Bombardier Outlander ATV (2006) - Workshop Manual / Repair Manual

BOMBARDIER OUTLANDER ATV (2006) - SERVICE MANUAL

- Workshop Manual, to vehicles Bombardier Outlander ATV (2006).


MODELS:

Outlander™ 400
Outlander™ XT 400
Outlander™ MAX 400
Outlander™ MAX XT 400
Outlander™ 800
Outlander™ XT 800
Outlander™ MAX 800
Outlander™ MAX XT 800


INDEX:


TABLE OF CONTENTS
SAFETY NOTICE IX
INTRODUCTION X

- General information x
- Vehicle identification number (v.i.n.) Xi
- Engine identification number (e.i.n.) Xi
- Arrangement of this manual, illustrations and procedures xi
- Engine emissions information xiv
- Self-locking fasteners procedure xiv
- Loctite application procedure xiv
- Tightening torques xviii

MAINTENANCE

01 - Maintenance Chart 1
- Noise emission control system regulation 1
- Maintenance chart 2

02 - Preseason Preparation 9

03 - Storage Procedures 11
- Vehicle cleaning 11
- Fuel stabilizer 11
- Engine lubrication 11
- Rags installation 12
- Coolant density 13
- Drive and driven pulleys protection 13
- Vehicle protection 13

04 - Special Procedures 15
- Turnover 15
- Atv immersion 15

TROUBLESHOOTING

01 - Troubleshooting Chart 17
- Outlander 400 series 17
- Cooling system 17
- Magneto system 18
- Lubrication 20
- Cylinder and head 21
- Crankshaft and balancer shaft 22
- Gearbox 23
- Rewind starter 24
- Cvt 25
- Engine general 29

02 - Troubleshooting Chart 35
- Outlander 800 series 35
- Cooling system 35
- Magneto system 36
- Lubrication 37
- Cylinder and head 39
- Crankshaft 40
- Gearbox 40
- Disconnect unit 41
- Cvt 42
- Engine general 46

ENGINE SYSTEM

01 - Air Intake Silencer 55
- Outlander 400 series 56
- General 57
- Procedures 57
- Air filter 57
- Air filter box cleaning/draining 57
- Air filter box 58
- Outlander 800 series 60
- General 61
- Procedures 61
- Air filter 61
- Air filter box 61

02 - Lubrication System 65
- Outlander 400 series 65
- General 65
- Procedures 65
- Oil level check 65
- Oil change 65
- Oil filter 66
- Outlander 800 series 67
- General 67
- Procedures 67
- Oil level check 67
- Oil change 68
- Oil filter 68

03 - Cooling S Y S T E M 71
- General 74
- Procedures 74
- Cooling system leak test 74
- Coolant replacement 75
- Thermostat 77
- Radiator cap 78
- Radiator 78
- Coolant tank 79
- Radiator fan 80
- Coolant temperature sensor (cts) 81
- Fan activation switch (fas) 81

04 - Exhaust S Y S T E M 83
- Outlander 400 series 84
- General 85
- Procedures 85
- Exhaust pipe 85
- Muffler 86
- Heat shield 86
- Muffler support 87
- Rubber bushing 88
- Outlander 800 series 89
- General 90
- Procedures 90
- Front exhaust pipe 90
- "y" exhaust pipe 91
- Fuel tank protector 91
- Heat shield 92
- Muffler support 92
- Rubber bushing 93

05 - Engine Removal A N D Installation 95
- Outlander 400 series 96
- General 97
- Procedures 97
- Engine removal 97
- Engine mount replacement 101
- Engine installation 102
- Outlander 800 series 103
- General 104
- Procedure 104
- Engine removal 104
- Engine mount replacement 110
- Engine installation 110

ENGINE MANAGEMENT (V-810)

01 - O V E R V I E W 113
- Operating principle 114
- Air induction 114
- Fuel system 114
- Electrical system 115
- Engine m a n a g e m e n t system 120
- Electronic fuel injection 120
- Ignition 120
- Other engine management functions 120
- Engine management system flowchart 122

02 - Diagnostic Procedure 123
- General 123
- Procedures 124
- Communication tools 124
- Software 124
- Electrical connections 124
- Communication procedures 126
- Fault codes 127
- Fault code table 129

03 - Component Inspection, Replacement A N D A D J U S T M E N T 137
- General 137
- Fuel system 137
- Electrical system 138
- Procedures 141
- Idle speed 141
- Ignition timing 141
- Throttle body 142
- Fuel rail 146
- Fuel injector 147
- Engine control module (ecm) 149
- Throttle position sensor (tps) 152
- Idle bypass valve 154
- Crankshaft position sensor (cps) 156
- Camshaft position sensor (caps) 157
- Manifold air pressure and temperature sensor (mapts) 158
- Coolant temperature sensor (cts) 160
- Oil pressure switch (ops) 161

FUEL SYSTEM

01 - Fuel T A N K A N D Fuel Pump 163
- Outlander 400 series 164
- General 165
- Procedures 165
- Fuel tank pressurization 165
- Fuel gauge 166
- Fuel tank protectors 166
- Fuel tank 167
- Fuel tank strainer 169
- Fuel valve 170
- Fuel pump 171
- Outlander 800 series 173
- Fuel delivery system diagnostic flow chart 174
- General 175
- Procedures 176
- Fuel tank pressurization 176
- In-line fuel filter 178
- Fuel tank 178
- Fuel pump 180
- Fuel level sender 183

02 - Carburetor 185
- Outlander 400 series 186
- General 187
- Procedures 187
- Carburetor 187
- Throttle cable 190
- Choke cable 192

ELECTRICAL SYSTEM

01 - Charging System 195
- General 195
- Procedures 196
- Voltage regulator/rectifier 196
- Stator 198
- Battery 202

02 - Ignition S Y S T E M 205
- Outlander 400 series 205
- General 205
- Procedures 207
- Main fuse condition 207
- Spark occurrence 207
- Battery condition 207
- Ignition switch 207
- Crankshaft position sensor 208
- Ignition coil 208
- Electronic module (cdi) 208
- Ignition timing 209
- Spark plug 209
- Outlander 800 series 212
- General 212
- Procedures 212
- Ignition switch 212
- Multi-function switch (run/stop) 213
- Ignition coil 214
- Ignition timing 216
- Sparkplug 216

03 - Starting S Y S T E M 217
- Outlander 400 series 217
- Starting system troubleshooting 217
- General 219
- Test 219
- Fuses 219
- Battery 219
- Ignition switch 219
- Engine stop switch 219
- Start switch 219
- Starting solenoid 219
- Electrical cables or connections 220
- Electric starter 220
- Electronic module 220
- Part replacement 220
- Electric starter 220
- Outlander 800 series 221
- Starting system troubleshooting 221
- General 223
- Test 223
- Fuses 223
- Battery 223
- Electrical cables or connections 223
- Ecm initialization 223
- Electric starter 223
- Ignition switch 223
- Engine stop switch 224
- Start switch 224
- Starting solenoid 225
- Ecm 227
- Part replacement 227
- Electric starter 227

04 - Digitally Encoded Security System 229
- General 229
- Key programming 229

05 - Lights, Instruments And Accessories 231
- General 231
- Fuses 232
- Relay 232
- Diode 233
- Speedometer functions 234
- Procedures 239
- Speedometer 239
- Vehicle speed sensor (vss) 244
- Fuel level sender 245
- Multi-function switch 246
- 12-volt auxiliary power outlet 247
- 12-volt power outlet 248
- Headlamp 249
- Taillight 251
- Winch 252
- Winch control switch 255

TRANSMISSION

01 - Continuously Variable Transmission (Cvt) 257
- Outlander 400 series 258
- General 259
- Procedures 259
- Drive belt 259
- Drive pulley 260
- Driven pulley 267
- Outlander 800 series 272
- General 273
- Procedures 273
- Drive belt 273
- Drive pulley 274
- Driven pulley 281
- Cvt air guide 287

02 - Gearbox A N D 4 X 4 Coupling Unit 289
- Outlander 800 series 290
- General 293
- Maintenance 293
- Oil change 293
- Procedures 294
- Shifting indicator switch 294
- Oil seals 295
- Actuator 297
- Output shaft and coupling mechanism 299
- Gearbox 304
- Engine drive shaft 318

03 - Transmission Linkage 319
- Outlander 400 series 319
- General 320
- Procedures 320
- Transmission lever handle 320
- Transmission lever 320
- Link rod 320
- Shifting plate 321
- Outlander 800 series 322
- General 323
- Procedures 323
- Transmission lever 323
- Link rod 324
- Shifting plate 325

DRIVETRAIN

01 - 4x4 Coupling Unit 327
- Outlander 400 series 328
- General 329
- Procedures 329
- Actuator 329
- 2wd/4wd switch 330
- Coupling unit 331

02 - Front Drive 337
- General 340
- Procedures 340
- Tires and wheels 340
- Wheel hub 340
- Front drive shaft 341
- Front differential 343
- Front propeller shaft 347
- Propeller shaft u-joint 348

03 - Rear Drive 351
- General 353
- Procedures 353
- Tires and wheels 353
- Wheel hub 353
- Differential protector 354
- Drive shaft 354
- Drive shaft boot 355
- Rear propeller shaft 355
- Rear propeller shaft u-joint 356
- Rear differential 357

STEERING SYSTEM

01 - Steering System 361
- General 364
- Tires and wheels 364
- Procedures 364
- Handlebar grip 364
- Handlebar cover 365
- Handlebar 366
- Steering column 366
- Steering column bearing '. 367
- Tie-rod 368
- Knuckle 368
- Wheel bearing 369
- Multi-function switch 370
- Throttle handle 371
- Handle brake 372
- Adjustment 372
- Steering alignment 372

SUSPENSION

01 - Front Suspension 375
- General 378
- Procedures 378
- Tires and wheels 378
- Shock absorber and spring 378
- Lower suspension arm protector 380
- Lower suspension arm 380
- Lower ball joint 381
- Upper suspension arm 381
- Upper suspension arm bracket 383
- Upper ball joint 383

02 - Rear Suspension 385
- General 387
- Procedures 387
- Tires and wheels 387
- Rear shock 387
- Torsion bar 389
- Trailing arm 390
- Trailing arm bearings 391

BRAKES

01 - Front And Rear Brakes 395
- General 397
- Procedures 397
- Brake fluid 397
- Brake light switch 399
- Parking brake mechanism 400
- Brake lever 400
- Front master cylinder 401
- Rear master cylinder 401
- Caliper 403
- Brake pads 404
- Brake disc 405
- Brake pedal 406
- Brake hoses 407

BODY/FRAME

01 - Body 409
- General 420
- Procedures 420
- Seat 420
- Central panel 422
- Dashboard 422
- Side panel 422
- Footrest 423
- Console 424
- Inner fender 425
- Heavy duty bumper 426
- Front bumper/front skid plate/front fascia 426
- Luggage rack 427
- Fender 427
- Fuel valve support 429
- Fender support 429
- Decals replacement 430
- Hitch/trailer ball 430
- Plastic maintenance 430
- Plastic repair 430

02 - Frame 431
- General 435
- Procedures 435
- Footrest support 435
- Battery support 436
- Hitch....- 436
- Frame 437

TECHNICAL SPECIFICATIONS

01 - Outlander Series 439

ELECTRICAL CONNECTORS AND WIRING SCHEMATICS

01 - Electrical Connectors 447
- Deutsch connectors 447
- Ecm connectors 448
- Multi-function speedometer connector 451
- Battery and starter cable terminals 452

02 - Wiring Schematics 455
- Wiring connectors coding 455
- Wire colors 455
- Wire gauge 455
- Connector housing area 455
- Connector identification 455
- Wire location in connector 456

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