BOMBARDIER OUTLANDER 330 H.O. 2x4 Manual

This Operator’s Guide utilizes the following symbols to emphasis particular infor-
mation:
CAUTION: Denotes an instruction which if not followed, may damage the
vehicle and/or components.
All safety documentation should remain with the vehicle at the time of sale.
All content of the Safety Information section should be interpreted by the reader
as a warning which if not followed, may result in injury including the possibility of
death.
In USA, products are distributed by Bombardier Motor Corporation of America. In
Canada, products are distributed by Bombardier Inc.
The following are trademarks of Bombardier Inc. or its subsidiaries:
BOMBARDIER®
ROTAX®
Outlander™
The Safety Alert Symbol indicates a potential personal injury hazard.
WARNING Indicates a potentially hazardous situation which, if not
avoided, could resullt in serious injury or death.
WARNING
YOUR VEHICLE CAN BE HAZARDOUS TO OPERATE. A collision or rollover
can occur quickly, even during routine maneuvers such as turning and driv-
ing on hills or over obstacles, if you fail to take proper precautions.
For your safety, understand and follow all the warnings contained in this
Operator’s Guide and the labels on your vehicle. Failure to follow these
warnings can result in SEVERE INJURY OR DEATH.
Keep this Operator’s Guide with the vehicle at all times.
WARNING
Disregarding any of the safety precautions and instructions contained in
this Operator’s Guide, Safety Videocassette and on-product labels could
cause injury including the possibility of death!
Printed in Canada (vmo2004_001a.fm AP)
®TMTrademarks of Bombardier Inc. or its subsidiaries.
©2003 Bombardier Inc. All rights reserved.
vmo2004_001a.book Page 0 Wednesday, January 29, 2003 2:03 PM

1
FOREWORD
Congratulations on your purchase of a
new Bombardier®all-terrain vehicle
(ATV). It is backed by the Bombardier
warranty and a network of authorized
Bombardier ATV dealers ready to pro-
vide the parts, service or accessories
you may require.
Your dealer is committed to your satis-
faction. He has taken training to per-
form the initial set-up and inspection of
your vehicle as well as completed the
final adjustment before you took pos-
session. At delivery, your dealer would
have explained the vehicle for the op-
eration, maintenance and safety fea-
tures. We trust you have taken full ad-
vantage of this! If you need more
complete servicing information, please
ask your dealer.
At delivery, you were also informed of
the warranty coverage and completed
the Warranty Registration Form which
is to be sent to us for processing. In
the near future you should be receiv-
ing a warranty card which will confirm
our receipt of the registration as well as
be used for warranty or recall purposes.
You are invited to contact our custom-
er assistance center should you expe-
rience problems which cannot be re-
solved by an authorized Bombardier ATV
dealer.
It is understood that this Operator’s
Guide may be translated into another
language. In the event of any discrep-
ancy, the English version shall prevail.
Throughout this document, the mas-
culine is used to denote the masculine
and feminine.
The information and components/
system descriptions contained in this
document are correct at the time of
publication. Bombardier Inc. however,
maintains a policy of continuous im-
provement of its products without im-
posing upon itself any obligation to install
them on products previously manufac-
tured. Due to late changes, some dif-
ferences between the manufactured
product and the descriptions and/or
specifications in this Operator’s Guide
may occur. Bombardier Inc. reserves
the right at any time to discontinue or
change specifications, designs, fea-
tures, models or equipment without
incurring any obligation upon itself.
The illustrations in this document show
the typical construction of the different
assemblies and may not reproduce the
full detail or exact shape of the parts.
However, they represent parts that
have the same or similar function.
The use of RIGHT and LEFT indications
in the text, always refers to driving po-
sition (when sitting on vehicle).
Specifications are given in the SI metric
system with the SAE U.S. equivalent in
parenthesis. Where precise accuracy is
not required, some conversions are
rounded off for easier use.
We recommend genuine Bombardier
products for replacement parts and ac-
cessories. They’ve been especially de-
signed for your vehicle and manufac-
tured to meet Bombardier’s demanding
standards.
A Shop Manual can be obtained for com-
plete service, maintenance and more
repair information.
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2
TABLE OF CONTENTS
While reading this Operator’s Guide, remember that:
NOTICE....................................................................................... 5
INTRODUCTION.......................................................................... 6
SAFETY INFORMATION
SPECIAL SAFETY MESSAGES.................................................... 8
OPERATION WARNINGS ............................................................ 10
SAFETY WARNING ..................................................................... 37
RIDING TIPS ............................................................................... 38
Clothing ................................................................................................... 39
Carrying Loads......................................................................................... 40
Hauling a Trailer....................................................................................... 40
Working with your ATV............................................................................ 40
Recreational Riding.................................................................................. 40
Environment ............................................................................................ 41
Design Limitation..................................................................................... 41
Off-Highway Operation............................................................................ 41
General Operating and Safety Precautions.............................................. 42
Uphill Driving ........................................................................................... 42
Downhill Driving ...................................................................................... 42
Side Hilling............................................................................................... 42
Drop-Offs................................................................................................. 43
Riding Techniques ................................................................................... 43
LOCATION OF THE IMPORTANT LABELS ................................... 51
VEHICLE INFORMATION
HOW TO IDENTIFY YOUR ATV ................................................... 56
Engine and Vehicle Identification Number Location................................ 56
EMISSION REQUIREMENTS........................................................ 57
CONTROLS/INSTRUMENTS/EQUIPMENTS.................................. 58
1) Throttle Lever.................................................................................... 60
2) 2WD/4WD Selector .......................................................................... 60
3) Brake Lever....................................................................................... 61
4) Brake Lever Lock .............................................................................. 61
WARNING
Indicates a potential hazard that, if not avoided, could result in serious
injury or death.
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3
5) Transmission Lever........................................................................... 62
6) Multi-Function Switch....................................................................... 63
7) Speedometer .................................................................................... 65
8) Ignition Switch .................................................................................. 67
9) Fuel Tank Cap ................................................................................... 67
10) Fuel Gauge........................................................................................ 68
11) Fuel Valve.......................................................................................... 69
12) Brake Pedal....................................................................................... 69
13) Footpeg............................................................................................. 70
14) Access Panel..................................................................................... 70
15) Rear Storage Compartment.............................................................. 70
16) Seat Latch......................................................................................... 71
17) Front/Rear Cargo Rack........................................................................... 71
18) Trailer Hitch....................................................................................... 72
19) Radiator Cap...................................................................................... 72
20) 12-Volt Power Outlet ........................................................................ 72
21) Fuses ................................................................................................ 72
22) Tool Box............................................................................................ 73
23) Rewind Starter Handle...................................................................... 73
24) Dipstick ............................................................................................. 73
25) Winch................................................................................................ 74
26) Winch Control Switch ....................................................................... 74
27) Fairlead.............................................................................................. 74
LIQUIDS...................................................................................... 75
Fuel.......................................................................................................... 75
Engine/Transmission Oil.......................................................................... 75
Engine Coolant ........................................................................................ 77
Brake Fluid............................................................................................... 78
Battery..................................................................................................... 79
BREAK-IN PERIOD ...................................................................... 80
Engine ..................................................................................................... 80
Belt.......................................................................................................... 80
10-Hour Inspection .................................................................................. 80
PRE-OPERATION CHECK ............................................................ 81
OPERATING INSTRUCTIONS ...................................................... 82
General.................................................................................................... 82
Initial Cold Starting .................................................................................. 82
Warm Engine Starting ............................................................................. 83
Emergency Manual Starting.................................................................... 83
Stopping the Engine................................................................................ 83
Shifting the Transmission........................................................................ 83
2WD/4WD Selector................................................................................. 84
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4
SPECIAL PROCEDURES.............................................................. 85
Flooded Engine........................................................................................ 85
Engine Overheat...................................................................................... 85
Post-Operation Care ................................................................................ 85
Turn Over................................................................................................. 86
ATV Immersion........................................................................................ 86
Storage and Preseason Preparation ........................................................ 86
CARGO AND TRANSPORTATION ............................................... 87
Cargo ....................................................................................................... 87
Transportation.......................................................................................... 88
MAINTENANCE INFORMATION
MAINTENANCE CHART .............................................................. 90
MAINTENANCE .......................................................................... 92
Engine/Transmission ............................................................................... 92
Carburetor................................................................................................ 96
Air Intake System .................................................................................... 96
Electrical .................................................................................................. 97
Drive Train ............................................................................................... 98
Steering/Control Systems........................................................................ 100
Suspension .............................................................................................. 102
Brake ....................................................................................................... 103
Body/Frame ............................................................................................. 103
TROUBLESHOOTING .................................................................. 105
SPECIFICATIONS........................................................................ 108
SI METRIC INFORMATION GUIDE............................................... 116
WARRANTY
BOMBARDIER LIMITED WARRANTY NORTH AMERICA:
2004 BOMBARDIER®ATV........................................................... 118
BOMBARDIER INTERNATIONAL LIMITED WARRANTY:
2004 BOMBARDIER®ATV........................................................... 121
FREQUENTLY ASKED QUESTIONS ............................................. 124
PRIVACY OBLIGATIONS/DISCLAIMER ....................................... 126
CHANGE OF ADDRESS/OWNERSHIP .......................................... 127
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5
NOTICE
This Operator’s Guide has been pre-
pared to acquaint the owner/operator
of a new vehicle with the various vehi-
cle controls, maintenance and safe op-
erating instructions. It is indispensable
for the proper use of the product.
This Operator’s Guide uses the follow-
ing symbols.
CAUTION: Denotes an instruction
which, if not followed, could severe-
ly damage vehicle components.
NOTE: Indicates supplementary infor-
mation needed to fully complete an in-
struction.
Although the mere reading of such in-
formation does not eliminate the haz-
ard, the understanding and application
of the information will promote the cor-
rect use of the all-terrain vehicle (ATV).
To fully appreciate the pleasures, en-
joyment and excitement of using an
ATV, there are some basic rules that
MUST be observed and followed by any
user.
WARNING
Indicates a potentially hazardous
situation which, if not avoided,
could result in serious injury or
death.
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6
INTRODUCTION
Your selling dealer should have provided you with some basic information on the
particular controls and features of your new ATV. Please take the time to study
this Operator’s Guide and all on-product warning labels that came with the ATV. It
more completely describes what you should know about the ATV before riding it.
Whether you are a new user or an experienced rider, it is important for your
personal safety that you know the controls and features of the ATV. Equally im-
portant is knowing how to properly ride.
Regardless of your age, experience or state regulations, it is safer for you or any
other person who may ride your ATV, to take an approved ATV safe riding course.
Please check with your dealer or local authorities for availability in your area. If
you are a completely new ATV rider, this should be done before your first ride.
Your ATV instructor should be able to provide advice on local conditions and safe
riding practices particular to the areas.
Riding conditions vary from place to place. Each is subject to weather conditions
which may radically change from time to time and from season to season. Riding
on sand is different than riding on snow or through forests or marshes. Each loca-
tion may require a greater degree of awareness and skill. Always proceed with
caution. Please do not take any unnecessary risks that could leave you stranded
or possibly injured.
The contents of this Operator’s Guide provide riding information which has been
proven reliable by other ATV users. They are not intended as a definitive to avoid-
ing accidents. How you apply this information, coupled with your mental and
physical condition, the particular terrain hazard and your acceptance level to risk
will have an effect on your riding experience. Have fun…and ride responsibly.
This Operator’s Guide has been prepared to acquaint the owner/operator of a new
vehicle with the various vehicle controls, maintenance and safe operating instruc-
tions. It is indispensable for the proper use of the product.
We would be pleased to receive any comments on the content and format of the
Operator’s Guide, Safety Videocassette or on-product warnings.
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SAFETY INFORMATION 7
SAFETY
INFORMATION
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8SAFETY INFORMATION
SPECIAL SAFETY MESSAGES
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
An ATV handles differently from other vehicles including motorcycles and cars. A
collision or rollover can occur quickly, even during routine maneuvers such as
turning and driving on hills or over obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this Operator’s Guide and all on-product warning labels carefully and fol-
low the operating procedures described.
Never operate an ATV without proper instruction. Take a training course. Begin-
ners should receive training from a certified instructor. Contact an authorized ATV
dealer to find out about the training courses nearest you or call the Specialty
Vehicle Institute of America (SVIA) at 1 800 887-2887 or in Canada, the Canada
Safety Council (CSC) at 1 [phone] ext. 227.
Always follow this age recommendation: A child under 16 years old should
never operate this ATV.
Never carry a passenger on an ATV.
Never operate an ATV on any paved surfaces, including sidewalks, driveways,
parking lots and streets.
Never operate an ATV on any public street, road or highway, even a dirt or gravel
one.
Never operate an ATV without wearing an approved helmet that fits properly.
You should also wear eye protection (goggles or face shield), gloves, boots, long
sleeved shirt or jacket, and long pants.
Never consume alcohol or drugs before or while operating this ATV.
Never operate at excessive speeds. Always go at a speed that is proper for the
terrain, visibility, and operating conditions, and your experience.
Never attempt wheelies, jumps, or other stunts.
Always inspect your ATV each time you use it to make sure it is in safe operating
condition. Always follow the inspection and maintenance procedures and sched-
ules described further in this Operator’s Guide.
Always keep both hands on the handlebars and both feet on the footrests of
the ATV during operation.
Always go slowly and be extra careful when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when operating the ATV.
Never operate on excessively rough, slippery or loose terrain until you have
learned and practiced the skills necessary to control the ATV on such terrain.
Always be especially cautious on these kinds of terrain.
Always follow proper procedures for turning as described further in this Opera-
tor’s Guide. Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speed.
Never operate the ATV on hills too steep for the ATV or for your abilities. Prac-
tice on smaller hills before attempting larger hills.
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SAFETY INFORMATION 9
Always follow proper procedures for climbing hills as described further in this
Operator’s Guide. Check the terrain carefully before you start up any hill. Never
climb hills with excessively slippery or loose surfaces. Shift your weight forward.
Never open the throttle suddenly or make sudden gear changes. Never go over
the top of any hill at high speed.
Always follow proper procedures for going down hills and for braking on hills as
described further in this Operator’s Guide. Check the terrain carefully before you
start down any hill. Shift your weight backward. Never go down a hill at high
speed. Avoid going down a hill at an angle that would cause the vehicle to lean
sharply to one side. Go straight down the hill where possible.
Always follow proper procedures for crossing the side of a hill as described fur-
ther in this Operator’s Guide. Avoid hills with excessively slippery or loose sur-
faces. Shift your weight to the uphill side of the ATV. Never attempt to turn the
ATV around on any hill until you have mastered the turning technique described
further in this Operator’s Guide on level ground. Avoid crossing the side of a
steep hill if possible.
Always use proper procedures if you stall or roll backwards when climbing a
hill. To avoid stalling, use proper gear and maintain a steady speed when climb-
ing a hill. If you stall or roll backwards, follow the special procedure for braking
described further in this Operator’s Guide. Dismount on the uphill side or to a
side if pointed straight uphill. Turn the ATV around and remount, following the
procedure described further in this Operator’s Guide.
Always check for obstacles before operating in a new area. Never attempt to
operate over large obstacles, such as large rocks or fallen trees. Always follow
proper procedures when operating over obstacles as described further in this
Operator’s Guide.
Always be careful when skidding or sliding. Learn to safely control skidding or
sliding by practicing at low speeds and on level, smooth terrain. On extremely
slippery surfaces, such as ice, go slowly and be very cautious in order to reduce
the chance of skidding out of control.
Never operate an ATV in fast flowing water or in water deeper than that spec-
ified further in this Operator’s Guide. Remember that wet brakes may have
reduced stopping ability. Test your brakes after leaving water. If necessary,
apply them several times for friction to dry out the pads.
Always be sure there are no obstacles or people behind you when you operate
in reverse. When it is safe to proceed in reverse, go slowly.
Always use the size and type tires specified further in this Operator’s Guide.
Always maintain proper tire pressure as described further in this guide.
Never modify an ATV through improper installation or use of accessories.
Never exceed the stated load limits for an ATV. Cargo should be properly dis-
tributed and securely attached. Reduce speed and follow instructions in this
Operator’s Guide for carrying cargo or pulling a trailer. Allow greater distance
for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Specialty Vehicle
Institute of America (SVIA) at 1 800 887-2887 or in Canada, the Canada Safety
Council (CSC) at 1 [phone] ext. 227 or contact an authorized ATV dealer to
find out about the training courses nearest you.
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10 SAFETY INFORMATION
OPERATION WARNINGS
While reading this Operator’s Guide, remember that:
The following warnings and their format have been requested by the United
States Consumer Product Safety Commission and are required to be in this Op-
erator’s Guide for all ATV’s.
NOTE: The following illustrations are general representations only. Your model
may differ.
WARNING
Indicates a potential hazard that, if not avoided, could result in serious
injury or death.
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does not know
how to operate the ATV properly in different situations and on different
types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the certified
training course offered by Bombardier Inc. They should then regularly
practice the skills learned in the course and the operating techniques de-
scribed further in this Operator’s Guide.
For more information about the training course, contact an authorized
ATV dealer or call Bombardier Inc. at 1 [phone].
V00A0AQ
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SAFETY INFORMATION 11
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this ATV.
WHAT CAN HAPPEN
Use by children of ATVs that are not recommended for their age can lead
to severe injury or death of the child.
Even though a child may be within the age group for which an ATV is
recommended, he or she may not have the skills, abilities, or judgment
needed to operate the ATV safely and may be involved in a serious acci-
dent.
HOW TO AVOID THE HAZARD
No one under 16 should operate a Bombardier ATV.
V00A01Q
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12 SAFETY INFORMATION
WARNING
POTENTIAL HAZARD
Carrying a passenger on this ATV.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and control this ATV.
Could cause an accident, resulting in harm to you and/or your passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The long seat is to allow the operator to shift
position as needed during operation. It is not for carrying passengers.
V00A02Q
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SAFETY INFORMATION 13
WARNING
POTENTIAL HAZARD
Operating this ATV on paved surfaces.
WHAT CAN HAPPEN
The ATV’s tires are designed for off-road use only, not for use on pave-
ment. Paved surfaces may seriously affect handling and control of the
ATV, and may cause the vehicle to go out of control.
HOW TO AVOID THE HAZARD
Never operate the ATV on any paved surfaces, including sidewalks, drive-
ways, parking lots and streets.
V00A03Q
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14 SAFETY INFORMATION
WARNING
POTENTIAL HAZARD
Operating this ATV on public streets, roads or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate this ATV on any public street, road or highway, even a dirt
or gravel one. In many states it is illegal to operate ATVs on public streets,
roads and highways.
V00A04Q
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SAFETY INFORMATION 15
WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an approved helmet, eye protection
and protective clothing.
WHAT CAN HAPPEN
Operating without an approved helmet increases your chances of a severe
head injury or death in the event of an accident.
Operating without eye protection can result in an accident and increases
your chances of a severe injury in the event of an accident.
Operating without protective clothing increases your chances of severe
injury in the event of an accident.
HOW TO AVOID THE HAZARD
Always wear an approved helmet that fits properly. You should also wear:
–eye protection (goggles or face shield)
–gloves
–boots
–Iong sleeved shirt or jacket
–Iong pants.
V00A06Q
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16 SAFETY INFORMATION
WARNING
POTENTIAL HAZARD
Operating this ATV after consuming alcohol or drugs.
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or while driving this ATV.
V00A07Q
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SAFETY INFORMATION 17
WARNING
POTENTIAL HAZARD
Operating this ATV at excessive speeds.
WHAT CAN HAPPEN
Increases your chances of losing control of the ATV, which can result in
an accident.
HOW TO AVOID THE HAZARD
Always travel at a speed which is proper for the terrain, visibility and op-
erating conditions, and your experience.
V00A08Q
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18 SAFETY INFORMATION
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps and other stunts.
WHAT CAN HAPPEN
Increases the chance of an accident, including an overturn.
HOW TO AVOID THE HAZARD
Never attempt stunts, such as wheelies or jumps. Do not try to show off.
V00A09Q
vmo2004_001a.book Page 18 Wednesday, January 29, 2003 2:03 PM