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

Section01MAINTENANCE
Subsection 01 (MAINTENANCE CHART)
MAINTENANCE CHART
MAINTENANCE CHART
The schedule should be adjusted according to operating conditions and use. The initial maintenance is
very important and must not be neglected.
NOTE: The chart gives an equivalence between number of hours and months/year. Perform the mainte-
nance operation to whatever time comes first.
IMPORTANT: ATV rental operations or intensive use of ATV, will require greater frequency of inspection
and maintenance.
INITIAL INSPECTION 10 H OR 30 DAYS OR 300 km (185 mi)
25 H OR 750 km (470 mi)
50 H OR 1500 km (930 mi)
100 H OR 1 YEAR OR 3000 km (1865 mi)
A:
C:
I:
L:
R:
ADJUST
CLEAN
INSPECT
LUBRICATE
REPLACE 200HOR2YEARSOR6000km(3730mi)
PART/TASK REFER TO
ENGINE
Engine oil and filter R R
LUBRICATION SYSTEM
Valves I, A I, A CYLINDER HEAD/CYLINDER
Engine seals I I
ENGINE
Engine mounting fasteners I I
ENGINE REMOVAL/INSTALLATION
Air filter C (1) R AIR INTAKE SYSTEM
Exhaust system I I
Spark arrester C
EXHAUST SYSTEM
Coolant II
(2) R
Radiator cap/cooling system pressure test I I
Radiator I, C
(1) I, C (1)
COOLING SYSTEM
Rewind starter rope I
REWIND STARTER
ENGINE MANAGEMENT SYSTEM
EMS sensors II
EMS fault codes I I
ENGINE MANAGEMENT
FUEL SYSTEM
Throttle body I I,L
ELECTRONIC FUEL INJECTION
Throttle cable I, A,
LI, A, L
STEERING SYSTEM
Fuel lines, connections and fuel tank
pressure test II
In-line fuel filter (2008 models only) R
Fuel pump pressure test I
FUEL TANK AND FUEL PUMP
vmr2008-114 1

Section 01 MAINTENANCE
Subsection 01 (MAINTENANCE CHART)
INITIAL INSPECTION 10 H OR 30 DAYS OR 300 km (185 mi)
25 H OR 750 km (470 mi)
50 H OR 1500 km (930 mi)
100 H OR 1 YEAR OR 3000 km (1865 mi)
A:
C:
I:
L:
R:
ADJUST
CLEAN
INSPECT
LUBRICATE
REPLACE 200HOR2YEARSOR6000km(3730mi)
PART/TASK REFER TO
ELECTRICAL SYSTEM
Spark plug IGNITION SYSTEM
Battery connections I I CHARGING SYSTEM
ECM connectors
(visual inspection without disconnecting) I
ELECTRONIC FUEL INJECTION
Electrical connections and fastening
(ignition system, starting system, fuel
injectors etc.) II
IGNITION SYSTEM , STARTING SYSTEM
and ELECTRONIC FUEL INJECTION
Ignition switch, engine start button and
engine stop switch II
IGNITION SYSTEM and STARTING SYSTEM
Lighting system (HI/LO intensity, brake
lamp, headlamp aiming, etc.) II
LIGHTS, GAUGE AND ACCESSORIES
CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
Drive belt I
Drive and driven pulleys I, C
One-way bearing inside CVT I, L
CVT air inlet/outlet duct I I, C
CONTINUOUSLY VARIABLE
TRANSMISSION (CVT)
DRIVE TRAIN
Front and rear differentials seals and
vents II
Front and rear differentials oil I I R
Drive shaft boots and protectors I I
Drive shaft joints I
FRONT DRIVE and REAR DRIVE
Rear propeller shaft joints (1) ILI REAR DRIVE
4 x 4 coupling unit I I 4X4COUPLINGUNIT
WHEELS/TIRES
Wheel bearings I
STEERING SYSTEM
Wheel nuts/studs I I WHEELS/TIRES
STEERING SYSTEM
Handlebar fastener I
Steering system mechanism
(column, bearing, etc.) II
(2)
Tie rod ends I
Front wheel alignment I I, A
STEERING SYSTEM
2vmr2008-114

Section01MAINTENANCE
Subsection 01 (MAINTENANCE CHART)
INITIAL INSPECTION 10 H OR 30 DAYS OR 300 km (185 mi)
25 H OR 750 km (470 mi)
50 H OR 1500 km (930 mi)
100 H OR 1 YEAR OR 3000 km (1865 mi)
A:
C:
I:
L:
R:
ADJUST
CLEAN
INSPECT
LUBRICATE
REPLACE 200HOR2YEARSOR6000km(3730mi)
PART/TASK REFER TO
SUSPENSION
Trailing arms I
Trailing arm bearings I
REAR SUSPENSION
Shock absorbers I
FRONT SUSPENSION and
REAR SUSPENSION
A-arms I, L
Ball joints I
FRONT SUSPENSION
BRAKES
Brake fluid I I R
Brake system (discs, hoses, etc.) I
Brake pads I (1)
BRAKES
BODY/FRAME
Frame fastener I
Frame I
BODY/FRAME
(1) More often under severe use such as dusty area, sand, snow, wet or muddy conditions.
(2) Every 100 hours, check coolant strength.
vmr2008-114 3

Section01MAINTENANCE
Subsection 02 (PRESEASON PREPARATION)
PRESEASON PREPARATION
Prior to use vehicle, proper vehicle preparation is
required after performing the storage procedure.
Any worn, broken or damaged parts found during
the storage procedure should have been replaced.
If not, proceed with the replacement.
Using the maintenance chart, performed items in
the column indicated: 100 h or 1 year or 3000 km
(1865 mi).
vmr2007-013-001_aen
1. Use this column
Furthermore, proceed with the following:
Vehicles Prepared as per Storage
Procedure
Remove rags from: CVT inlet and outlet hoses,
engine air intake and muffler.
Test drive vehicle to confirm proper operation.
Vehicles Not Prepared as per
Storage Procedure
Replace engine oil and filter.
Drain fuel tank and fill with fresh fuel.
Test drive vehicle to confirm proper operation.
vmr2008-115 5

Section01MAINTENANCE
Subsection 03 (STORAGE PROCEDURE)
STORAGE PROCEDURE
SERVICE PRODUCTS
Description Part Number Page
BRP heavy duty cleaner........................................................ 293 110 001 ............................................. 8
XP-S Lube............................................................................. 293 600 016 ............................................. 8
BRP fuel stabilizer................................................................. 413 408 600 ............................................. 7
Vinyl & Plastic Cleaner.......................................................... 413 711 200 ............................................. 8
storage oil............................................................................. 413 711 600 ............................................. 7
storage oil (US)..................................................................... 413 711 900 .............................................7
IftheATVisnotusedoristobestoredforan
extended period of time, more than 4 months, be
sure to perform the storage procedures described
below.
FUEL SYSTEM
Fuel System Protection
With the new fuel additives, it is critical to use the
BRP fuel stabilizer (P/N 413 408 600) or an equiva-
lent to prevent fuel deterioration and fuel system
gumming. Follow the manufacturer's instructions
forproperuse.
CAUTION: Fuel stabilizer should be added
prior to engine lubrication to ensure fuel sys-
tem components protection against varnish
deposits.
Pour fuel stabilizer in fuel tank. Fill up fuel tank.
Do not drain fuel system.
ENGINE
Engine Oil and Filter Replacement
Change engine oil and filter. Refer to LUBRICA-
TION SYSTEM
.
Engine Internal Lubrication
Engine internal parts must be lubricated to protect
them from rust formation during the storage peri-
od.
WARNING
This procedure must only be performed in a
well-ventilated area. Do not run engine dur-
ing storage period.
Proceed as follows:
Start the engine and allow it to run at idle speed
until the engine reaches its operating tempera-
ture.
Stop the engine.
Change engine oil and filter. Refer to LUBRICA-
TION SYSTEM
section.
Remove spark plug and spray storage oil
(P/N 413 711 600) into cylinder.
NOTE: For US citizens, use storage oil (US)
(P/N 413 711 900) only.
CAUTION: Do not inject storage oil into throttle
body bore to avoid blocking idle bypass valve.
Press start button, 1 or 2 seconds maximum, to
lubricate cylinder.
Reinstall the spark plug.
COOLING SYSTEM
Coolant Inspection
Test coolant density using an antifreeze hydrome-
ter.
NOTE: Follow manufacturer's instructions for
proper use.
A 50/50 mixture of antifreeze and distilled water
will provide the optimum cooling, corrosion pro-
tection and antifreeze protection.
CAUTION: Do not use tap water, straight
antifreeze 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
antifreeze will cause system temperature prob-
lems.
Change coolant if necessary. Refer to
COOLING
SYSTEM
section.
CVT TRANSMISSION
Pulley Inspection, Cleaning and
Protection
Remove drive belt from pulleys.
vmr2008-116 7

Section 01 MAINTENANCE
Subsection 03 (STORAGE PROCEDURE)
Inspect and clean pulleys then spray XP-S Lube
(P/N 293 600 016) on pulley faces.
Do not reinstall drive belt. Close CVT cover.
ELECTRICAL SYSTEM
Battery Removal and Storage
Remove the battery. Store it in dry and cool place
out of the sun, refer to
BATTERY in CHARGING
SYSTEM
section.
VEHICLE
Vehicle Cleaning
To facilitate the inspection and ensure adequate
lubrication of components, it is recommended to
clean the entire vehicle.
Wash and dry the vehicle.
CAUTION: Never use a high pressure washer
to clean the vehicle. USE LOW PRESSURE ON-
LY (like a garden hose). The high pressure can
cause electrical or mechanical damages.
Remove any dirt or rust.
To clean the vinyl or plastic parts, use only flannel
clothes with Vinyl & Plastic Cleaner (P/N 413 711
200).
CAUTION: It is necessary to use flannel cloths
on plastic parts to avoid damaging surfaces.
Never clean plastic parts with strong detergent,
degreasing agent, paint thinner, acetone, prod-
ucts containing chlorine, etc.
To clean the entire vehicle, including metallic parts
use BRP heavy duty cleaner (P/N 293 110 001).
Inspect the vehicle and repair any damage. Touch
up all metal spots where paint has been scratched
off. Spray all metal parts with XP-S Lube (P/N 293
600 016).
Vehicle Protection
To prevent the intrusion of small animals or oth-
er debris, block the following locations with clean
rags:
– CVT air inlet duct
– CVTairoutletduct
– Air intake inlet
– Muffler.
CAUTION: Do not forget, these rags must be
removed during preseason preparation before
starting the vehicle.
To reach the CVT air inlet duct and the air intake
inlet, lift the console. Refer to BODY .
vmr2008-116-001_a
1. Console
vmr2008-116-002_a
1. CVT inlet hose
2. Air intake inlet
The CVT outlet hose is located at the rear of en-
gine, against vertical frame beam. The removal of
the left side panel is necessary to reach the hose.
vmr2008-116-003_a
1. CVT outlet hose
2. CVT cover
Protect the vehicle with a cover to prevent dust
accumulation during storage.
CAUTION: The vehicle has to be stored in a
cool and dry place and covered with an opaque
tarpaulin. This will prevent sun rays and grime
from affecting plastic components and vehicle
finish.
8vmr2008-116

Section01MAINTENANCE
Subsection 04 (SPECIAL PROCEDURES)
SPECIAL PROCEDURES
SERVICE PRODUCTS
Description Part Number Page
XP-S Lube............................................................................. 293 600 016 ....................................... 9–10
NOTE: These procedures give a guideline of
things to do if one of these abnormal situations
occur with the vehicle.
TURN OVER
When vehicle is turned over or stays tilted on the
side, put the vehicle back on its wheels, then wait
3 to 5 minutes before starting the engine.
Inspect air filter housing drain tube for oil accumu-
lation, if any oil is found, clean air filter and air filter
housing. Refer to
AIR INTAKE SYSTEM section.
Check oil level and refill if necessary.
Check engine coolant level and refill if necessary.
Start engine and let it run at idle, around 1 minute,
then stop engine. Check oil level immediately.
CAUTION: Stop engine immediately if the LOW
OIL message and check engine indicator light
stay ON.
If the engine oil level is good, check the following:
– Oil filter for contamination. Replace oil filter and
oil.
If the problem is still not resolved, check the fol-
lowing:
– Oil pressure switch for damages. Replace it if
necessary.
– Oil strainer cleanliness and damages. Clean or
replace oil strainer.
– Oil pressure regulator valve stays open in the
crankcase due to contamination (metallic parti-
cles). Clean or replace the valve.
– Valve piston stuck in the oil pump housing. Re-
pair valve piston.
– Oil pump cleanliness and operation. Clean or
replace oil pump if necessary.
ATV IMMERSION
ATV Submerged for a Long Time
(Over One Hour)
Disassemble engine and transmission to clean the
internal parts and check if there is no rust or cor-
rosion on any internal parts. Refer to the specific
ENGINE section.
Drain air filter housing then clean and dry air filter.
Remove muffler and empty it. Let muffler dry
then reinstall it on the vehicle.
Flush fuel tank and refill with new gas.
Lubricate throttle body. Refer to
FUEL SYSTEM .
Look for water in:
– Brake system (replace brake fluid)
– Differentials (drain oil and check internal parts
for rust or corrosion then refill).
Lubricate all cables. Check if the cables operate
properly.
Spray all metal parts with XP-S Lube (P/N 293 600
016).
Test ride to confirm all is working well (electrical
and mechanical components).
ATV Submerged for a Short Time
(Less than One Hour)
Check if engine oil is contaminated (oil will be
milky). If so, perform the following instructions.
Drain engine oil.
Drain air filter housing then clean and dry air filter.
Look for water in fuel tank, in doubt, flush fuel
tank and refill with new gas.
Drain the CVT housing. Refer to CONTINUOUS-
LY VARIABLE TRANSMISSION (CVT)
.
Remove the CVT cover then clean and check all
parts of CVT.
Lubricate all cables. Check if the cables operate
properly.
Remove spark plug then crank engine slowly
several times.
Add a small quantity of engine oil in cylinder
(approximately 2 teaspoonfuls). Do not reinstall
spark plug at this moment.
Refill engine at the proper level with the recom-
mended oil. Crank engine several times.
Check condition of spark plug. If spark plug ap-
pears good reinstall it, if not install a new one.
vmr2008-117 9

Section 01 MAINTENANCE
Subsection 04 (SPECIAL PROCEDURES)
Start the engine and allow it to run at idle speed
until the engine reaches its operating tempera-
ture.
Stop the engine.
Change engine oil and filter.
NOTE: Change oil as many times as necessary,
until there is no white appearance in engine oil.
Spray all metal parts with XP-S Lube (P/N 293 600
016).
Test drive to confirm all is working well (electrical
and mechanical components).
10 vmr2008-117

Section02TROUBLESHOOTING
Subsection 01 (TECHNICAL GUIDELINES)
TECHNICAL GUIDELINES
The following charts are provided to help in diagnosing the probable source of troubles. It should be used
as a guideline.
ENGINE
Cooling System
Symptom: HIGH ENGINE OPERATING TEMPERATURE
1. Check mud/dust in radiator fins.
-Radiator fin obstructed, hard air cooling. Clean radiator fins.
2. Check coolant level.
-Coolant less than recommended level. Refill.
3. Check radiator cap.
-Defective radiator cap relief valve. Replace.
4. Check vent holes in coolant expansion tank cap.
-Inner cap vent hole of coolant expansion tank is clogged. Replace.
-Cap vent hole of coolant expansion tank is clogged. Replace.
5. Check cooling fan fuse and relay.
-Faulty fan switch and/or faulty fuse. Replace defective part(s).
6. Check cooling fan and connection.
-Fan motor faulty. Replace.
-Wire harness is brittle or hard (no connection). Replace.
7. Check radiator condition for leakage.
-Radiator swelled, cracked or deformed. Replace radiator.
8. Check condition of hoses and clamps fixation.
-Hoses are brittle and/or hard. Replace.
-Hose clamps are loose. Retighten clamps.
9. Check for air bubbles in cooling system.
-Air in cooling system. Refill and bleed cooling system (refer to COOLING SYSTEM ).
10. Check engine temperature sensor for electrical/mechanical failure.
-Engine is not overheating. Temperature sensor defective. Replace.
11. Check thermostat.
-Thermostat defective. Replace.
12. Check coolant bleeding screw on thermostat housing.
-Screw is loosed/missing and/or gasket ring is missing/broken. Retighten/add screw and replace
gasket ring.
13. Check gasket(s) of water pump cover.
-Leakage in water pump cover area. Retighten screws and/or replace gasket.
14. Check leak indicator hole (water pump housing area MAG side) if coolant leaks.
-Coolant leaking from leak indicator hole means a damaged rotary seal inside magneto cover.
Replace both rotary seal and oil seal (refer to COOLING SYSTEM and MAGNETO/STARTER ).
15. Check condition of water pump impeller.
-Impeller wings broken and/or impeller thread is damaged. Replace.
vmr2008-118 11

Section 02 TROUBLESHOOTING
Subsection 01 (TECHNICAL GUIDELINES)
Symptom: HIGH ENGINE OPERATING TEMPERATURE (cont’d)
16. Check cylinder head and/or cylinder base gasket.
-Worn out gasket(s) is (are) causing water leakage. Replace gasket(s) and refill with coolant and
oil (refer to
COOLING SYSTEM and LUBRICATION SYSTEM ).
17. Check intermediate gear(s) behind magneto cover.
-Worn out and/or broken gear(s) is (are) causing less coolant supply. Replace worn out and/or
broken gear(s) (refer to
LUBRICATION SYSTEM and MAGNETO/STARTER ).
18. Check if water pump shaft is seized.
-Water pump shaft does not turn. Replace defective part(s).
Lubrication System
Symptom: LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION
1. Check oil level and look for leakage on crankcase and/or defective seals.
-Crankcase is leaking due to damage. Rebuild engine with new crankcase and gasket parts. Use
recommended oil (refer to TECHNICAL SPECIFICATIONS ).
-Crankcase is leaking due to loose screws. Retighten screws with recommended torque.
-Sealing rings, O-rings and/or gaskets are brittle and/or hard or damaged. Replace damaged parts.
-Piston rings worn out (blue-colored engine exhaust emission). Replace piston rings (refer to
CYLINDER HEAD/CYLINDER ).
-Piston rings are broken (low compression and blue-colored engine exhaust emission). Replace
piston rings (refer to
CYLINDER HEAD/CYLINDER ).
-Valve stem seal damaged and/or sealing lip is hard and/or brittle. Replace all valve stem seals.
2. Check oil drain plug underneath engine.
-Plug is loosen and/or gasket ring is missing. Retighten the plug and/or place gasket ring.
3. Check leak indicator hole for oil leaks (crankcase MAG, beside water pump housing area).
-Oil leaking from leak indicator hole means a damaged oil seal of water pump shaft inside mag-
neto cover. Replace both rotary seal and oil seal (refer to
COOLING SYSTEM and MAGNE-
TO/STARTER ).
4. Check oil filter for contamination.
-Oil filter clogged. Replace oil filter and oil at the same time. Use recommended oil (refer to
TECHNICAL SPECIFICATIONS ).
5. Check oil pressure switch operation.
-Oil pressure switch damaged. Replace oil pressure switch.
6. Check oil strainer underneath engine.
-Screw(s) is (are) loosed and/or gasket is damaged, brittle or hard. Retighten screw and/or replace
gasket.
-Oil strainer is clogged due to contamination. Clean or replace strainer and diagnose causes. Re-
place possible damaged parts. Use recommended oil (refer to
TECHNICAL SPECIFICATIONS ).
7. Check oil orifice(s) on the oil pump suction side.
-Oil orifice(s) is (are) clogged. Clean from contamination. Replace oil and oil filter if necessary
(refer to
MAINTENANCE or LUBRICATION SYSTEM ).
8. Check oil pressure regulator valve (spring) operation.
-Valve spring damaged (valve always open). Replace spring.
-Valve piston in oil pump housing stays open due to contamination (metallic particles). Clean
and/or repair valve piston and oil pump housing.
12 vmr2008-118