BRP Outlander 400 EFI 2008 User manual

SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to correctly service and repair 2008/2009 Outlander™ 400 EFI
Series ATVs as describe in the model 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 B.R.P.T.I.
Please note that the instructions will apply only if proper hand tools and special service tools are used.
This shop manual uses technical terms which may be slightly different from the ones used in the
PARTS
CATALOG
.
It is understood that this manual may be translated into another language. In the event of any discrepan-
cy, the English version shall prevail.
The content depicts parts and/or procedures applicable to the particular product at time of writing. Ser-
vice 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.
WARNING
Unless otherwise specified, engine should be turned OFF and cold for all maintenance and repair
procedures.
This manual emphasizes particular information denoted by the wording and symbols:
WARNING
Identifies an instruction which, if not followed, could cause serious personal injury including pos-
sibility of death.
CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle compo-
nents.
NOTE: Indicates supplementary information needed to fully complete an instruction.
Although the mere reading of such information does not eliminate the hazard, your understanding of the
information will promote its correct use. Always use common shop safety practice.
BRP disclaims liability for all damages and/or injuries resulting from the improper use of the contents.
We strongly recommend that any services be carried out and/or verified by a highly skilled professional
mechanic. It is understood that certain modifications may render use of the vehicle illegal under existing
federal, provincial and state regulations.
VIII vmr2008-113

INTRODUCTION
Vehicle Serial Number
The Vehicle Identification Number (V.I.N.) is
scribed on vehicle description decal. See above.
It is also engraved on frame near vehicle descrip-
tion decal.
vmr2007-011-001_c
1. Vehicle serial number
Engine Serial Number
vmo2008-019-010_a
1. Engine serial number
ENGINE EMISSIONS
INFORMATION
Manufacturer's Responsibility
Manufacturers of engines must determine the ex-
haust emission levels for each engine horsepower
family and certify these engines with the United
States of America
ENVIRONMENTAL PROTEC-
TION AGENCY (EPA)
. An emissions control infor-
mation label, showing emission levels and engine
specifications, must be placed on each vehicle at
the time of manufacture.
Dealer Responsibility
When performing service on ATVs that carry an
emissions control information label, adjustments
must be kept within published factory specifica-
tions.
Replacement or repair of any emission related
component must be executed in a manner that
maintains emission levels within the prescribed
certification standards.
Dealers are not to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sion levels to exceed their predetermined factory
specifications.
Exceptions include manufacturer's prescribed
changes, such as altitude adjustments for exam-
ple.
Owner Responsibility
The owner/operator is required to have engine
maintenance performed to maintain emission
levels within prescribed certification standards.
The owner/operator is not to, and should not al-
low anyone to modify the engine in any manner
that would alter the horsepower or allow emis-
sions levels to exceed their predetermined factory
specifications.
EPA Emission Regulations
Some ATVs manufactured by BRP are certified
to the EPA as conforming to the requirements
of the regulations for the control of air pollution
from new ATV engines. This certification is con-
tingent on certain adjustments being set to factory
standards. For this reason, the factory procedure
for servicing the product must be strictly followed
and, whenever practicable, returned to the origi-
nal intent of the design.
The responsibilities listed above are general and
in no way a complete listing of the rules and regu-
lations pertaining to the EPA requirements on ex-
haust emissions for ATVs products. For more de-
tailed information on this subject, you may contact
the following locations:
FORALLCOURIERSERVICES:
U.S. Environmental Protection Agency
Office of Transportation and Air Quality
1310 L Street NW
Washington D.C. 20005
REGULAR US POSTAL MAIL:
1200 Pennsylvania Ave. NW
Mail Code 6403J
Washington D.C. 20460
INTERNET: http://www.epa.gov/otaq/
E-MAIL: [e-mail]
Xvmr2008-113

INTRODUCTION
TIGHTENING TORQUE
Tighten fasteners to torque mentioned in explod-
ed views and/or text, When they are not specified,
refer to following table.
WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pins,
etc.) must be replaced with new ones.
In order to avoid a poor assembling, tighten
screws, bolts or nuts in accordance with the
following procedure:
Manually screw all screws, bolts and/or nuts.
Apply the half ofthe recommended torque value.
CAUTION: Be sure to use proper tightening
torque for the proper strength grade.
NOTE: When possible, always apply torque on the
nut.
Torque at the recommended torque value.
NOTE: Always torque screws, bolts and/or nuts in
a crisscross sequence.
A00A8BS
Property
class and
head
markings
Property
class and
nut
markings
5
5
8
8
10
10
12
12
4.8
4.8
4.8
8.8
8.8
8.8
.8
.8
.8
10.
10.
10.
12.
12.
12.
12.
FASTENER GRADE/TORQUE
FASTENER
SIZE 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Grade
M4 1.5 – 2 N•m
(13 – 18 lbf•in)2.5 – 3 N•m (22 – 27 lbf•in)3.5–4N•m (31 – 35 lbf•in)4–5N•m (35 – 44 lbf•in)
M5 3–3.5N•m
(27 – 31 lbf•in)4.5 – 5.5 N•m (40 – 47 lbf•in)7–8.5N•m (62 – 75 lbf•in)8–10N•m (71 – 89 lbf•in)
M6 6.5 – 8.5 N•m
(58 – 75 lbf•in)8–12N•m (71 – 106 lbf•in)10.5 – 15 N•m (93 – 133 lbf•in)16 N•m (142 lbf•in)
M8 15 N•m (133 lbf•in) 25 N•m (18 lbf•ft) 32 N•m (23 lbf•ft) 40 N•m (30 lbf•ft)
M10 29 N•m (21 lbf•ft) 48 N•m (35 lbf•ft) 61 N•m (45 lbf•ft) 73 N•m (53 lbf•ft)
M12 52 N•m (38 lbf•ft) 85 N•m (63 lbf•ft) 105 N•m (77 lbf•ft) 128 N•m (94 lbf•ft)
M14 85 N•m (63 lbf•ft) 135 N•m (100 lbf•ft) 170 N•m (125 lbf•ft) 200 N•m (148 lbf•ft)
vmr2008-113 XI

INTRODUCTION
SELF-LOCKING FASTENERS
PROCEDURE
A00A6LA
TYPICAL — SELF-LOCKING FASTENER
The following describes the most common appli-
cation procedures when working with self-locking
fasteners.
Use a metal brush or a tap to clean the hole prop-
erly then use a solvent, let act during 30 minutes
and wipe off. The solvent utilization is to ensure
the adhesive works properly.
LOCTITE®APPLICATION
PROCEDURE
The following describes the most common ap-
plication procedures when working with Loctite
products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this shop manual.
Threadlocker
Uncovered Holes (bolts and nuts)
A00A3LA
1
2
1. Apply here
2. Do not apply
Clean threads (bolt and nut) with solvent.
Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
Choose proper strength Loctite threadlocker.
Fit bolt in the hole.
Apply a few drops of threadlocker at proposed
tightened nut engagement area.
Position nut and tighten as required.
Blind Holes
1
2
lmr2007-040-004_a
1. On threads
2. On threads and at the bottom of hole
Clean threads (bolt and hole) with solvent.
Apply Loctite Primer N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30 sec-
onds.
Choose proper strength Loctite threadlocker.
Apply several drops along the threaded hole and
at the bottom of the hole.
Apply several drops on bolt threads.
Tighten as required.
Stud in Blind Holes
2
13
lmr2007-040-005_a
1. On threads
2. On threads and in the hole
3. Onto nut threads
Clean threads (stud and hole) with solvent.
Apply Loctite Primer N (P/N 293 800 041) on
threads and allow to dry.
Put 2 or 3 drops of proper strength Loctite
threadlocker on female threads and in hole.
XII vmr2008-113

INTRODUCTION
NOTE: To avoid a hydro lock situation, do not apply
too much Loctite.
Apply several drops of proper strength Loctite on
stud threads.
Install stud.
Install cover, etc.
Apply drops of proper strength Loctite on uncov-
ered threads.
Tighten nuts as required.
Pre-Assembled Parts
A00A3OA
1
2
1. Apply here
2. Do not apply
Clean bolts and nuts with solvent.
Assemble components.
Tighten nuts.
Apply drops of proper strength Loctite on
bolt/nut contact surfaces.
Avoid touching metal with tip of flask.
NOTE: For preventive maintenance on exist-
ing equipment, retighten nuts and apply proper
strength Loctite on bolt/nut contact surfaces.
Adjusting Screw
A00A3PA
12
1. Apply here
2. Plunger
Adjust screw to proper setting.
Apply drops of proper strength Loctite thread-
locker on screw/body contact surfaces.
Avoid touching metal with tip of flask.
NOTE: If it is difficult to readjust, heat screw with
a soldering iron (232°C (450°F)).
Stripped Thread Repair
A00A3QA
5
8
6
7
1
2
3
4
1. Release agent
2. Stripped threads
3. Form-A-Thread
4. Tapes
5. Cleaned bolt
6. Plate
7. New threads
8. Threadlocker
Standard Thread Repair
– Follow instructions on Loctite FORM-A-
THREAD 81668 package.
– If a plate is used to align bolt:
a. Apply release agent on mating surfaces.
b. Put waxed paper or similar film on the sur-
faces.
– Twist bolt when inserting it to improve thread
conformation.
NOTE: NOT intended for engine stud repairs.
vmr2008-113 XIII

INTRODUCTION
Repair of Small Holes/Fine Threads
Option 1: Enlarge damaged hole, then follow
STANDARD THREAD REPAIR procedure.
Option 2: Apply FORM-A-THREAD on the screw
and insert in damaged hole.
Permanent Stud Installation (light duty)
– Use a stud or thread on desired length.
– DO NOT apply release agent on stud.
–Doa
STANDARD THREAD REPAIR .
– Allow to cure for 30 minutes.
– Assemble.
Gasket Compound
21
1
3
1
lmr2007-040-006_a
1. Proper strength Loctite
2. Loctite Primer N (P/N 293 800 041) and Loctite 518
(P/N 293 800 038) on both sides of gasket
3. Loctite Primer N only
Remove old gasket and other contaminants
with Loctite Chisel (gasket remover (P/N 413
708 500). Use a mechanical mean if necessary.
NOTE: Avoid grinding.
Clean both mating surfaces with solvent.
Spray Loctite Primer N on both mating surfaces
and on both sides of gasket. Allow to dry 1 or 2
minutes.
Apply Loctite 518 (P/N 293 800 038) on both
sides of gasket, using a clean applicator.
Place gasket on mating surfaces and assemble
immediately.
NOTE: If the cover is bolted to blind holes (above),
apply proper strength Loctite in the hole and on
threads. Tighten.
If holes are sunken, apply proper strength Loc-
tite on bolt threads.
Tighten as usual.
Mounting on Shaft
Mounting with a Press
A00A3UA
1
2
3
1. Bearing
2. Proper strength Loctite
3. Shaft
Clean shaft external part and element internal
part.
Apply a strip of proper strength Loctite on shaft
circumference at insert or engagement point.
NOTE: Retaining compound is always forced out
whenappliedonshaft.
DO NOT use antiseize Loctite or any similar
product.
No curing period is required.
Mounting in Tandem
Apply retaining compound on internal element
bore.
Continue to assemble as shown above.
Case-In Components
Metallic Gaskets
A00A3VA 1
1. Proper strength Loctite
Clean inner housing diameter and outer gasket
diameter.
XIV vmr2008-113

INTRODUCTION
Spray housing and gasket with Loctite Primer N
(P/N 293 800 041).
Apply a strip of proper strength Loctite on lead-
ing edge of outer metallic gasket diameter.
NOTE: Any Loctite product can be used here. A
low strength liquid is recommended as normal
strength and gap are required.
Install according to standard procedure.
Wipe off surplus.
Allow it to cure for 30 minutes.
NOTE: Normally used on worn-out housings to
prevent leaking or sliding.
It is generally not necessary to remove gasket
compound applied on outer gasket diameter.
MANUAL INFORMATION
The manual is divided into many major sections as
you can see in the main table of contents at the
beginning of the manual.
Each section is divided in various subsections, and
again, each subsection has one or more division.
Illustrations and photos show the typical construc-
tion of the different assemblies and, in all cases,
may not reproduce the full detail or exact shape of
the parts shown. However, they represent parts
which have the same or a similar function.
CAUTION: Most components of those vehicles
are built with parts dimensioned in the metric
system. Most fasteners are metric and must
not be replaced by customary fasteners or
vice-versa. Mismatched or incorrect fasteners
could cause damage to the vehicle or possible
personal injury.
As many of the procedures in this manual are inter-
related, we suggest, that before undertaking any
task, you read and thoroughly understand the en-
tire section or subsection in which the procedure
is contained.
A number of procedures throughout the book re-
quire the use of special tools. Before commenc-
ing any procedure, be sure that you have on hand
all the tools required, or approved equivalents.
The use of RIGHT and LEFT indications in the text,
always refers to driving position (when sitting on
vehicle).
vmr2008-113 XV

INTRODUCTION
Section 06 ENGINE
Subsection 01 (MAGNETO)
MAGNETO
Models
55
mmr2008-001
XXX0000
Model
Loctite 243
5 Nm
(44 lbfin)
1
NEW
Page heading
indicates section
and subsection.
Exploded view assists
you in identifying parts
and their related
positions.
TYPICAL PAGE
Illustration number
for publishing process.
Subsection title
Indicates applicable
models.
Document number for
publishing process.
Bold face number
is used to identify
a part referred to
the text.
Drop represents a
service product
to be applied.
Dotted box contains
parts applicable to a
specific model.
Page number
NEW indicates that the
part must be replaced
with a new one.
Typical_iso_2008_en
XVI vmr2008-113

INTRODUCTION
TYPICAL PAGE
Subsection 0 (MAGNETO SYSTEM)
GENERAL
NOTE: he following procedures can be done
without removing the engine.
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 the
SELF-LOCKING FASTENERS
and
LOC-
I E APPLICA ION
sections at the beginning of
this manual for complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones.
PROCEDURES
MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean magneto flywheel using only
a clean cloth.
Magneto Flywheel Removal
Remove muffler, refer to the EXHAUST S STEM
section.
Remove acoustic panel.
Remove rewind starter.
Remove starting pulley no. 2.
TYPICAL
NOTE: o remove starting pulley bolts, hold mag-
neto flywheel with a socket as shown.
TYPICAL
Models
Remove the connecting flange retaining the
rewind starter to the engine housing.
Section 03 ENGINE
1. Starting pulley
1
Subsection 0 (MAGNETO SYSTEM)
GENERAL
NOTE: he following procedures can be done
without removing the engine.
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 the
SELF-LOCKING FASTENERS
and
LOC-
I E APPLICA ION
sections at the beginning of
this manual for complete procedure.
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, etc.) must
be replaced with new ones.
PROCEDURES
MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean magneto flywheel using only
a clean cloth.
Magneto Flywheel Removal
Remove muffler, refer to the EXHAUST S STEM
section.
Remove acoustic panel.
Remove rewind starter.
Remove starting pulley no. 2.
TYPICAL
NOTE: o remove starting pulley bolts, hold mag-
neto flywheel with a socket as shown.
TYPICAL
Models
Remove the connecting flange retaining the
rewind starter to the engine housing.
Section 03 ENGINE
1. Starting pulley
1
Indicates component
procedures apply to.
Reference to a
specific section
or subsection.
Call-outs pertaining
to above illustration.
Italic bold face type-
setting indicates a
procedure applicable
to a specific
model(s).
 YPICAL
indicates a general
view which may
not represent exact
details.
Illustration always
follows text to which
it applies.
Indicates specific
procedure to be
carried out.
Bold face number following part
name refers to exploded view
at beginning of subsection.
mmr2007-016-002
ittle in bold
indicates category
of information to be
carried out.
mmr2008-001 57
typical_txt_2008_en
vmr2008-113 XVII