BOMBARDIER ATV BRP Outlander™ Series/Outlander™ MAX Series
Год выпуска: 2006Автор: BRPЖанр:Руководство по ремонту и техническому обслуживанию + каталогИздательство: «Midwest Manuals & Collectibles»Серия: -----ISBN: -----Формат: PDF/DjVu/(полностью распознан)+DОСКачество: Распознанный текст(OCR)Количество страниц: 504Язык : АнглийскийSAFETY NOTICE This manual has been prepared as a guide to correctly service and repair 2006 Outlander™ and Outlander™ MAX Series ATVs as describe in the nnodel list in the INTRODUCTION. This edition was primarily published to be used by mechanical technicians who are already familiar with all service procedures relating to BRP products. Mechanical technicians should attend training courses given by BRP Training Dept. Please note that the instructions will apply only if proper hand tools and special service tools are used. This Vehicle Shop Manual uses technical terms which may be slightly different from the ones used in the PARTS CATALOG. It is understood that this manual may be translated into another language. In the event of any discrepancy, the English version shall prevail. The content depicts parts and/or procedures applicable to the particular product at time of writing. Service and Warranty Bulletins may be published to update the content of this manual. Make sure to read and understand these. It does not include dealer modifications, whether authorized or not by BRP, after manufacturing the product. In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of the general configuration of the parts. They are not to be interpreted as technical drawings or exact replicas of the parts. The use of BRP parts is most strongly recommended 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 for which it was designed..
БЕЗОПАСНОЕ УВЕДОМЛЕНИЕ Это руководство подготовлено как справочник по правильно услуге и ремонт 2006 Outlander и Outlander MAX Series ATVs как описываться в списке nnodel в ВВЕДЕНИИ. Это издание первоначально было опубликовано, чтобы быть использован механическими техниками, которые уже знакомы со всеми процедурами услуги иметь отношение к продуктам BRP. Механические техники должны посетить подготовку курсов данных BRP, готовящий Отд. Пожалуйста отметьте, что инструкции приложит только если соответствующие инструментальные средства руки и инструментальных средств спецслужбы использованы. Это Руководство Магазина Машины использует технические условия, которые могут отличаться от тех использованное в КАТАЛОГЕ ЧАСТЕЙ. Понято, что это руководство может быть переведено на другой язык. В случае любого несоответствия, Английская версия должна преобладать. Содержимое изображает части и/или процедуры применительные к конкретному продукту в момент сочинения. Услуга и Гарантийные Бюллетени могут быть опубликованы, чтобы корректировать содержимое этого руководства. Убедитесь, чтобы читать и понимать их. Это не включает дилерские модификации, независимо разрешенные или не BRP, после производства продукта. Кроме того, единственная цель иллюстраций для всего руководства, должна помочь идентификации общей конфигурации частей. Они не должны быть интерпретирован как технические чертежи или точные копии частей. Использование частей BRP - наиболее сильно рекомендуемое рассматривая замену любого компонента. Дилерская и/или помощь распределителя должна быть поискана в случае сомнения. Двигатели и соответствующие компоненты идентифицированные в этом документе не должно использовано в продукте(продуктах) кроме для которого он был создан.
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 01 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 02 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 03 ENGINE SYSTEM 01 - AIR INTAKE SILENCER 55 OUTLANDER 400 SERIES 56 GENERA L 57 PROCEDURE S 57 AIR FILTER 57 AIR FILTER BOX CLEANING/DRAINING 57 AIR FILTER BOX 58 OUTLANDE R 80 0 SERIES 60 GENERA L 61 PROCEDURE S 61 AIR FILTER 61 AIR FILTER BOX 61 02 - LUBRICATION SYSTEM 65 OUTLANDE R 40 0 SERIES 65 GENERA L 65 PROCEDURE S 65 OIL LEVEL CHECK 65 OIL CHANGE 65 OIL FILTER 66 OUTLANDE R 80 0 SERIES 67 GENERA L 67 PROCEDURE S 67 OIL LEVEL CHECK 67 OIL CHANGE 68 OIL FILTER 68 03 - COOLING SYSTE M 71 GENERA L 7 4 PROCEDURE S 7 4 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 - EXHAUS T SYSTE M 83 OUTLANDE R 40 0 SERIES 8 4 GENERA L 85 PROCEDURE S 85 EXHAUST PIPE 85 MUFFLER 86 HEAT SHIELD 86 MUFFLER SUPPORT 87 RUBBER BUSHING 88 OUTLANDE R 80 0 SERIES 89 GENERA L 90 PROCEDURE S 9 0 FRONT EXHAUST PIPE 90 "Y" EXHAUST PIPE 91 FUEL TANK PROTECTOR 91 HEAT SHIELD 92 MUFFLER SUPPORT 92 RUBBER BUSHING 93 05 - ENGINE REMOVA L AN D INSTALLATION 9 5 OUTLANDE R 40 0 SERIES 96 GENERA L 97 PROCEDURE S 97 ENGINE REMOVAL 97 ENGINE MOUNT REPLACEMENT 101 ENGINE INSTALLATION 102 OUTLANDE R 80 0 SERIES 103 GENERA L 104 PROCEDURE 104 ENGINE REMOVAL 104 ENGINE MOUNT REPLACEMENT 110 ENGINE INSTALLATION 110 04 ENGINE MANAGEMENT (V-810) 01-OVERVIE W 113 OPERATING PRINCIPLE 114 AIR INDUCTION 114 FUEL SYSTEM 114 ELECTRICAL SYSTEM 115 ENGINE MANAGEMEN T SYSTEM 120 ELECTRONIC FUEL INJECTION 120 IGNITION 120 OTHER ENGINE MANAGEMENT FUNCTIONS 120 ENGINE MANAGEMENT SYSTEM FLOWCHART 122 02 - DIAGNOSTI C PROCEDURE 123 GENERA L 123 PROCEDURE S 124 COMMUNICATION TOOLS 124 SOFTWARE 124 ELECTRICAL CONNECTIONS 124 COMMUNICATION PROCEDURES 126 FAULT CODES 127 FAULT CODE TABLE 129 03 - COMPONEN T INSPECTION, REPLACEMEN T AN D ADJUSTMEN T 137 GENERA L 137 FUEL SYSTEM 137 ELECTRICAL SYSTEM 138 PROCEDURE S 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 05 FUEL SYSTEM 01 - FUEL TAN K AN D FUEL PUM P 163 OUTLANDE R 40 0 SERIES 164 GENERA L 165 PROCEDURE S 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 OUTLANDE R 80 0 SERIES 173 FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHART 174 GENERA L 175 PROCEDURE S 176 FUEL TANK PRESSURIZATION 176 IN-LINE FUEL FILTER 178 FUEL TANK 178 FUEL PUMP 180 FUEL LEVEL SENDER 183 02 - CARBURETOR 185 OUTLANDE R 40 0 SERIES 186 GENERAL 187 PROCEDURE S 187 CARBURETOR 187 THROTTLE CABLE 190 CHOKE CABLE 192 06 ELECTRICAL SYSTEM 01 - CHARGIN G SYSTEM 195 GENERA L 195 PROCEDURE S 196 VOLTAGE REGULATOR/RECTIFIER 196 STATOR 198 BATTERY 202 02 - IGNITION SYSTE M 20 5 OUTLANDE R 40 0 SERIES 20 5 GENERA L 20 5 PROCEDURE S 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 OUTLANDE R 80 0 SERIES 212 GENERA L 21 2 PROCEDURE S 212 IGNITION SWITCH 212 MULTI-FUNCTION SWITCH (RUN/STOP) 213 IGNITION COIL 214 IGNITION TIMING 216 SPARKPLUG 216 03 - STARTING SYSTE M 217 OUTLANDE R 40 0 SERIES 217 STARTING SYSTEM TROUBLESHOOTING 217 GENERA L 219 TES T 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 07 TRANSMISSION 01 - CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 257 OUTLANDER 400 SERIES 258 GENERAL 259 PROCEDURES 259 DRIVE BELT 259 DRIVE PULLEY 260 DRIVEN PULLEY 267 OUTLANDE R 80 0 SERIES 272 GENERA L 273 PROCEDURE S 273 DRIVE BELT 273 DRIVE PULLEY 274 DRIVEN PULLEY 281 CVT AIR GUIDE 287 02 - GEARBO X AN D 4X 4 COUPLING UNI T 28 9 OUTLANDE R 80 0 SERIES 290 GENERA L 293 MAINTENANC E 293 OIL CHANGE 293 PROCEDURES 29 4 SHIFTING INDICATOR SWITCH 294 OIL SEALS 295 ACTUATOR 297 OUTPUT SHAFT AND COUPLING MECHANISM 299 GEARBOX 304 ENGINE DRIVE SHAFT 318 03 - TRANSMISSIO N LINKAGE 31 9 OUTLANDE R 40 0 SERIES 319 GENERA L 32 0 PROCEDURE S 32 0 TRANSMISSION LEVER HANDLE 320 TRANSMISSION LEVER 320 LINK ROD 320 SHIFTING PLATE 321 OUTLANDE R 80 0 SERIES 322 GENERA L 323 PROCEDURE S 32 3 TRANSMISSION LEVER 323 LINK ROD 324 SHIFTING PLATE 325 08 DRIVETRAIN 01 - 4X 4 COUPLING UNI T 327 OUTLANDE R 40 0 SERIES 32 8 GENERA L 329 PROCEDURE S 32 9 ACTUATOR 329 2WD/4WD SWITCH 330 COUPLING UNIT 331 02 - FRONT DRIVE 337 GENERA L 34 0 PROCEDURE S 34 0 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 35 1 GENERA L 35 3 PROCEDURE S 35 3 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 09 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 10 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 11 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 12 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 13 TECHNICAL SPECIFICATIONS 01 - OUTLANDER SERIES 439 14 ELECTRICAL CONNECTORS AND WIRING DIAGRAMS 01 - ELECTRICAL CONNECTORS 447 DEUTSCH CONNECTORS 447 ECM CONNECTORS 448 MULTI-FUNCTION SPEEDOMETER CONNECTOR 451 BATTERY AND STARTER CABLE TERMINALS 452 02 - WIRING DIAGRAMS 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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