

1. Side arm
module and windshield motor as an assembly.
2. C-clip

3. Remove side arm pins.

4. Rotate windshield support toward front.
5. Remove C-clip from center arm pin.

38 rmr2013-044 33
Subsection XX (BODY (RT SERIES))

Windshield Wiring Diagram

MULTIFUNCTION MAIN RELAY 2

SWITCH (LEFT) (R3)
CAN-LO (PIN-8)

OR/RD-16
WH/BE-20 D CAN-HI (PIN-6)
D
2-
IC
WH/BK-20

OR/RD-16

-2
-1
-8

-5
-6

0
-1

PM
PM
PM

PM
PM

rmo2010-001-020_h
PM

W
W
W

W
W

1. Windshield adjustment switch

WPM WINDSHIELD & PARKING BRAKE MODULE
DWN UP

-7
5. Check proper operation in B.U.D.S.
1
-2

-9

-3
-4

-1

PM
PM

PM

PM
PM

PM

W
W

W
W

W
GY/LTGN-18

GY/RD-18

BK-16
-2

-1
GN/OR-20

BU/OR-20
M

M
W

WM
WINDSHIELD MOTOR
rmr2011-087-200_a

Windshield Motor Monitoring

(with B.U.D.S.) rmr2010-038-059_b

TYPICAL
To monitor windshield motor during troubleshoot- 1. Windshield operation monitoring lights
ing operation, proceed as follows:
1. Connect vehicle to B.U.D.S. Refer to COMMU- Windshield Motor Operation Test
NICATION TOOLS AND B.U.D.S. SOFTWARE 1. Connect vehicle to B.U.D.S. Refer to COMMU-
subsection. NICATION TOOLS AND B.U.D.S. SOFTWARE
2. Select Monitoring page. subsection.
3. Select WPM tab. 2. Select Activation page.
3. Select WPM tab.

rmr2010-038-059_a

TYPICAL
Step 1: Select monitoring
Step 2: Select WPM

4. Press windshield adjustment switch on vehicle.

39
34 rmr2013-044
 Subsection XX (BODY (RT SERIES))

rmr2010-038-060_a rmr2010-038-060_b

TYPICAL
Step 1: Activation page
Step 2: WPM folder
4. Press Windshield Up button.
rmr2010-038-060_b
TYPICAL
1. Windshield Up and Down button
5. Verify if windshield motor works to raise wind-
shield.
If windshield motor does not work:
– Check input voltage at motor (PIN-1), refer to
the WIRING DIAGRAM.
– Check ground circuit continuity at motor (PIN-
2), refer to the WIRING DIAGRAM.
– Check connector and terminal condition.
6. Press Windshield Down button.
TYPICAL
1. Windshield Up and Down button
7. Verify if windshield motor works to lower wind-
shield.
If windshield motor does not work:
– Check input voltage at motor (PIN-2), refer to
the WIRING DIAGRAM.
– Check ground circuit continuity at motor (PIN-
1), refer to the WIRING DIAGRAM.
– Check connector and terminal condition.
If the fault is not found after having carried out the
previous tests:
– Test motor operation by connecting it directly to
the battery posts.
• If motor works properly, test module, refer to
WINDSHIELD MODULE (WPM) in this sub-
section.
• If motor does not work properly, replace
windshield base with WPM module and
windshield motor as an assembly.
NOTICE Do not power motor directly with the
battery for a long period. Apply voltage quickly
to ensure that the motor will not overheat at
the end of its stroke.
Windshield Motor Removal
1. Remove windshield and windshield support
together. Refer to WINDSHIELD SUPPORT in
this subsection.
2. Remove front fascia. Refer to FRONT FASCIA
in this subsection.
3. Remove retaining screws of upper wind deflec-
tors.
4. Remove upper wind deflectors from vehicle.

40 rmr2013-044 35
Subsection XX (BODY (RT SERIES))

7. Remove console panel by lifting it toward front.

8. Remove retaining screws from WPM module.

rmr2010-038-049_a

1. Upper wind deflector

2. Retaining screws

5. Remove lower retaining screws from console

panel. rmr2010-038-052_a

1. WPM module
2. Retaining screws

9. Slightly lift WPM module upwards.

10. Disconnect WPM module connector.

rmr2010-038-050_a

1. Console panel
2. Lower retaining screws

6. Remove upper retaining screws from console

panel. rmr2010-038-053_a

1. WPM module connector

11. Disconnect windshield motor wires.

12. Remove windshield base (WPM module) from
vehicle.
13. Remove both side arms as follows:
13.1 Remove retaining nut and washer.
13.2 Remove retaining bolt and washer.
13.3 Remove sleeve.
13.4 Remove side arm.

rmr2010-038-051_a

1. Upper retaining screws

41
36 rmr2013-044
 Subsection XX (BODY (RT SERIES))

NOTICE Do not remove windshield motor WINDSHIELD MODULE (WPM)

from windshield base. Both are calibrated at
the factory. If windshield motor needs to be NOTE: WPM module has 2 functions, it controls
changed, replace windshield base with WPM windshield and parking brake. The WPM module
module and windshield motor as an assembly. is integrated into the windshield base.

Windshield Motor Installation

The installation is the reverse of the removal pro-
cedure. However, pay attention to the following.
Torque WPM module retaining screws to 4.5 N•m
(40 lbf•in) as per the following sequence.

rmr2010-038-058

WPM MODULE AND WINDSHIELD BASE

WPM Module CAN Wire Test

1. Check WPM module power and ground cir-
cuits. refer to WINDSHIELD WIRING DIA-
GRAM in this subsection.
2. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
rmr2011-087-003_a

TIGHTENING SEQUENCE
3. Measure resistance as per the following table.
WPM MODULE CAN WIRE TEST
Torque console panel retaining screws to specifi-
cation as per the following sequence. TEST PROBES OHMS ( )
CONSOLE PANEL RETAINING SCREWS TORQUE DLC (Diagnostic
WPM module Close to
Link Connector)
Upper retaining screws 2.5 N•m (22 lbf•in) pin 6 (CAN HI) 0.2
connector pin 1
Lower retaining screws 3.0 N•m (27 lbf•in) DLC (Diagnostic
WPM module Close to
Link Connector)
pin 8 (CAN LO) 0.2
connector pin 2

NOTE: The DLC (Diagnostic Link Connector) is lo-

cated underneath the right side service panel.
If the CAN wire verification test fails, repair related
circuit.
If the WPM module power, ground and CAN veri-
fication tests are all pass and the WPM module is
inoperative, replace the WPM module.

WPM Module Signal Circuit Continuity

Test
1. Remove body parts as required to access to the
rmr2011-087-002_a WPM module. Refer to WPM MODULE RE-
TIGHTENING SEQUENCE MOVAL in this subsection.
Torque upper wind deflector retaining screws to 2. Disconnect WPM module connector.
4.5 N•m (40 lbf•in).

42
rmr2013-044 37
Subsection XX (BODY (RT SERIES))

NOTICE Do not remove windshield motor

from windshield base. Both are calibrated
at the factory. If WPM module needs to be
changed, replace windshield base with WPM
module and windshield motor as an assembly.

rmr2010-038-053_a

1. WPM module connector

3. Disconnect LH multi-switch (MSL) connector.

Refer to LIGHTS, GAUGE AND ACCESSORIES
subsection.
4. Set the FLUKE 115 MULTIMETER (P/N 529 035
868) to .
5. Measure resistance as per the following table.
TEST PROBES RESISTANCE
MSL switch connector
pin 2 (WH/BK)
Close to 0
WPM module connector
pin 8 (WH/BK)

TEST PROBES RESISTANCE

MSL switch connector
pin 3 (WH/BG)
Close to 0
WPM module connector
pin 6 (WH/BG)

If results are not as per the previous tables:

– Test MSL switch, refer to LIGHTS, GAUGE
AND ACCESSORIES.
– Check connector and terminal condition.
– Repair open circuit in wiring.
If the fault is not found after having carried out the
previous operations:
– Check input voltage at WPM module (PIN-5),
refer to the WIRING DIAGRAM.
– Check ground circuit continuity at WPM module
(PIN-7), refer to the WIRING DIAGRAM.
If the fault is still not found:
– Replace WPM module.

WPM Module Replacement

To replace WPM module, refer to WINDSHIELD
MOTOR in this subsection.
43
38 rmr2013-044
 Subsection 09 (FRAME)

FRAME
NEW
15 N•m
(133 lbf•in)

NEW
24 N•m
(17 lbf•ft)
NEW
10 N•m
(89 lbf•in)

NEW
10 N•m
(89 lbf•in) NEW
24 N•m
(17 lbf•ft)

NEW
15 N•m
(133 lbf•in)
NEW
7 N•m
NEW (62 lbf•in)
24 N•m
(17 lbf•ft)

NEW
10 N•m
(89 lbf•in)
NEW
15 N•m
(133 lbf•in) NEW = Component must be replaced when removed.
rmr2014-035-001_a

rmr2014-035 1
2
 Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RT (SM6/SE6))

SPYDER RT (SM6/SE6)
ENGINE
ROTAX® 1330 ACE, 4-stroke,
Engine type Dual Over Head Camshaft (DOHC),
liquid cooled
Number of cylinders 3
Number of valves 12
Bore 84 mm (3.31 in)
Stroke 80 mm (3.15 in)
Displacement 1 330 cm³ (81.16 in³)
Compression ratio 12:1
Dry sump with integrated oil tank
Type
and oil cooler
BRP Rotax microglass fiber type,
Engine
replaceable
Oil filter
BRP Rotax multi-layer surface filter,
Transmission/HCM
replaceable
400 kPa (58 PSI) @ 4000 RPM / 80°C
Engine oil pressure Minimum
(176°F) oil temperature
Engine oil and
engine oil filter 5.3 L (5.6 qt (U.S. liq.))
replacement
Lubrication SE6 Engine oil,
engine oil
filter and HCM 5.6 L (5.9 qt (U.S. liq.))
surface filter
replacement
Engine oil Engine oil and
SM6 engine oil filter 4.9 L (5.2 qt (U.S. liq.))
replacement
XPS synthetic blend oil (summer
grade) (P/N 293 600 121) or a
5W40 motorcycle oil (semi-synthetic
Recommended
(minimum) or synthetic) meeting the
requirements for API service SL, SJ,
SH or SG classification
3 into 1 manifold, primary muffler with
Exhaust system
catalytic converter, with secondary muffler
Air filter Paper element
Valve adjustment Not required
Intake valve opening 5° ATDC @ 1 mm (.04 in)
Intake valve closing 40° ABDC @ 1 mm (.04 in)
Exhaust valve opening 50° BBDC @ 1 mm (.04 in)
Exhaust valve closing 10° BTDC @ 1 mm (.04 in)
Intake Not adjustable
Valve clearance
Exhaust Not adjustable

rmr2014-036 1
Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RT (SM6/SE6))

ENGINE
4.966 mm to 4.980 mm
New
Intake (.1955 in to .1961 in)
Service limit 4.940 mm (.1945 in)
Valve stem diameter
4.956 mm to 4.970 mm
New
Exhaust (.1951 in to .1957 in)
Service limit 4.940 mm (.1945 in)
New 0.005 mm (.0002 in)
Valve out of round Intake and exhaust
Service limit 0.010 mm (.0004 in)
5.000 mm to 5.012 mm
New
Valve guide diameter (.1969 in to .1973 in)
Service limit 5.050 mm (.1988 in)
New 1.05 mm to 1.35 mm (.041 in to .053 in)
Intake
Service limit 1.70 mm (.067 in)
Valve seat contact width
New 1.30 mm to 1.50 mm (.051 in to .059 in)
Exhaust
Service limit 1.80 mm (.071 in)
New 0.03 mm (.0012 in)
Cylinder head warpage
Service limit 0.05 mm (.002 in)
28.354 mm to 28.370 mm
New
Hydraulic valve lifter diameter (1.1163 in to 1.1169 in)
Service limit 28.340 mm (1.1157 in)
Hydraulic valve lifter radial clearance Service limit 0.100 mm (.0039 in)
New 31.35 mm (1.2343 in)
Valve spring free length
Service limit 29.50 mm (1.1614 in)
Chain guide groove depth Service limit 0.5 mm (.02 in)
14.992 mm to 15.000 mm
Intermediate timing gear shaft - Needle bearing New
(.5902 in to .5906 in)
running surface diameter
Service limit 14.985 mm (.59 in)
Chain guide (Tensioner Side) groove depth Service limit 0.5 mm (.02 in)
83.950 mm to 83.966 mm
New
Piston measurement (3.3051 in to 3.3057 in)
Service limit 83.940 mm (3.3047 in)
0.027 mm to 0.057 mm
New
Piston/cylinder clearance (.0011 in to .0022 in)
Service limit 0.070 mm (.0028 in)
1st Upper compression ring, L-section
Piston ring type 2nd Lower compression ring, taper-face
3rd Oil scraper ring

2 rmr2014-036
 Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RT (SM6/SE6))

ENGINE
New 0.025 mm to 0.070 mm (.001 in to .0028 in)
Upper compression ring
Service limit 0.100 mm (.0039 in)
0.020 mm to 0.060 mm
New
Ring/piston groove Lower compression ring (.0008 in to .0024 in)
clearance Service limit 0.100 mm (.0039 in)
0.010 mm to 0.045 mm
New
Oil scraper ring (.0004 in to .0018 in)
Service limit 0.080 mm (.0031 in)
New 0.10 mm to 0.30 mm (.0039 in to .0118 in)
Upper compression ring
Service limit 0.40 mm (.0157 in)
New 0.35 mm to 0.55 mm (.0138 in to .0217 in)
Ring end gap Lower compression ring
Service limit 0.60 mm (.0236 in)
New 0.20 mm to 0.70 mm (.0079 in to .0276 in)
Oil scraper ring
Service limit 0.80 mm (.0315 in)
New 0.036 mm (.0014 in)
Cylinder taper
Service limit 0.050 mm (.002 in)
New 0.008 mm (.0003 in)
Cylinder out of round
Service limit 0.020 mm (.0008 in)
Crankshaft plain bearing inside diameter Service limit 50.085 mm (1.9719 in)
Balancer shaft plain bearing inside diameter Service limit 36.080 mm (1.4205 in)
38.350 mm to 38.550 mm
New
Intake (1.5098 in to 1.5177 in)
Service limit 38.300 mm (1.5079 in)
Camshaft lobe height
38.800 mm to 39.000 mm
New
Exhaust (1.5276 in to 1.5354 in)
Service limit 38.750 mm (1.5256 in)
31.959 mm to 31.975 mm
New
PTO side (1.2582 in to 1.2589 in)

Camshaft journal Service limit 31.950 mm (1.2579 in)

diameter 22.967 mm to 22.980 mm
New
Center and clutch side (.9042 in to .9047 in)
Service limit 22.960 mm (.9039 in)
New 0.025 mm to 0.066 mm (.001 in to .0026 in)
PTO side
Camshaft journal radial Service limit 0.075 mm (.003 in)
clearance New 0.020 mm to 0.054 mm (.001 in to .002 in)
Center and clutch side
Service limit 0.065 mm (.0026 in)
49.984 mm to 50.000 mm
New
Crankshaft bearing journal diameter (1.9679 in to 1.9685 in)
Service limit 49.980 mm (1.9677 in)
Crankshaft radial play Service limit 0.090 mm (.0035 in)

rmr2014-036 3
Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RT (SM6/SE6))

ENGINE
0.080 mm to 0.313 mm
New
Crankshaft axial play (.0031 in to .0123 in)
Service limit 0.350 mm (.0138 in)
47.984 mm to 48.000 mm
New
Crankshaft pin diameter (1.8891 in to 1.8898 in)
Service limit 47.980 mm (1.889 in)
36.019 mm to 39.3035 mm
New
Balancer shaft bearing journal diameter (1.4181 in to 1.5474 in)
Service limit 36.015 mm (1.4179 in)
Balancer shaft radial play Service limit 0.080 mm (.0031 in)
New 0.10 mm to 0.23 mm (.0039 in to .0091 in)
Balancer shaft axial e
Service limit 0.30 mm (.012 in)
Connecting rod big end diameter
Service limit 48.060 mm (1.8921 in)
(with plain bearings)
Connecting rod big end radial play Service limit 0.080 mm (.0031 in)
New 0.100 mm to 0.352 mm (.004 in to .014 in)
Connecting rod big end axial play
Service limit 0.400 mm (.016 in)
20.010 mm to 20.020 mm
New
Connecting rod small end diameter (.7878 in to .7882 in)
Service limit 20.025 mm (.7884 in)
Connecting rod small end radial play Service limit 0.045 mm (.0018 in)
19.995 mm to 20.000 mm
New
Piston pin diameter (.7872 in to .7874 in)
Service limit 19.990 mm (.787 in)
Oil pump radial clearance Service limit 0.25 mm (.0098 in)
Oil pump axial clearance Service limit 0.15 mm (.0059 in)
Alternator shaft plain bearing diameter Service limit 30.070 mm (1.1839 in)
29.987 mm to 30.000 mm
New
Alternator shaft journal diameter (1.1806 in to 1.1811 in)
Service limit 29.977 mm (1.1802 in)
11 N•m to 15 N•m
New
Alternator clutch slipping moment (97 lbf•in to 133 lbf•in)
Service limit 10 N•m (89 lbf•in)

CLUTCH (SE6)
Hydraulic clutch + wet multi-plate clutch
Type
automatically controlled by TCM
Clutch fluid Use engine oil for lubrication
New 23.33 mm (.919 in)
Clutch spring free length
Service limit 22.00 mm (.866 in)

4 rmr2014-036
 Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RT (SM6/SE6))

CLUTCH (SE6)
41.48 mm to 41.72 mm
Clutch plate assembly New
(1.633 in to 1.643 in)
(friction and steel driven plates) thickness
Service limit 38.50 mm (1.516 in)
Clutch plate warpage Service limit 0.15 mm (.0059 in)
New 2.3 mm to 2.5 mm (.091 in to .098 in)
Disc spring free length
Service limit 2.1 mm (.083 in)
Disc spring warpage Service limit 0.2 mm (.008 in)
30.015 mm to 30.035 mm
New
Clutch gear bearing sleeve inner diameter (1.1817 in to 1.1825 in)
Service limit 30.040 mm (1.1827 in)
New 29.46 mm (1.16 in)
Compression spring free length
Service limit 29.00 mm (1.142 in)
New 10.99 mm (.433 in)
Anti backlash spring free length
Service limit 10.50 mm (.413 in)

CLUTCH (SM6)
Wet, multi-plate, manual operation through
Type
a hydraulic piston, vacuum assist
Recommended Brake fluid DOT 4
Clutch fluid
Capacity 60 ml (2 U.S. oz)
New 59.95 mm (2.36 in)
Clutch spring free length
Service limit 58.50 mm (2.303 in)
41.48 mm to 41.72 mm
Clutch plate assembly New
(1.633 in to 1.643 in)
(friction and steel driven plates) thickness
Service limit 38.50 mm (1.516 in)
Clutch plate warpage Service limit 0.15 mm (.0059 in)
30.015 mm to 30.035 mm
New
Clutch gear bearing sleeve inner diameter (1.1817 in to 1.1825 in)
Service limit 30.040 mm (1.1827 in)
New 29.46 mm (1.16 in)
Compression spring free length
Service limit 29.00 mm (1.142 in)
New 10.99 mm (.433 in)
Anti backlash spring free length
Service limit 10.50 mm (.413 in)

GEARBOX
Sequential Electronic 6-speed
SE6 semi-automatic with remote electronic
Type reverse interlock
Sequential Manual 6-speed with remote
SM6
electronic reverse interlock
Primary reduction gear ratio 75/52

rmr2014-036 5
Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RT (SM6/SE6))

GEARBOX
1st 37/15
2nd 32/17
3rd 35/23
Gear ratio 4th 33/26
5th 30/28
6th 29/32
Reverse 32/13
New 5.825 mm to 5.900 mm (.2293 in to .2323 in)
Shift fork claw thickness
Service limit 5.750 mm (.2264 in)
New 5.958 mm to 5.970 mm (.2346 in to .235 in)
Shift fork engagement pin diameter
Service limit 5.940 mm (.2339 in)
New 6.100 mm to 6.200 mm (.2402 in to .2441 in)
Width of shift fork engagement groove
Service limit 6.230 mm (.2453 in)
42.000 mm to 42.016 mm
1st, 2nd, 4th and New
(1.6535 in to 1.6542 in)
Reverse (main shaft)
Service limit 42.020 mm (1.6543 in)
33.000 mm to 33.016 mm
New
3rd (1.2992 in to 1.2998 in)

Free pinion bore Service limit 33.020 mm (1.3 in)

diameter 26.000 mm to 26.013 mm
New
5th (1.0236 in to 1.0241 in)
Service limit 26.020 mm (1.0244 in)
35.000 mm to 35.016 mm
New
6th (1.378 in to 1.3786 in)
Service limit 35.020 mm (1.3787 in)
29.987 mm to 30.000 mm
New
Clutch side (1.1806 in to 1.1811 in)
Service limit 29.980 mm (1.1803 in)
36.989 mm to 37.000 mm
Main shaft bearing New
Free pinion bearings (1.4563 in to 1.4567 in)
journal diameter
Service limit 36.984 mm (1.4561 in)
34.986 mm to 34.997 mm
New
PTO side (1.3774 in to 1.3778 in)
Service limit 34.980 mm (1.3772 in)

6 rmr2014-036
 Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RT (SM6/SE6))

GEARBOX
29.980 mm to 29.993 mm
Clutch drum gear New
(1.1803 in to 1.1808 in)
journal
Service limit 29.975 mm (1.1801 in)
34.975 mm to 34.991 mm
New
Clutch side (1.377 in to 1.3776 in)
Service limit 34.970 mm (1.3768 in)
29.991 mm to 30.000 mm
New
Free pinion bearing 6th (1.1807 in to 1.1811 in)

Clutch shaft journal Service limit 29.985 mm (1.1805 in)

diameter 27.991 mm to 28.000 mm
New
Free pinion bearing 3rd (1.102 in to 1.1024 in)
Service limit 27.985 mm (1.1018 in)
21.991 mm to 22.000 mm
New
Free pinion bearing 5th (.8658 in to .8661 in)
Service limit 21.985 mm (.8656 in)
19.987 mm to 20.000 mm
New
PTO side (.7869 in to .7874 in)
Service limit 19.980 mm (.7866 in)

COOLING SYSTEM
Liquid cooled, double radiators with
Type two reversible cooling fans (temperature
and speed controlled)
Ethyl glycol/water mix
(50% coolant, 50% water).
Use premixed coolant sold by BRP:
Type
Coolant Long life antifreeze (P/N 219 702 685) or
coolant specifically designed for
aluminum engines
Capacity 3.75 L (1 U.S. gal.)
Thermostat Opening temperature 80°C (176°F)
Turn on @ 102°C (216°F)
Radiator fan
Turn off @ 96°C (205°F)
Radiator cap opening pressure 90 kPa (13 PSI)

ELECTRICAL SYSTEM
850 W @ 2910 engine RPM, 1250 W
Alternator output
@ 1720 engine RPM
Ignition system type Electronic ignition with dual output coil
Ignition timing Electronically controlled, not adjustable
Quantity 3
NGK MR7BI-8 (iridium)
Spark plug Type (apply heat-sink paste P12 (P/N 420
897 186) on spark plug thread)
Gap (not adjustable) 0.7 mm - 0.8 mm (.028 in - .031 in)

rmr2014-036 7
Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RT (SM6/SE6))

ELECTRICAL SYSTEM
8100 RPM with engaged drivetrain
Engine RPM limiter setting Forward
7500 RPM with open clutch or on neutral
Type Maintenance free
Model Yuasa YTX24HL-BS
Battery
Voltage 12 V
Nominal rating 21A•h
High Beam: Halogen, 2 x 65 W (type H9)
CE models
Headlight Low Beam: Halogen, 2 x 60 W
Other Models Halogen, 2 x 60 W (type H4)
RT-S and
Fog lights 2 x 35 W halogen
RT Limited
Bulb: 2 x 5 W
Japanese Model
Taillight/brake light LED,3.1 W total
Other Countries LED,3.1 W total
Front LED,4.5 W each side
Turn signal lights LED, 2 x 10 W
Rear
CE models: 2 x 20 W
RT 2 x 5 W
Front RT-S and
Position lights LED 2 x 1 W
RT Limited
Rear 2 x 5 W
License plate light 5 W
Backup light 2 x 21 W
RT-S and
Day light 2 x 0.5 W
RT Limited
RT-S and
Front storage compartment light 0.15 W
RT Limited

8 rmr2014-036
 Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RT (SM6/SE6))

ELECTRICAL SYSTEM
LEFT fuse box F1: Cluster, DLC, DESS 15 A
F2: Wakeup ECM, VCM, MSR, DESS,
10 A
SAS, YRS, PRS
F3: Alternator 10 A
F4: WPM, PBM 20 A
F5: ECM 5 A
Fuses F6: Injectors and ignition coils 15 A
F7: Wakeup TCM, DPS, Cluster,
Fuel gauge and Coolant temperature 10 A
gauge
F8: HO2S, CAPS, Fuel pump, EVAP,
15 A
CSV, PSR
J1: VCM pump 40 A
J2: VCM valves 25 A
J3: DPS 40 A
J4: Main control (F1, F2,R4, R5) 40 A
J5: Not used Not used
R1: Reverse actuator —
R2: Pre-starting —
R3: Main relay and accessories —
Relays (in left fuse box)
R4: Suspension —
R5: Not used —
R6: Main head lamp —
RIGHT fuse box F1: Daylights, Parking lamps, Plate
15 A
lights
F2: Brake lights, Hazard 10 A
F3: VBattery, Radio 15 A
F4: Trailer Module 10 A
F5: Horn, Load shedding 25 A
Fuses F6: DC plugs, Vkey 5 A
F7: DC Plugs, Vbat 5 A
F8: Not used Not used
J1: Cooling fan 30 A
J2: Accessories 40 A
J3:TCM solenoids 20 A
J4: LO headlamps 30 A
J5: HI headlamps 20 A

rmr2014-036 9
Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RT (SM6/SE6))

ELECTRICAL SYSTEM
R1: HI headlamps —
R2: LO headlamps —
R3: Cooling fan —
Relays (in right fuse box)
R4: Load shedding —
R5: Fan reverse #1 —
R6: Fan reverse #2 —

FUEL SYSTEM
Multi-point Electronic Fuel Injection (EFI)
with ETC (Electronic Throttle Control),
Type
Fuel delivery system single throttle body (54 mm) with
an actuator
Operating pressure 400 kPa (58 PSI)
Fuel pump Type Electrical module in fuel tank
900 ± 50 RPM
Idle speed
(electronically controlled - not adjustable)
Use Premium unleaded gasoline with
an AKI (R+M)/2 octane rating of
Fuel 91, or an RON octane rating of 95.
Do NOT use fuel from fuel pumps
labeled E85.
Fuel tank capacity 26 L (6.9 U.S. gal.)

DRIVE SYSTEM
Type Drive belt
Final drive
Ratio 28/79
Material Carbon reinforced
Drive belt 1 050 N ± 150 N (236 lbf ± 33.7 lbf)
Tension (with rear wheel lifted)
(fully extended suspension)
Final drive ratio 2.8:1

STEERING
Turning radius 3 m (9.8 ft)
0° ± 0.2°
Total toe-in (vehicle on ground) (see STEERING (DPS) AND
WHEELS subsection
Camber angle 0° ± 0.5°
Tie-rod maximum length unengaged threads 12 mm (.4724 in) maximum
Tie-rod maximum length (c/c ball joints) 577 mm (22.72 in)

SUSPENSION
FRONT
Suspension type Double suspension arm with anti-roll bar
Suspension travel 174 mm (6.9 in)

10 rmr2014-036
 Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RT (SM6/SE6))

SUSPENSION
Qty 2
Shock absorber
Type Oil damper
Spring free length 235 mm ± 3 mm (9.3 in ± .1 in)
Spring preload adjustment Not adjustable

REAR

Swing arm with mono shock with a manually

RT
adjustable pneumatic preload
Suspension type Swing arm with mono shock. Air Controlled
RT-S,
Suspension (ACS). Compressor-controlled
RT Limited
with remote adjustment only.
Through air pressure setting
RT
135 kPa to 625 kPa (20 PSI to 90 PSI)
Preload adjustment
RT-S,
5 positions selectable through the cluster
RT Limited
Suspension travel 152 mm (6 in)
Qty 1
Shock absorber
Type Oil damper
Spring free length 278 mm ± 3 mm (10.9 in ± .1 in)
Part number indicated on spring, no
Spring color code
color code available

BRAKES
Foot-actuated. Fully integrated hydraulic
Type
3-wheel braking system with ABS and EBD
Dual discs of 270 mm (10.6 in) with
Front brake
4 piston calipers
Single disc of 270 mm (10.6 in) with
Rear brake
1 piston caliper
Capacity 530 ml (17.9 U.S. oz)
Brake fluid
Type DOT 4
Mechanical, electrically actuated to
Parking brake
the rear caliper
Front 4 pistons caliper
Caliper
Rear Single piston. Sliding pins caliper
Front Sintered
Brake pad material
Rear Sintered
Minimum brake pad thickness 1 mm (.04 in)
Minimum brake disc thickness Front/rear 6.4 mm (1/4 in)
Maximum brake disc warpage 0.1 mm (.004 in)

rmr2014-036 11
Section 08 TECHNICAL SPECIFICATIONS
Subsection 01 (SPYDER RT (SM6/SE6))

TIRES AND WHEELS

TIRES
Front KR31 165/55/R15 (special motorcycle type)
Type (use BRP recommended tires)
Rear KR21 225/50/R15 (special motorcycle type)
Minimum: 117 kPa (17 PSI) (1.17 bar).
Front
Recommended: 138 kPa (20 PSI) (1.38 bar)
Pressure
Minimum: 179 kPa (26 PSI) (1.79 bar).
Rear
Recommended: 193 kPa (28 PSI) (1.93 bar)
Front 2.5 mm (3/32 in)
Minimum tire thread depth
Rear 4.0 mm (5/32 in)
WHEELS
Front 381 mm x 128 mm (15 in x 5 in)
Size
Rear 381 mm x 178 mm (15 in x 7 in)
Front wheel nuts torque 109 N•m (80 lbf•ft)
Rear drive axle nut torque 225 N•m (166 lbf•ft)

DIMENSION
Overall length 2 667 mm (105 in)
Overall width 1 572 mm (62 in)
Overall height 1 510 mm (59 in)
Seat height 772 mm (30.4 in)
Wheel base 1 714 mm (67.5 in)
Front wheel track 1 384 mm (54.5 in)
Ground clearance (front and under engine) 110 mm (4.3 in)

WEIGHT AND LOADING CAPACITY

Dry weight 459 kg (1,012 lb)
Capacity 55 L (14.5 U.S. gal.)
Front storage compartment
Maximum load 16 kg (35 lb)
Capacity 1.2 L (.32 U.S. gal.)
Glove box
Maximum load 2 kg (4.4 lb)
Capacity 49.7 L (13.1 U.S. gal.)
Side storage compartment
Maximum load 7 kg (15 lb)
Capacity 40.5 L (10.7 U.S. gal.)
Rear storage compartment
Maximum load 9 kg (20 lb)
Total vehicle load allowed (including operator, passenger, cargo and added accessories) 224 kg (494 lb)
Gross vehicle weight rating (GVWR) 680 kg (1,499 lb)
Maximum weight on trailer tongue 18 kg (40 lb)
Maximum towed weight (trailer and cargo) 181 kg (400 lb)

12 rmr2014-036
 Subsection 01 (WIRING DIAGRAM INFORMATION)

WIRING DIAGRAM INFORMATION

GENERAL Relay Identification
The relays are identified on the WIRING DIA-
WIRING DIAGRAM LOCATION GRAM as per following example:
Wiring diagrams are located in the WIRING DIA-
GRAMS BOOKLET (P/N )

WIRING DIAGRAM CODES

Fuse Identification
The fuses are identified on the WIRING DIAGRAM
as per following example:

rmr2013-040-017_a

RELAY IDENTIFICATION
1. Relay location:
LFB = Left fuse box
RFB = Right fuse box
2. Relay name
3. Relay identification and its position in fuse box (position R5)
4. Terminal position in fuse box

Wire Identification
The wires used in the electrical system are
rmr2013-040-015_a
identified on the WIRING DIAGRAM using an
J-CASE FUSE IDENTIFICATION
1. Fuse location: alphanumeric code which, identifies the color and
LFB = Left fuse box the AWG (American Wire Gauge) gauge of a wire.
RFB = Right fuse box
2. Fuse name When a 2-color scheme is used, the first color
3. Fuse identification is the main color while the second color is the
4. Fuses (F) and relays (R) supplied by that fuse
5. Fuse amperage rating tracer color.
6. Position of fuse in fuse box (position J4)

OR/WH-20
1 2 3
rmr2008-038-001_a

1. Main wire color

2. Tracer color
3. Wire gauge

The splices used in wiring harnesses are identi-

fied on the WIRING DIAGRAM using an alphabetic
code that identifies the color of all the wires that
rmr2013-040-016_a are joined together. Ex: JT GY/GN.
BLADE FUSE IDENTIFICATION
1. Fuse location
LFB: Left fuse box Connector Identification
RFB: Right fuse box
2. Fuse identification The connectors used in the electrical system are
3. Components supplied by that fuse identified on the WIRING DIAGRAM using an al-
4. Fuse amperage rating
5. Position of fuse blades in fuse box (position A8 and B8) phanumeric code which identifies the following:

rmr2014-037 1
Subsection 01 (WIRING DIAGRAM INFORMATION)
-1
PS
5-T
1 2
rmr2008-038-002_a
1. Connector location in vehicle
2. Connector code
3. Terminal position in connector
Some electrical components have more than one
connector attached to them. In theses cases, the
connectors will be identified as follows.
MULTIPLE CONNECTOR IDENTIFICATION
EXAMPLE
VR2-1 Voltage regulator connector 2, pin 1
ECMB-L1 ECM connector B, pin L1
Connector Location in Vehicle
It is provided using a vehicle outline and tables
on the wiring diagram. The zones identified by a
number on the vehicle indicate the general area in
which the connector can be found. A body panel
or component must usually be removed to access
the connector.
NOTE: Use the connector location in conjunction
with the vehicle outline on the WIRING DIAGRAM
to find where in vehicle the connector is located.
Connector Code
It refers to the component or system wiring har-
ness the connector is attached to.
NOTE: Use the connector code table in POWER
DISTRIBUTION AND GROUNDS subsection for a
description of the connectors.
Terminal Position in Connector
The last digit(s) after the dash identifies the termi-
nal (pin) position.
2 rmr2014-037
TROUBLESHOOTING
DIAGNOSTIC TIPS
IMPORTANT: When trying to solve an electrical
problem, check the following:
– The ignition switch is turned ON.
– The engine RUN/STOP switch is in RUN posi-
tion.
– The battery condition as well as its cables and
connections.
– The system fuse condition of the related circuit
using an ohmmeter.
– Ensure a positive electrical connection of the
3 fuse to the fuse holder contacts.
– Examine related circuit harness and connec-
tions.
Install a battery charger before any tests that in-
volve prolonged "key ON". If system voltage is too
low, some accessories will be shut off and test
results can be altered. Also, it is advisable to re-
move the headlight relay while testing, however
fault codes will have to be erased afterwards.
Pay particular attention to electrical connectors
and ensure that pins are not out of their housings,
loose, or damaged. The troubleshooting proce-
dures may not cover problems resulting from one
of these causes.
NOTE: Ensure all terminals are properly crimped
on wires and connector housings are properly fas-
tened. When replacing any electric or electronic
part(s), always check electrical connections.
Make sure that they are clean, corrosion-free,
tight and make good contact. The voltage and
current might be too weak to go through dirty or
corroded connector pins or terminals.
If a fault is intermittent and cannot be found
through static continuity checks, it may indicate:
– A loose connection
– A bad splice in a harness
– A pin that is unlocked in a connector and barely
making contact
– An intermittent electronic component within a
module.
Do the following:
– Try moving the harness and connectors to sim-
ulate vehicle vibration as you carry out your
checks with the multimeter.
– Try spraying water to the harness, connectors
or sensors to simulate riding under the rain or
high humidity as you carry out your checks with
the multimeter.
 Subsection 01 (WIRING DIAGRAM INFORMATION)

IMPORTANT: In an electrical circuit, the bat-

tery usually provides power to a switch, which
then supplies the electric component when the
switch is closed (low power circuits). There-
fore the switch opens and closes the positive
side of the circuit. In circuits controlled by the
ECM and other modules, the battery supplies
the electric component, and the ECM/module
acts as the switch which completes the circuit to
ground. A relay acts as a remote switching device
for higher power components or for supplying
multiple circuits. Take this into account when
troubleshooting the electrical system.
Pay attention to ground wires. They could be-
come loose or corroded which causes them to
act as an additional load in a circuit, dropping
voltage and reducing current to components.
Some components may be grounded through
their outer casing and mounting hardware. This
should also be considered.

rmr2014-037 3
Subsection 01 (WIRING DIAGRAM INFORMATION)

Simplifying Electrical System Tests

For complex systems where there are electronic modules, sensors, actuators, relays etc., it is often
beneficial for diagnosing problems to divide up the system into some basic smaller subsystems, to help
narrow down where the problem lies.
Use B.U.D.S. to check for fault codes, refer to COMMUNICATION TOOLS AND B.U.D.S. and also DIAG-
NOSTIC AND FAULT CODES subsections. Follow Service Actions listed in B.U.D.S..
COMMON SUBSYSTEM GUIDELINE
POWER AND GROUNDS – Battery – Check if a group of components or systems
– Fuses stopped working or if nothing works (lights, gauge,
– Relays etc.).
– Connections – Start from the power source (battery) and move
outwards towards the modules, checking for
voltage at each connection.
– Check grounds and battery (+) using a voltmeter.
– Disconnect and test wiring.
INPUTS AND OUTPUTS – Sensors – View monitoring functions in B.U.D.S.
– Gauges – Activate each item and monitor response.
– Actuators – Disconnect and test wiring.
– Motors
COMMUNICATION – Between Modules and – View monitoring functions in B.U.D.S.
with B.U.D.S. – Disconnect and test wiring.

For ALL wiring tests, you need to check for:

POSSIBLE PROBLEM COMMON CAUSE
– Open circuit – Loose terminals, broken wires.
– Shorts to ground (battery -) – Wires rubbed through, water in connectors.
– Shorts to battery (+) – Corroded wires and terminals.
– Shorts to other circuits
– Higher resistance than desired

4 rmr2014-037
 A

S
RT ELECTRICAL SYSTEM
SPYDER ROADSTER 2014
AL

+
T- AL LFB
3 T RD- 6 -B RD- 6
6

(1/2)
ECM
1

1
R
ECMB- F4

L
AL R6 R6

RTL
RRS2
RRS1
RRH
RLS2
RLS1
RLH
RHS
RDO1
RCS
R1
PRC
PL
LTL
LCS
GPS2
DIN
DC4
DC3
CIC2
CIC1
AUX1
PTS
AAPTS
ACRONYMS ZONES
T- OG/YE- 18 LFB
WH/RD- 20 -2 -1 YE/GN- 16 VT/PK- 16

ALTERNATOR
4 -A

JT BK2A
6

S
F
100 A
AL

ALT

JT RD2
10
T-

JT RD1
10 WATTS
1%
OHMS
50
RESISTOR
R10
YE/GN- 18
2

RD- 6
BA

8
15
15
8
14
14
7
7
8
8
8
8
17
7
7
8
8
15
15
7
7
8
5
6
T2

BA
BK- 6

(F3)
ALTERNATOR
LFB
BK- 6 T1 RD- 6

JT RD3
RD- 6

WINDSHIELD MOTOR
CARGO HARNESS
710003809
AAPTS EXTENSION
710003810
CABLES #

BRAKE MODULE
PARKING
WINDSHIELD &
WPM
-
WP
BK- 12

RD- 6
BK- 6

RD- 6
WM M-

JT BK6

21 AH
12 VDC
BATTERY
BAT
GN/OG- 20 2 GY/LT GN- 18 2
BK- 12

JT BK5

WM
GN
BK- 12

JT BK3A
D1

JT BK4
BK- 12
PIC WP

+
D3 CH BK- 6 BU/OG- 20 WM1 WP

JT BK3
D3 -C 1- AS GY/RD- 18 M- M- LFB RF
-A G BK- 12 B
9 8
BK- 20 DIC BK- 20 WP
2- WH/BK- 20

JT BK2
M-

BK- 6
F

-
D3 DIODE
JT BK10

PARKING BRAKE
6
DIC DIC WP LFB
BK- 16 DIC

(BRP USING ONLY)

BK- 16 GN/OG- 20 PM2 M- WP
FLH
ECMB
DPS2
DPS1
DLC3
DLC2
DLC1
DIC3
DIC2
DIC1
DESS
DC2
DC1
D2
CIC2
CIC1
CES
BLS
BFS2
BFS1
BA
ASC
ALT
TCS
ACRONYMS ZONES
2- VT/LT GN- 18 3- VT/LT GN- 18 WH/BG- 20 2- -B

MOTOR
R C 4 M- D 5

JT BK9

PM
5
CIC WP DIC PIC PB LFB
BK- 16 1- BK- 16 M- BG/OG- 16 3- BG/OG- 16 1- S- -A
C VT/PK- 16

BK- 12
K 2

(1/2)
SWITCH
BRAKE
PARKING
PBS
5

TANK
FUEL
WP 10 A
2

2
M-

+
BK- 16 CIC BK- 16 DIC PB

20
GN PM DIC WP PIC
VT/LT BU- 18 VT/LT BU- 18 11 YE/LT GN- 20 YE/LT GN- 20 S-
6
5
9
9
1
1
1
5
5
5
1
1
1
1
7
7
6
21
8
8
18
23
5
16

M
2 D7 BU/OG- 20 1 3- M- 2- 1- YE/LT GN- 20

JT BK8
-A 3

OT
B C L
WP 1

BK- 16
M- DIC PIC P
BK- 16 GN/WH- 20 3 WP
M- LT BU/GN- 20 3-
D LT BU/GN- 20 1-
J
LT BU/GN- 20 BS- 1

MAIN HARNESS
710003436 & 710003646
710003436 ONLY

MAIN HARNESS
710003436 & 710003646
710003809 CARGO HARN
CABLES #

JT GN/WH

(F4)
WPM
LFB
WPM- 7 12
PB
BK- 16 GY/OG- 20 GY/OG- 20 GY/OG- 20 S-
OG/RD- 18

CAN-LO
PBS- 8

CAN-HI
CAN-LO
CAN-HI
7

WH/BK- 20

WH/BG- 20

WH/BG- 20
WH/BK- 20
CIC HB OG/RD- 18 PIC
1- S- BK- 20 1-

(1/6)

CL
L 3 H

FREE
CL
-1

ON
HB DIC FG

BK- 16
BK- 18 RD- 18 GN/WH- 20 GN/WH- 20 7

JT BK7

P
BK- 20 1-

BK- 16
S- 2- GN/WH- 20
1 E G

FUEL GAUGE
FG

PARKING
FG

FG
BU- 18 BK/VT- 18 1- 1- OG/RD- 18

SWITCH

JT WH/BK 3
JT WH/BK 2
JT WH/BK 1
JT WH/BG 3
JT WH/BG 2
JT WH/BG 1
JT WH/GN
JT WH/BN
S P

BRAKE

HBS
DIC

L
1- FP- FP- DIC FG
BU- 20 BU- 20 BU- 20 2 OG/RD- 20

JT BU
PIC1
PBM2
PBM1
MSR2
MSL3
MSL2
LPS
LFB
LED
LCF
LBHL
KIC
HO2S1
HN2
HN1
HIC
HBS
GND1
FSS
FSA
FRH
FPL2
FPL1
FP
ACRONYMS ZONES CABLES #
K D A 1-
D

JT OG/RD2
BK/VT- 20 BK/VT- 20

FUEL LEVEL

CTG COOLANT
TEMP GAUGE

JT WH/BG5
FP 1/2
CT

SENSOR
OG/RD- 18

JT WH/BK5
G1
-P
5
6
6
6
6
6
21
1
1
1
3
2
8
5
5
5
6
9
1
1
6
9
9
6
CT CT DIC
G1 G2 OG/RD- 20
-G 1-
CL P
-8
3

3
CL

MAIN HARNESS
710003436 & 710003646
CT -2
BK/VT- 18 G1
-S BG/BK- 18 CL
-2 OG/RD- 20 OG/RD- 20 OG/RD- 20

JT BK/VT
CL 4
-1 DIC
5
BU- 20 CL WH/BG- 20 WH/BG- 20 1- WH/BG- 20

CLUSTER 2/6
-2 S
CL 3
-1 DIC
2 DIC

CL
BK/VT- 18 CL WH/BK- 20 2- WH/BK- 20 1-
R
WH/BK- 20
-9 B
LFB LFB
RD/YE- 18 -B -J
RD/YE- 18 8 4
EC
MS MB EC DE LFB
-E MB SS RD/WH- 16

JT RD/WH
BK/YE- 20 RD/YE- 16 RD/WH- 12

JT RD/YE
R2 4 -B -A
BK/YE- 20 -3 -B

40
2 8

D.E.S.S.
ANTENNA
ANT
FG1
DIC3
DIC2
DIC1
CTG2
CTG1
CL
YRS
VSS3
VSS2
VSS1
VCM
TCMB
TAS
STS2
STS1
SRV
SPS
SAS
RFB
RCF
RBHL
R6
PRS
ACRONYMS ZONES

EC DE AN

15
(STOP SWITCH)
SS

JT BK10
JT BK9

JT BK8
JT BK7

JT BK6
JT BK5
JT BK4
JT BK3
JT BK2
MB

MODULE
D.E.S.S
DESS
BK- 20 VT- 20 VT- 20 BK- 20 T-
-C BK- 20
D3- C
D3- A -F 2

STOP
2

RUN

(J4)
F1, R4, R5, F2
MAIN FUSE
LFB
MSR 1/4
AN
BK/BG- 20 BK- 20 BK- 20 T- BK- 20

SWITCH
MULTI.
1

(F1)
DLC
POWER
HAZARD
CLUSTER
LFB
RIGHT
2
5
5
5
2
2
2
2
9
9
9
9
6
6
1
1
8
23
9
1
1
4
5
13

EC DE
MB OG/PK- 20 SS
-A -A OG/PK- 20
EC 2
MB EC
-L MB OG/PK- 20
DASHBOARD HARNESS
710003717

MAIN HARNESS
710003436 & 710003646
710003646 ONLY

MAIN HARNESS
710003436 & 710003646
CABLES #

BK- 16 1 -B
EC 4
MB EC
-M MB
BK- 16 2
-A WH/GN- 20
4
4

4
MS EC EC
R2 KS MB MB
-5 1- BK- 16 -M -C WH/BN- 20

ECM ENGINE CONTROL MODULE (2/2)

JT BK

+
1

SENSOR #1
KNOCK
KS1
3 2
EC EC

PIEZO
KS MA

BK- 20
BE/BU- 20 MB
BK- 20 1-
2
-G
2 -C WH/BK- 20
1

S
EC
MA
YE/BU- 20

INJECTOR
-C WH/BG- 20

CLUTCH
3
INJ

INJ1
EC MO HIC

SIDE
1-
GPS2
FBG
R5
R4
PIC1
PBS
FHS
FGS
D3
CSS
WPM
WM2
WM1
RHL
RDL
LHL
LDL
FRS2
FRS1
FRF
FLS2
FLS1
FLF
FG2
ACRONYMS ZONES

MA -1

#1
-B T1 1

+
EC 3

THROTTLE ACCELERATOR SENSOR

MB
VT- 22 TAS -J INJ

SPLICE 1
S2
- D OG/LT BU- 20 3 BN/RD- 18 1- VT/BU- 18 VT/BU- 16 VT/BU- 16

CLUTCH

COIL1
HALL
EC
MB CO 2
TAS EC IL1

COIL
SIDE
BU- 22 -A

1/6
HIC
MA -3

#1
- F GN/LT GN- 20
8
8
5
5
5
12
12
12
5
12
2
2
2
24
24
20
20
24
24
11
20
20
10
2

3 -M

-
EC 4
TAS MB CO

TAS

INJECTOR
BN- 22 - E OG/LT GN- 20 -B
3 BN/BK- 16 IL1 VT/BU- 16

CENTER
+
-1
GPS HARNESS
710003822

SWITCHES HARNESS
710003658

DASHBOARD HARNESS
710003717
CABLES #

INJ2
TAS EC EC INJ HIC LFB
RD- 22 MB MA 2-

#2
- A PK/LT GN- 20 -2 -B

S1
-K -K 1 3

HALL
1 1
EC
GN- 22 TAS MB INJ LFB VT/PK- 16
- C PK/LT BU- 20 BN/BU- 18 VT/GN- 18

JT VT/BU
-E 2- VT/GN- 16 VT/BU- 16 -A

COIL2
VT/BU- 16

CENTER

SPLICE 2
1 3

-
EC CO 2

COIL
TAS EC IL2

15
2/6
HIC
BK- 22 MB MA

#2
- B GN/LT BU- 20 -K -M -3
3 2
5

5
CP CO

INJECTOR
S- BN/OG- 16 VT/GN- 16
IL2

POSITION SENSOR TEMP SENSOR

CRANK SHAFT
CPS
1
-1

(F6)
INJECTORS
COILS &
IGNITION
LFB
S

INJ3
EC INJ

BELT
EC HIC

SIDE
CP MA MA 3-

#3
S- BU/YE- 18 -H -3
-J 1
CIC3
XM
RDO2
HS
CIC3
CB2
CB1
FL
BHL
GND7
CHAS
STS3
RFB
LFB
BAT1
ALT
MOT
DPS
CHAS
BAT2
STS4
SM
ACRONYMS ZONES

2 1 1
EC
MA INJ

-
YE/WH- 18 -K BN/GY- 18 3- VT/OG- 18 VT/OG- 16 VT/BU- 16

SPLICE 3
COIL3
2
CO 2
EC IL3

BELT

COIL
SIDE

3/6
HIC
MA -3

#3
-M

COOLANT
CTS

S
7
8
8
7
7
7
7
3
3
8
8
1
1
1
1
5
22
9
9
1
1
22

EC 1
CT MA CO
S-
BG/OG- 18 -A BN/YE- 16 IL3 VT/OG- 16
2 -1

t
1
EC
710003387 HEADSET

CB / XM HARNESS
710003115
FOG ADAPTATOR
710002619
FUEL TANK GROUND
710002374

POSITIVE CABLE
710003549

GROUND CABLE
710003550
STARTER CABLE
710002562
CABLES #

CT MA EC LFB

-
S- -J MB -8
1 BK/OG- 18 2 -H
2 5
EC HO LFB
MB 2S
-L BN- 20 1- BN- 20 -8 RD/WH- 16

+
SENSOR
GEARBOX POSITION
GBPS
2 D 6
EC
GB MA EC H0 LFB LFB
PS
-1 OG/BU- 18 -C MB BN/GN- 20 2S
1- WH- 20 WH- 20 HO
2S OG/GN- 20 -B -8
4 -J 1- 2 7

HALL
A

S
EC 1 C

02 SENSOR
HEATER
HO2S1
-
GB MA EC HO

VALVE
PURGE
EVAP
LFB

4/6
HIC
PS MB 2S GY- 20 LFB

JT OG/RD1
-F - A VT/PK- 16 RD/WH- 16

JT VT/PK
-2 WH/RD- 18 4 -D BK/PK- 20 1-
B OG/RD- 16 VT/PK- 16 -3
0
2 2
EC

S
GB MA EC EV

10
BK- 20 AP

-
PS BK/RD- 18 -G MA WH/PK- 20 -1
-3 1 -M
6

6
(R3)
POWER
MAIN
LFB
3
EV HIC

POSITION
BK/YE- 18 AP OG/GN- 18
BK/WH- 18

SENSOR
-2 -4

CAPS
SWITCH
PRESSURE
ENGINE OIL
EOP

SHAFT

(F7)
TCM & DPS
FG,CTG,
CLUSTER,
LFB
EC

CAM
EO MA EC CA

DIODE
D3
LT BU- 18 -E MA PS
P- -E -2 OG/GN- 18 OG/GN- 18

P
3

+
2

S
HALL
2
EC EC CA
EO MA MA CA

SOLENOID
P- BK/YE- 18 -J -D YE/GN- 18 PS
-1 PS OG/GN- 18

CLUTCH
1 4 4 -3

VALVE

CSV
-
EC CS
MA

-
-A BK/GN- 18 V-
1
3

OG/GN- 16
EC
SENSOR
PRESSURE/TEMP
AMBIENT AIR
AAPTS

AA
YE
PK
LT GN
LT BU
WH
VT
RD
OG
GN
GY
BN
BU
BK
BG

PT MA CS

T
PT
S- GN/BU- 20 S-
GY- 18 -F GN/GY- 18 GN/GY- 18 V- OG/GN- 18
COLOR

1 2
CODE

S
1 EC
AA PT MA EC LFB
MB

DIODE
D4
PT WH/GY- 20 S- -H FP- -B
S- 2 PK/OG- 18 4 -M C 1
2 1

S
hPa
EC
AA PT MA EC CE
YELLOW
PINK
LIGHT GREEN
LIGHT BLUE
WHITE
VIOLET
RED
ORANGE
GREEN
GRAY
BROWN
BLUE
BLACK
BEIGE

PT OG/BU- 20 S- -G MB FP- LFB

JT OG/GN
S- 4 WH/OG- 18 -D BN/PK- 16 S- B OG/GN- 16 -A VT/PK- 16

PUMP
2/2 FUEL
FP
3

SWITCH
CLUTCH ENGAGE
CES
A

S
4 3 1
COLORS

EC
+
AA MA

15
GY/BU- 20 PT GN/YE- 20
PT S- -B BU- 20

SPLICE 3
S- 3 PK/BU- 18 PK/BU- 18 4
3
EC CE ST
MB S- S4
+

-B B
SENSOR
TEMPERATURE
PRESSURE &
MANIFOLD ABSOLUTE
MAPTS

(F8)
CAPS
CLUTCH VALVE,
PURGE VALVE,
PRE- STARTING RELAY
HO2S HEATERS
FUEL PUMP MOTOR
LFB
1
JAUNE
ROSE
VERT CLAIR
BLEU CLAIR
BLANC
VIOLET
ROUGE
ORANGE
VERT
GRIS
BRUN
BLEU
NOIR
BEIGE

MA

-
BN- 20 RD- 6 ST
COULEURS

PS PK/BU- 18 SM RD- 6
BK/LT GN- 20 S3

STARTER
-3

MOTOR
hPa
7

7
SOLENOID
STARTER
STS
SM
EC
MA MA
S

PS WH/BU- 18 -G
-4 4
MA EC EC ST
MA MB D2
S

PS WH/GY- 18 -H -L -A S1

STARTING
-2
T

3 4
EC

RELAY
MA MA ST

(R2)
VT/BG- 20
-

LFB
PRE-
PS BK/BU- 18 -H YE/PK- 20 YE/PK- 20 S2
REVERSE

-1
DOWN SHIFT

2
FREE
UP SHIFT

EC D2 LFB

DIODE
D2
MB -C -B
FREE

-E 1 0 OG/GN- 16
3
LFB

(F5)
ECM
LFB
VT/BG- 20 VT/BG- 20 -A
+

9
EC EC LFB
ET MA MB
-L -B OG/GN- 16
C- BG/RD- 18 -C

JT BG/GY
1 9
( DASHED LINE ) = ALL OTHERS MODELS & OPTIONS

( FULL LINE ) = STANDARD MODEL SM

LEGEND

4 4
LFB
BG/GY- 20 BG/GY- 20

5
-A
10
EC LFB
MB -B
-M
CONTROL
ELECTRIC TROTTLE
ETC

4
EC 4
/RESET
LEFT

EC
/RESET
RIGHT

LFB
FREE

MA MB LFB
-

ET -B
C- BG/BK- 18 -L -G LT GN/OG- 20 11 - A VT/PK- 16
+

1 2 1 4
EC
WINDWHIELD
WINDSHIELD

ET MA LFB
- AOG/RD- 16
TALK
PUSH

FREE

C- BG/YE- 18 -K LT BU/VT- 20
FREE

S1

3
DOWN

4 12
UP

M
8

8
EC
(OTHER FUNCTIONS)
LEFT
MULTI. SWITCH
MSL

MA EC LFB
ET MB -B
C- -F -C
ALL THESES SWITCHES USED CAN SYSTEM

6 BG/WH- 18 3 3 1 2
-

EC EC
ET MA MB LFB
- AOG/RD- 16
MODE

C-
FREE

-A -F WH- 20
2 BG/GY- 18 2 1 11
M

EC
MA
S2

ET -K
C- BG/GN- 18 BN/WH- 20

JT BN/WH
3

5/6
HIC
5
JT OG/YE

6/6
HIC

(R1)
RELAY
ACTUATOR
REVERSE
LFB
RF HIC EC HIC RF
B- -5 MA -6 B-
85
JT GY/YE

C3 -A
LEFT

4
RIGHT
FREE

DOWN

RF ECMA- C2
RF
OG/YE- 20
UP

OG/YE- 20
LT BU
JT GY/
FAN
COOLING
LCF

B- GY/GN- 18 OG/WH- 20 B- OG/RD- 16

D1 GY/BU- 18 86
SET

FREE

RF RF RF RF RF
B- LC LC B- B- B- B-
F- F- BK- 16 87 J1
D6 B A C1 D2
RF RF RF
BK- 16 B- RF GY/YE- 16 GY/YE- 16 BU- 16 BK- 16 B-
D3 YE/OG- 16 YE/OG- 16 B- RD/VT- 16

JT YE/OG
D5 B- GY/LT BU- 16 30

30
C4 GY/LT BU- 16

(R3)
RELAY
FAN
COOLING
RFB
RF
B-
YE/OG- 16 D4

(J1)
RELAY
FAN
COOLING
RFB
RF
OG/YE- 20
(R6)
REVERSE 2
FAN
RFB

BK- 16 B-
FAN
COOLING
RCF

C6
9

9
(R5)
REVERSE 1
FAN
RFB

RC RC
F- F-
B A

GY/YE- 16 BU- 16 BK- 16 GY/LT BU- 16

HARNESS WIRES EXIT

ACTUATOR
BACKUP
DAYS LIGHTS / PARKING LAMPS / PLATE LIGHTS (F1)

BA

BK- 18 BA RD- 18 BA YE- 18

BU- 18 -2
HI HEADLAMPS (R1)

-1
(START)
RIGHT
SWITCH
MULTI.
MSR 2/4
START

FREE
COOLING FANS (R3)

LINK CONNECTOR
DL
LO HEADLAMPS (R2)

C1 WH/BK- 20

DIAGNOSTIC
-2

DLC1
DL
MODEL

BK- 20 C1 WH/BG- 20
ONLY

-1
STD
10

10
MS DL DL
R2 C1 C1 OG/RD- 18
BG/GY- 20 -4 BG/GY- 20 -3 -4
RFB VUE DE DESSUS / RFB TOP VIEW

LOAD SHEDDING (R4)

DL
HI HEADLAMPS (J5)

BK- 16 RD/YE- 16

JT WH/BK 3
JT WH/BK 2
JT WH/BK 1
JT WH/BG3
JT WH/BG2
JT WH/BG1
C1

JT WH/GN
JT WH/BN
FPL1
FRONT

-5
LIGHT
PILOT

FPL
1-
LO HEADLAMPS (J4)

BK- 20 FPL
JT GY/GN

BK- 20 WH- 20 1- OG- 20

1
LAMP)
HEAD
(LOW
ONLY
CE
LIGHT
PILOT
FRONT
FPL2

DESS, PRS,
VCM, ECM,
SAS, YRS,
FPL
BRAKE LIGHTS / HAZARD CONTROL (F2)

& MSR
SWITCH
LIGHTS
FOG
FGS
2- OFF

(F2)
2
ON

LFB
RADIO (F3)

IGNITION KEY
IK
FPL
BK- 20 BK- 20 WH- 20 2- OG- 20
1 FGS- 7
PIC
LAMP
HEAD
BOTTOM
LEFT
LBHL
LTD & S

FG

LOCK
FG
MODEL

BK- 20 OG/RD- 18

10
1- S- S-

OFF
ONLY

F 3

ON
8
FANS REVERSE 1 (R5)

LB LB KIC LFB
HL HL GY/GN- 18 GY/GN- 16 GY/GN- 16 -B
-2 -3 -A 7
TCM SOLENOIDS (J3)
ACCESSORIES (J2)

LB FG LFB
BK- 18 BK- 20 HL GY/BG- 18 S- LT GN/GY- 16 KIC RD/BN- 18 RD/WH- 16
TRAILER (F4)

GY/BG- 20 -1 -E -A
2 7
11

11
RB
HL BK- 18 BK- 18 OG/PK- 18
LOAD SHEDDING (F5)

-2

(F1)
LDL,RDL
PL, RTL, LTL,
FPL1,FPL2
RFB
JT OG/PK
RB KIC
BK- 18 BK- 20 HL GY/GN- 18

15
GY/BG- 20 -3 -D
LAMP
HEAD
BOTTOM
RIGHT
RBHL
DC PLUGS VKEY (F6)

RB KIC RF

OG/PK- 18
HL KIC B-
-1 GY/BG- 18 -C -B B8

RF
JT OG1

KIC
-F YE/RD- 16 B- OG/BK- 16
JT GY/BG2

A8
LIGHTS)

CAN/US
ONLY

HEADLAMP
LEFT
LHL

DIC LH DIC
ONLY

LH
(FOG
CE

L- L-
FANS REVERSE 2 (R6)

OG- 18 1- 2-
OG- 18 5 2
DC PLUGS VBAT (F7)

A N
DIC

YE/WH- 20
2-

JT GY
LH BN/VT- 16 OG/BK- 20
L- P BN/WH- 16 WH/BN- 20

(R1)
RELAY
LAMP
HEAD
HI
RFB
1 RF
COOLING FAN (J1)

LH LH DIC B- RF
GY/BG- 18 2- B-
L- L- GY/BG- 16 GY/BG- 16 B1
2 J5
NOT USED (F8)

4 3 S
JT BK10
JT BK9

GY- 18 GY- 16 GY- 16 RF

JT BK8
JT BK7

JT BK6
JT BK5
JT BK4
JT BK3

BK- 18 BK- 18 B- YE/BK- 16

JT BK2
D3- A

GY- 18
D3- C

20
A1

JUMPER
CAN/US
RF 1 LFB
POWER CABLE EXIT

B-

ONLY
B1 -D
1 3

(J5)
LAMPS
HEAD
HI
RFB
RF

YL/WH
JT
BN/WH- 20 B- BN/VT- 20
LIGHT
PLATE
PL

A1
12

12
2
RF LFB
PL- PL- B- -D LFB
B9 2 -C OG/BK- 16
REVERSE ACTUATOR (R1)

JT GY/BG1

2 1 1
CLUSTER / DLC / HAZARD POWER (F1)

RF LFB
CAN/US

BK- 20 BK- 20 WH- 20 OG- 20 BN/WH- 20 B- YE/WH- 20 -D

MAIN POWER(R3)

ONLY

A1
0
YE/WH- 20 1
RF RF
B- LFB B-
B1
0 GN/RD- 20 -C OG/BK- 16 J4
3
HEADLAMP
RIGHT
RHL

RH RF
PRE- STARTING (R2)

(R6)
RELAY
LAMP
HEAD
MAIN
LFB
L- GY/BG- 16

JT OG/BK
B- OG/BK- 16
1 A9 OG/BK- 12

30
CIC

(R2)
RELAY
LAMP
HEAD
LO
RFB
JT OG2

2-
YE/GN- 18 GY/BG- 18 B

(J4)
LAMPS
HEAD
LO
LIGHTS,
RFB
RH RH
L- OG- 20 OG- 20

DIAGNOSTIC(ROTAX)
LFB VUE DE DESSUS / LFB TOP VIEW

L- 3
NOT USED (J5)

LINK CONNECTOR
4
DL
BK- 18 GY- 18 GY- 18 C2 WH/GN- 20
SUSPENSION (R4)

BK- 18

DLC2
-2
MAIN CONTROL (J4)

DL
C2
-1
WH/BN- 20
LD LD
L- BK- 20 L-
2 1
JT OG3

BK- 20 OG/BK- 20 OG- 20

LIGHT
WAKE UP ECM, VCM, MSR & DESS / SAS / YAS / PRS (F2)

LDL
LEFT
13

13
DAY

HI

RD RD DIC
L- L- 1- GN/RD- 22 MS
2 1 G L2-
2
PASS

LOW

HI

BK- 20 BK- 20 OG/BK- 20 OG- 20 OG- 20 OG- 20

DPS (J3)

RIGHT
LIGHT

RDL
FLASHER

DAY
FRONT
ALTERNATOR (F3)

RIGHT

(HEADLAMP)
LEFT
SWITCH
MULTI.
MSL 1/3
FRF
NOT USED (J5)

FR FR
F- F-
2 1
WPM / PBM (F4)

BK- 20 BK- 20 BK/YE- 20 BN/YE- 20

SWITCH
LIGHTS

RT RT
BRAKE
ECM (F5)

L- L-
BLS

5 2
SWITCH)
(HAZARD
RIGHT
SWITCH
MULTI.
MSR 3/4

BK- 18 BK- 20 OG- 22 OG- 20

VCM VALVES (J2)

JT WH1
BRAKE, TAIL LIGHT
REAR RIGHT FLASHER
RTL

RT CIC BL BL RF
L- 2- S- S- B-
1 C 2 1 B7
VCM PUMP (J1)

INJECTORS / COILS (F6)

JT WH2

RD- 18 RF
JT RD/OG

WH- 22 WH- 20 WH- 20 WH- 20 WH- 20 BK- 18 RD/OG- 20 RD/OG- 18 B- OG/BK- 16

A7
14

14
WAKE UP TCM, DPS / CLUSTER (F7)

RT MS

10
L- R2
H02S / CAPS / FUEL PUMP / EVAP / CSV (F8)

3 -6
JT BN/YE

OG/PK- 20

BN/BK- 22 PK/BG- 20 OG/PK- 20

(F2)
LIGHTS
BRAKE
CONTROL &
HAZARD
RFB
MAIN HEADLAMPS (R6)

HAZARD

RT CIC DIC
FREE

L- 2- 1- CL
4 E L -1 GY- 20
CL 6
-5 DIC MS
BN/YE- 20 R2
BN/YE- 22 BN/YE- 20 BN/YE- 20 BN/YE- 20 CL
-1
2-
A -2
HARNESS WIRES EXIT

CL 0
CIC DIC -1 MS
LTL 2- 1- BK- 20 1 YE/GY- 20 R2
YE/GY- 20
YE/GY- 20

-4 F M -1
CLUSTER

CL
CL

CIC DIC -4
2- 1- GY/PK- 20 OG/BK- 20 RD/OG- 20
GY/PK- 22 GY/PK- 20 GY/PK- 20 GY/PK- 20
JT GY/PK

D C
BRAKE, TAIL LIGHT
REAR LEFT FLASHER
LTL

3/6

CL
LTL -7
-3 PK/BG- 20 PK/BG- 20 PK/BG- 20
JT PK/BG

TCM TRANSMISSION CONTROL MODULE

TCMB- B4
BN/BK- 22 TC
PK/BG- 20 MB WH/GN- 20
-A
4
LTL TC OP
-1 MA WH/BN- 20 S-
ACTUATION

SENSOR
PRESSURE
OIL
OPS

-J 1
SOLENOID

GND Vo

TC 3
SENSOR

MC
UPSHIFT

Y4 MA
PRESSURE

-B RD- 18 C- TC OP
BG/WH- 18 -H VT/BU- 18
TEMP

WH- 22 WH- 20 MA S-
OTS

F 1 -B 2
15

15
OIL

2
Y4

Y4 MC TC
-A GY- 18 C- MA OP
BG/GY- 18 VT/GN- 18 S-
DOWNSHIFT

G
ACTUATION

-M 3
SOLENOID

Vs

MC TC 2
LTL LTL Y3 MA TC
-5 -2 -A RD- 18 C-
E BG/GY- 18 BG/GY- 18 -M MA YE/WH- 18
1 -B
S

TC
Y3

MC MA 3
Y3 -J TC MC
BK- 18 BK- 20 OG- 22 OG- 20 -B GY- 18 C- BG/GN- 18 MA OG/GN- 18 C- WH- 18
MODULATION

D 1
t

-H A
TC
PRESSURE

3
SOLENOID
FLASHER

Y1 MC MA TC MC
-

-2 GY- 18 C- BG/YE- 18 -E MB GN/GY- 18 C- WH- 18

FRONT

K 2 -A J
FLF
LEFT

2
LINE

FLF
Y1

FLF Y1 MC TC
-2 -1 -1 RD- 18 C- BG/BK- 18 MB OG/RD- 18
B -C
ACTUATION

PRESSURE

TC 2
SOLENOID

Y2 MC MA
CLUTCH

BK- 20 GY/PK- 20 -1 C- TC
BK- 20 GY/PK- 20 GY- 18 H BG/BK- 18 BG/BK- 18 -L
4 MB WH/BK- 20
-C
MC TC 1
Y2

Y2 MA TC
-2 C- -G MB WH/BG- 20
RD- 18 M BG/RD- 18 2 -L
TC 3
MB RF
-M TC B-
BK- 18 2 MB
-M
RD/GY- 18 J3
TCMB- L1 4
BK- 18 RD/GY- 18 DP RD/GY- 16
RD/GY
JT

S
(J3)
FUSE
SOLENOID
TCM
RFB

20
STEERING
POWER
DYNAMIC
DPS

VS VS DP
S1 S3 BK- 6 S1
-2 -2 -A OG/RD- 20
LEFT)
(FRONT
SENSOR
SPEED
WHEEL
VSS1
16

16
(REAR)
SENSOR
SPEED
WHEEL
VSS3

VC
VCM VEHICLE CONTROL MODULE

VCM- 17
HALL

HALL

VS M- VS DP
S1 BU/RD- 20 19 VC PK/RD- 20 S3 S1 WH/BK- 20
-1 M- -1 -D
VC 29
M- DP LFB
8 PK/GN- 20 S1 WH/BG- 20
17

BU/GN- 20 -C -J
3
VC VS
M- VC S2 DP
BK- 12 -2
(J3)
FUSE
MOTOR
DPS
LFB

13 M- S2 RD/GN- 10
JT BK8
JT BK7

JT BK6
JT BK5
JT BK4

JT BK2

-A
JT WH/BK 3
JT WH/BK 2
JT WH/BK 1
JT WH/BE 3
JT WH/BE 2
JT WH/BE 1
RIGHT)
(FRONT
SENSOR
SPEED
WHEEL
VSS2

40

16
HALL

VS
BRAKE FLUID LEVEL SENSOR

VC VT/RD- 20 S2
M- -1
VC 4
BFS1 & BFS2

BF M- LFB
4.4 K

BK- 18 S1 VC VT/GN- 20
L

100 OHMS -A BG/BU- 20 9 M- -J

2
VC 25
BF M-
BK- 18 S1 VC RD/PK- 14
-B BG/BK- 20 34
(J2)
FUSE
VALVES
VCM
LFB

M-
25

VC 28
BF M-
4.4 K

BK- 18 S2
L

100 OHMS 22 VC OG/PK- 20

-A BG/GN- 20 M-
VC 14
BF M-
BK- 18 S2
-B BG/WH- 20 2 VC
M- WH/BK- 20
VC 26
M- LFB
LPS 38
-3 BK- 14 VC
M-
WH/BG- 20 -J
1
VC 1 PR
21

LPS M- S- PR
BK- 20 BK- 18 BU- 18 WH/VT- 20 VC RD/BK- 12 S-
(J1)
FUSE
PUMP
VCM
LFB

-2 12 M- B A
40
17

17
+

37
SWITCH
PRESSURE
LOW BRAKE
LPS

PR
RD- 18 VC
M- VT/BN- 20 S-
C
BU- 18 RD- 18 OG/PK- 20
SENSOR
RATE
YAW
YRS
SWITCH
RIDER
PILLION
PRS

32
-

YR
BK/BU- 20 GN- 18 S- OG/PK- 20
4
YR YR
S- S- WH/BK- 20
1 2
6

YR SA
BK- 20 S-
3 WH/BG- 20 S-
6
SA
BK- 20 S-
3
OG/PK- 20
GP SA
S2
-A S- WH/BK- 20
19

1
USB

RDO1- 34
SYSTEM
POSITION
GLOBAL
GPS

AU SA
RD BK- 22 (GND) X1 WH/BG- 20
LT GN/YE- 18 S-
JT RD

O1 -T 4
RADIO CONTROL
PRC PASSAGER

-7
JT SHLD

RD
SENSOR
ANGLE
STEERING
SAS
-

PR O1 AU
C- WH/LT GN- 20 -2 RD X1
1 O1 BN/LT BU- 20 TIP- 22 -S
S1/S2 S3/

A -8
JT LT BU /GY

RD
PR O1 AU
11

C- WH/ LT BU- 20 -1 RD X1
4 O1 RD/LT GN- 20 SHIELD- 22 -R
JT WH

B
-9
S4

RD GP
PR O1 S2
-1
RADIO

C- BU/LT BU- 20 RD RING- 20

VBAT:

LT GN/BG- 20 -B
RFB
(F3)
MIC IN

C 5 O1
18

18
24

2A

-6
GPS

RD RF
O1 CIC B- RF
BK- 18 -3
1
RD
O1 LT GN/BK- 18 RD- 18 RD- 18 RD- 22
1-
K B6
B-
J2
RD -2
O1 7
JT LT GN/RD

BK- 18 -3 RF
0 RD
O1 LT GN/RD- 18 LT GN/RD- 16 LT GN/RD- 16 B- LT BU/GY- 14 LT BU /GY- 14
40

-2 A6
RD 9
O1
15

BK- 18 -3 RD
2 O1 LT GN/RD- 18
-

-2
(J2)
FUSE
ACCESSORIES
RFB
SPEAKER
FRONT LEFT

RD 8 CIC
FLS O1
FLS

DIC CIC -3 RD 1-
2 PK/BK- 18 2- PK/BK- 18 1- PK/BK- 18 O1 LT GN/RD- 18 R
H G -1
3

RD 7
O1
+

FLS DIC CIC -2 CIC

1 PK- 18 PK- 18 1- PK- 18 RD 1- WH/BK- 20
7

2- O1 WH/BK- 20 S
14

G F -1
6
RD WH/BG- 20
O1 WH/BG- 20
-

-1
SPEAKER
FRONT RIGHT
9

RD 1 PO
FR DIC CIC O1 D-
FRS

RD
IPOD CONNECTION
POD

S2 1- BN/LT GN- 18 -1
BN/LT GN- 18 2- BN/LT GN- 18 0 O1 BN- 22 BN- 22 2
12

K J -1
RD 2 PO
O1
+

FR DIC CIC -1 RD D-
S1 LT GN- 18 2- LT GN- 18 1- LT GN- 18 O1
-1 OG- 22 OG- 22 4
J D
3 PO
RD D-
O1 BK- 22 BK- 22 1
-2
-
SPEAKER
REAR RIGHT

RD 2 PO
O1 D-
RRS

RR VT/BK- 18 -2 RD 7
S2 6 O1 BU- 22 BU- 22
13

RDO RADIO

-2
19

19
1
2

RD 3 PO
O1 D-
+

RR RD
S1 VT- 18 -1
8 O1 GN- 22 GN- 22 6
-2
4 PO
D-
RD YE- 22 YE- 22 5
O1
-

-2
SPEAKER
REAR LEFT

RD 5 POD- 3
O1
RLS

RL GN/BK- 18 -5 CB
S2 RD- 22 1- RD- 22
A
HEADSET
FRONT
DIN

RD DIN
RL O1 CB -2
+

S1 GN- 18 -4 RD 2- GN- 22 CB BN- 22

G 1-
O2 B
-9 DIN
9
15

XM CB CB -4
-G RD
O2 WH/BK- 22 2-
A YE/BK- 22 WH- 22 1- OG- 22
C
8

RD -2 DIN
O2 -1
RADIO
SATELLITE
XM

CITIZEN BAND
CB

XM -1 CB CB
YE/BK- 20 -A WH/GN- 22 5
RD
O2 WH/BG- 22 2- YE- 22 BN- 22 1- BK- 22
-3 B D
RD DIN
4

XM O2 CB CB -3
YE- 20 -B WH/BN- 22 -2
1 RD
O2 GY/BK- 22 2- RD/BK- 22 YE- 22 1- RD- 22
-1 C F
RD DIN
XM O2 CB -5
RD/BK- 20 -C GY/BK- 22 -1
6 RD
O2 BU/GY- 22 2- RD- 22 RD- 22 YE- 22
-4 D
RD DIN
TRAILER
OUTPUT
POWER

-7
20

O2 CB
RD- 20 BU/GY- 22 -1
4
RD
O2 BG/LT GN- 22 2- WH- 22 BU- 22
-1 E CB
3 DIN
MODULE

1
TRAILER

-6
CB
ANT.

RD CB GN- 22
GY/LT BU- 22
RFB

BR- 22
(F4)

O2 2-
10
20

F
20

-5
CB RF
B-
BU/LT GN- 22 WH/BK- 22 1- CIC B5
E 2-
DIN
HEADSET
REAR
DIN

H
XM CB CB -6 RF
RD 2- BU- 22 1- B-
-H O2
-1 H G GN- 22 OG/VT- 16 A5 LT BU/GY- 14
RD 0 DIN
18

O2 CB -2
10

XM -2 RD CB
BU/BK- 20 -J GY/BK- 22 2 O2 GY/BK- 22 2-
J BU/BK- 22 GN/BK- 22 1-
H BN- 22
RD -8 DIN
O2 -4
XM CB CB
BU- 20 -K BU/GY- 22 -2
0
RD
O2 BU/GY- 22 2- BU- 22 WH/BK- 22 1- OG- 22
-1 K J
RD 3 DIN
O2 CB CB -1
XM -1
GN- 20 -L LT GN/LT BU- 22 9 RD
O2 LT BU/WH- 22 2-
L GN- 22 BN/BK- 22 1-
K
BK- 22
SHEDDING

RD -6 DIN
O2 CB -3
5

BN/BK- 20 XM CB
GY/VT- 22 -2 RD 1- RD- 22
SHEDDING

YE/BK- 22
RELAY

-M GY/WH- 22 2-
BR/BK- 22
(R4)

LOAD

O2
RFB

L
CLUSTER 4/6

5 -1 M
2 DIN
RD
HORN,
RELAY

CB -7
CL

LOAD

O2
RFB
(F5)

GN/BK- 20 GN/PK- 22 -1 BU/BN- 22 BU/BK- 22 1- BU- 22