Can-Am commander 800R Install guide

2011
Shop Manual
CommanderTM 800R/1000
Series
can-am

Legal deposit:
National Library of Quebec
National Library of Canada 2010
All rights reserved. No parts of this manual may be reproduced in any form
without the prior written permission of Bombardier Recreational Products Inc. (BRP)
© Bombardier Recreational Products Inc. (BRP) 2010
Printed in Canada
Technical Publications
Bombardier Recreational Products Inc. (BRP)
Valcourt QC Canada
®
TM
Trademarks of Bombardier Recreational Products Inc. (BRP) or its affiliates.
* Trademarks. of Bombardier Inc., used under license.
Can-AmTM

iTC
TM
D.E.S.S.TM

Rotax®
XPSTM
This document contains the trademarks of the following companies:
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Visco-lok® is a trademark of GNK Viscodrive GmbH

TABLE OF CONTENTS
SAFETY NOTICE  IX
INTRODUCTION 
X
VEHICLE INFORMATION

X
ENGINE EMISSIONS INFORMATION 
XII
MANUAL INFORMATION 
XIII
FASTENER INFORMATION 
XVII
01 MAINTENANCE
01 - BREAK-IN INSPECTION 
5
02 - PERIODIC MAINTENANCE SCHEDULE

7
03 - PERIODIC MAINTENANCE PROCEDURES

9
GENERAL  9
PROCEDURES 
9
AIR FILTER REPLACEMENT 
9
MUFFLER SPARK ARRESTER CLEANING AND INSPECTION 
10
ENGINE OIL LEVEL VERIFICATION 
11
ENGINE OIL CHANGE

12
ENGINE OIL FILTER REPLACEMENT 
12
RECOMMENDED ENGINE COOLANT

13
ENGINE COOLANT LEVEL VERIFICATION 
13
ENGINE COOLANT SPECIFIC GRAVITY CHECK 
14
ENGINE COOLANT REPLACEMENT 
14
COOLING SYSTEM INSPECTION 
17
COOLING SYSTEM LEAK TEST

18
PRESSURE CAP TEST 
19
ENGINE VALVE CLEARANCE ADJUSTMENT 
19
CVT AIR FILTER CLEANING 
19
DRIVE BELT INSPECTION 
20
DRIVE PULLEY, DRIVEN PULLEY AND ONE-WAY BEARING MAINTENANCE 
20
CVT AIR INLET/OUTLET CLEANING 
20
GEARBOX OIL LEVEL VERIFICATION 
21
GEARBOX OIL REPLACEMENT 
21
THROTTLE BODY INSPECTION 
22
FUEL TANK VENT BREATHER FILTER REPLACEMENT

22
FUEL SYSTEM INSPECTION 
22
FUEL PUMP PRESSURE TEST 
22
FUEL PUMP PREFILTER CLEANING 
22
BATTERY INSPECTION

22
SPARK PLUG REPLACEMENT 
22
VEHICLE SPEED SENSOR (VSS) CLEANING

23
FRONT DIFFERENTIAL OIL LEVEL VERIFICATION

23
FRONT DIFFERENTIAL OIL REPLACEMENT

23
REAR FINAL DRIVE OIL LEVEL VERIFICATION

24
REAR FINAL DRIVE OIL REPLACEMENT

24
DRIVE SHAFT BOOT AND PROTECTOR (VISUAL INSPECTION)

24
DRIVE SHAFT JOINT INSPECTION

25
PROPELLER SHAFT U-JOINT CONDITION

25
PROPELLER SHAFT U-JOINT LUBRICATION

25
WHEEL LUG NUT TORQUE CHECK

25
WHEEL BEARING INSPECTION

25
STEERING SYSTEM INSPECTION

25
SHOCK ABSORBER INSPECTION

25
SHOCK ABSORBER SPHERICAL BEARING LUBRICATION

25
FRONT SUSPENSION ARM LUBRICATION

26

TABLE OF CONTENTS
01 MAINTENANCE
(cont'd)
03 - PERIODIC MAINTENANCE PROCEDURES
(cont'd)
PROCEDURES
(cont'd)
FRONT SUSPENSION ARM INSPECTION

26
BRAKE SYSTEM INSPECTION AND CLEANING

27
BRAKE FLUID REPLACEMENT

27
PASSENGER HANDHOLD CONDITION

29
TOW HITCH INSPECTION

29
04 - PRESEASON PREPARATION

31
05 - STORAGE PROCEDURE

33
GENERAL

33
PROCEDURES

33
FUEL SYSTEM

33
ENGINE

33
ELECTRICAL SYSTEM

34
DRIVE SYSTEM

34
CHASSIS

34
06 - SPECIAL PROCEDURES

35
GENERAL

35
ROLLED OVER VEHICLE

35
.
SUBMERGED VEHICLE

35
02 ENGINE, CVT AND GEARBOX
01 - ENGINE REMOVAL AND INSTALLATION

37
GENERAL

38
PROCEDURES

38
ENGINE REMOVAL

38
ENGINE INSTALLATION

40
ENGINE MOUNTS

40
02 - AIR INTAKE SYSTEM

41
GENERAL

43
PROCEDURES

43
AIR FILTER

43
AIR FILTER HOUSING

43
03 -
EXHAUST SYSTEM

45
GENERAL

46
PROCEDURES

46
SPARK ARRESTER

46
MUFFLER

46
"Y" EXHAUST PIPE

47
HEAD PIPE (FRONT CYLINDER)

47
HEAD PIPE (REAR CYLINDER)

48
04 - LUBRICATION SYSTEM

49
GENERAL

52
INSPECTION

52
ENGINE OIL PRESSURE

52
TROUBLESHOOTING

52
PROCEDURES

53
OIL COOLER

53
OIL PRESSURE SWITCH (OPS)

54
ENGINE OIL PRESSURE REGULATOR

54
OIL PUMP

55
ENGINE OIL STRAINER

57
REED VALVE

58

TABLE OF CONTENTS
02 ENGINE, CVT AND GEARBOX
(cont'd)
05 - COOLING SYSTEM 
59
GENERAL 
64
PROCEDURES 
64
THERMOSTAT 
64
RADIATOR 
66
COOLANT TEMPERATURE SENSOR (CTS)
 67
RADIATOR COOLING FAN RELAY (R1)
 67
RADIATOR COOLING FAN 
68
WATER PUMP HOUSING
 70
WATER PUMP IMPELLER
 71
WATER PUMP SHAFT AND SEALS

71
06 - MAGNETO SYSTEM

81
GENERAL 
83
PROCEDURES  83
MAGNETO COVER 
83
STATOR 
84
ROTOR

85
SPRAG CLUTCH 
87
SPRAG CLUTCH GEAR  88
STARTER DRIVE GEARS
 89
07 - TOP END 
91
GENERAL 
96
INSPECTION 
96
LEAK TEST  96
PROCEDURES  98
INTAKE MANIFOLD 
98
VALVE COVER 
99
ROCKER ARM  100
CYLINDER HEAD

102
CAMSHAFT 
104
VALVE SPRINGS 
106
VALVES 
108
VALVE GUIDES 
110
CYLINDER 
111
PISTON 
113
PISTON RINGS

116
08 - TIMING CHAIN 
119
GENERAL 
121
TROUBLESHOOTING 
121
PROCEDURES 
121
TIMING CHAIN TENSIONERS 
121
CAMSHAFT TIMING GEARS 
123
TIMING CHAIN 
128
TIMING CHAIN GUIDE (TENSIONER SIDE)

130
09 - BOTTOM END 
131
GENERAL 
135
PROCEDURES

135
ENGINE DRIVE SHAFT 
135
PTO COVER OIL SEAL

137
PTO COVER 
138
DRIVE GEARS 
140
CRANKCASE

141
CRANKSHAFT 
145

TABLE OF CONTENTS
02 ENGINE, CVT AND GEARBOX
(cont'd)
10 - CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

153
GENERAL

156
PROCEDURES

156
CVT COVER

156
DRIVE BELT

157
DRIVE PULLEY

158
DRIVEN PULLEY

166
CVT AIR GUIDE

172
11 - GEARBOX AND 4X4 COUPLING UNIT

173
GENERAL

175
GEARBOX OVERVIEW

175
TROUBLESHOOTING

175
PROCEDURES

176
VSS (VEHICLE SPEED SENSOR)

176
GBPS (GEARBOX POSITION SENSOR)

177
4WD INDICATOR SWITCH

179
ACTUATOR

180
GEARBOX OIL SEALS

181
GEARBOX

183
12 - SHIFTER

199
GENERAL

200
PROCEDURES

200
SHIFT LEVER

200
SHIFTER CABLE

201
SHIFT PLATE

202
03 ELECTRONIC MANAGEMENT SYSTEM
01 - ENGINE MANAGEMENT SYSTEM (EMS)

205
GENERAL

206
SYSTEM DESCRIPTION

206
02 - COMMUNICATION TOOLS AND B.U.D.S

209
GENERAL

209
TROUBLESHOOTING

209
DIAGNOSTIC TIPS

209
PROCEDURES

211
MPI-2

211
B.U.D.S. SOFTWARE

212
03 - DIAGNOSTIC SYSTEM AND FAULT CODES

215
GENERAL

215
DIAGNOSTIC SYSTEM

215
FAULT CODES

216
SPECIFIC FAULTS

219
04 FUEL SYSTEM
01 - INTELLIGENT THROTTLE CONTROL (iTC)

221
GENERAL

221
SYSTEM DESCRIPTION

221
SYSTEM MAIN FEATURES

221
SYSTEM OTHER FEATURES

221
PROCEDURES

222
SPORT/NORMAL SWITCH

222
SEAT BELT SWITCH

222
OVERRIDE SWITCH

222
THROTTLE ACCELERATOR SENSOR (TAS)

222
IV

TABLE OF CONTENTS
04 FUEL SYSTEM (cont'd)
02 - ELECTRONIC FUEL INJECTION (EFI) 
225
GENERAL 
225
SYSTEM DESCRIPTION 
225
ADJUSTMENT 
226
IDLE SPEED 
226
TROUBLESHOOTING

227
DIAGNOSTIC TIPS 
227
PROCEDURES 
227
ENGINE CONTROL MODULE (ECM) 
227
FUEL INJECTOR 
233
FUEL RAIL 
237
THROTTLE BODY 
238
THROTTLE POSITION SENSOR (TPS)

240
CRANKSHAFT POSITION SENSOR (CPS) 
242
MANIFOLD AIR PRESSURE AND TEMPERATURE SENSOR (MAPTS)

243
CTS (COOLANT TEMPERATURE SENSOR) 
246
03 - FUEL TANK AND FUEL PUMP 
249
GENERAL 
251
SYSTEM DESCRIPTION 
251
INSPECTION 
252
FUEL TANK LEAK TEST 
252
FUEL PUMP PRESSURE TEST 
252
TROUBLESHOOTING

255
FUEL SYSTEM DIAGNOSTIC FLOW CHART

255
PROCEDURES 
256
FUEL HOSE AND OETIKER CLAMPS

256
FUEL TANK

256
FUEL PUMP

258
FUEL LEVEL SENDER

262
FUEL TANK VENT VALVE

263
05 ELECTRICAL SYSTEM
01 - POWER DISTRIBUTION

265
GENERAL 
265
POWER DISTRIBUTION DIAGRAM

265
FUSE BOX 1

266
FUSE BOX 2 
266
02 -
CONTROLLER AREA NETWORK (CAN)

267
GENERAL 
267
SYSTEM DESCRIPTION 
267
03 -
IGNITION SYSTEM

269
GENERAL 
269
SYSTEM DESCRIPTION

269
TROUBLESHOOTING

269
DIAGNOSTIC GUIDELINES

269
PROCEDURES 
270
IGNITION SWITCH 
270
IGNITION COIL 
270
SPARK PLUG 
271
04 - CHARGING SYSTEM

273
GENERAL 
273
SYSTEM DESCRIPTION

273
INSPECTION 
273
CHARGING SYSTEM OUTPUT

273
v

TABLE OF CONTENTS
05 ELECTRICAL SYSTEM
(cont'd)
04 - CHARGING SYSTEM
(cont'd)
TROUBLESHOOTING

274
PROCEDURES

274
VOLTAGE REGULATOR/RECTIFIER

274
BATTERY

274
05 - STARTING SYSTEM

277
GENERAL

277
SYSTEM DESCRIPTION

277
TROUBLESHOOTING

277
DIAGNOSTIC GUIDELINES

277
PROCEDURES

278
D2 DIODE (STARTER SOLENOID)

278
START BUTTON

278
STARTER SOLENOID

279
ELECTRIC STARTER

280
06 - DIGITALLY ENCODED SECURITY SYSTEM (D.E.S.S.)

283
GENERAL

283
SYSTEM DESCRIPTION

283
TROUBLESHOOTING

283
DIAGNOSTIC TIPS

283
PROCEDURES

283
KEY PROGRAMMING

283
07 - LIGHTS, GAUGE AND ACCESSORIES

285
GENERAL

285
TROUBLESHOOTING

285
DIAGNOSTIC TIPS

285
PROCEDURES

285
CONSOLE SWITCHES

285
MULTIFUNCTION GAUGE (LCD AND ANALOG/DIGITAL)

286
12 VOLT POWER OUTLET

288
HEADLIGHTS

289
TAILLIGHTS/BRAKE LIGHTS

291
WINCH

292
TURN SIGNALS/HAZARD(EC MODELS ONLY)

293
HORN (EC MODELS ONLY)

294
06 DRIVE SYSTEM
01 - FRONT DRIVE

295
GENERAL

298
SYSTEM DESCRIPTION

298
PROCEDURES

298
WHEEL HUB

298
FRONT DRIVE SHAFT

299
DRIVE SHAFT BOOT

299
FRONT DIFFERENTIAL

300
FRONT PROPELLER SHAFT

303
PROPELLER SHAFT U-JOINTS

303
02 - REAR DRIVE

305
GENERAL

308
PROCEDURES

308
WHEEL HUB

308
DRIVE SHAFT

309
DRIVE SHAFT BOOT

309
PROPELLER SHAFT

310
VI

TABLE OF CONTENTS
06 DRIVE SYSTEM
(cont'd)
02 - REAR DRIVE
(cont'd)
PROCEDURES (cont'd)
PROPELLER SHAFT U-JOINTS 
310
REAR FINAL DRIVE

311
07 CHASSIS
01 - WHEELS AND TIRES  315
GENERAL  315
PROCEDURES 
315
TIRES  315
WHEELS 
317
02 - STEERING SYSTEM 
319
GENERAL
 321
ADJUSTMENT 
321
STEERING ALIGNMENT 
321
TROUBLESHOOTING 
323
DIAGNOSTIC TIPS 
323
PROCEDURES 
323
STEERING WHEEL

323
STEERING COLUMN 
323
RACK AND PINION 
325
TIE-ROD ENDS 
325
KNUCKLES 
326
WHEEL BEARINGS 
326
03 - FRONT SUSPENSION 
329
GENERAL 
330
PROCEDURES 
330
SHOCK ABSORBER

330
SHOCK ABSORBER BUSHINGS 
331
SPRINGS 
331
LOWER SUSPENSION ARM

331
UPPER SUSPENSION ARM 
332
SUSPENSION ARM BUSHINGS 
333
BALL JOINTS 
333
04 - REAR SUSPENSION

335
GENERAL 
336
PROCEDURES 
336
SHOCK ABSORBERS 
336
SHOCK ABSORBER BUSHINGS 
337
SPRINGS

337
ANTI-SWAY BAR 
338
TRAILING ARM 
338
05 -
BRAKES 
341
GENERAL 
343
INSPECTION

343
BRAKE SYSTEM PRESSURE VALIDATION

343
PROCEDURES 
344
BRAKE LIGHT SWITCH

344
MASTER CYLINDER 
345
CALIPER 
347
BRAKE PADS 
347
BRAKE DISC 
348
VII

TABLE OF CONTENTS
07 CHASSIS (cont'd)
06 - BODY  349
GENERAL  359
PROCEDURES 
359
PLASTIC RIVET 
359
DECALS 
359
UPPER CONSOLE  359
LOWER CONSOLE 
359
LATERAL CONSOLE PANELS 
360
GLOVE BOX REMOVAL AND INSTALLATION 
361
07 - CARGO BOX 
363
GENERAL 
369
ADJUSTMENT 
369
CARGO BOX ADJUSTMENTS 
369
PROCEDURES 
371
CARGO BOX GAS SHOCK

371
CARGO BOX

371
08 - FRAME
 373
GENERAL 
376
PROCEDURES 
376
CAGE  376
FRAME 
377
08 TECHNICAL SPECIFICATIONS
01 - COMMANDER 800R AND 1000

379
09 WIRING DIAGRAM
01 - WIRING DIAGRAM INFORMATION 
389
GENERAL 
389
WIRING DIAGRAM LOCATION 
389
WIRING DIAGRAM CODES

389
02 - CONNECTOR INFORMATION 
391
GENERAL 
391
DEUTSCH CONNECTORS 
391
PACKARD CONNECTORS 
393
PACKARD CONNECTOR (MULTIFUNCTION GAUGE)

394
MOLEX CONNECTOR 
395
FURUKAWA CONNECTOR 
398
BATTERY AND STARTER CABLE TERMINALS

398
VIII

SAFETY NOTICE
SAFETY NOTICE
This manual has been prepared as a guide to cor-
rectly service and repair the 2011 Can-Am' Com-
mander SSV as described 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 prod-
ucts. Mechanical technicians should attend train-
ing courses given by BRPTI.
Please note that the instructions will apply only
if proper hand tools and special service tools are
used.
The contents of this manual depicts parts and/or
procedures applicable to a particular product at
the time of writing. Service and warranty bulletins
may be published to update the content of this
manual. Dealer modifications that were carried
out after manufacturing of the product, whether
or not authorized by BRP, are not included.
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 ex-
act replicas of the parts.
The use of BRP parts is most strongly recom-
mended 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 mentioned in this
document.
This manual emphasizes particular information
which, is denoted by the following wording and
symbols:
A
WARNING
Indicates a potential hazard that, if not
avoided, could result in serious injury or
death.
A
CAUTION
Indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
NOTICE
Indicates an instruction which, if not
followed, could result in severe damage to ve-
hicle components or other property.
NOTE: Indicates supplementary information re-
quired to fully complete an instruction.
Although the mere reading of such information
does not eliminate the hazard, your understand-
ing of the information provided will promote its
correct use. Always use common shop safety
practices.
It is understood that this manual may be trans-
lated into another language. In the event of any
discrepancy, the English version shall prevail.
BRP disclaims liability for all damages and/or in-
juries resulting from the improper use of the con-
tents of this publication. We strongly recommend
that any services be carried out and/or verified by
a highly skilled professional mechanic. It is under-
stood that certain modifications may render use of
the vehicle illegal under existing federal, provincial
and state regulations.
tmr2011-002

IX

3

2
MANUFACTURED BY: BOMB 
RECREATIONAL PRODUCTS INC
FORME PAR: BOMBARDIE . 41 
R R -TIFS INC.
MEl. DATE FAB: XX tXXXXMODELMX
IN i NW: 2BPS1234X2V000123
11111111i1111111111 111111111111111
INS VENUE CONFORMS TO ALL APPLICABLE STANDARDS
PRESCRIBED UNDER THE FEDERAL AND CANADIAN MOTOR
SAFETY REGULATKNIS 14 AFFECT ON THE DATE OF MANUFACTURF-
CE VENICIAE EST CON FORME ATOOTER LES NORMES WI
SONT API:MAKES EN VERTU DU REGLEmewr SUR LA =Mit
DES YEHICULES AUTOMMES DU CANADA EN VIGUEUR ALA
DATE DE SA FABRICATION.
MADE IN/FABRIQUE AU: MEXICVMEXIQUE
 roa 002 aoe
tmr2011-002-005_a
INTRODUCTION
INTRODUCTION
This shop manual covers the following BRP made
2011 Can-Am side by side vehicles.
MODEL
ENGINE
TYPE
MODEL NUMBER
Commander 800R
810
6CBA, 6CBC,
6DBA, 6DBD
Commander 1000
1010
6ABA, 6ABC,
6BBA, 6BBB,
6BBC, 6BBD,
6BBE, 6BBF, 6EBA,
6EBC, 6CBA, 6CBC
The information and component/system descrip-
tions contained in this manual are correct at time
of writing. BRP however, maintains a policy of
continuous improvement of its products without
imposing upon itself any obligation to install them
on products previously manufactured.
Due to late changes, there may be some differ-
ences between the manufactured product and the
description and/or specifications in this document.
BRP reserves the right at any time to discontinue
or change specifications, designs, features, mod-
els or equipment without incurring obligation.
VEHICLE INFORMATION
VEHICLE IDENTIFICATION
NUMBER (VIN)
TYPICAL
1. VIN (Vehicle Identification Number) location
The VIN (Vehicle Identification Number) decal is lo-
cated under the glove box on the passenger side.
VIN Decal Description
TYPICAL — VEHICLE IDENTIFICATION NUMBER LABEL
1. VIN (Vehicle Identification Number)
2. Model number
3. Manufacturing date
ENGINE IDENTIFICATION
NUMBER (EIN)
TYPICAL - RH SIDE OF ENGINE
1. Engine Identification Number (EIN)
LIFTING AND SUPPORTING THE
VEHICLE
Front of Vehicle
1.
Place vehicle on a flat non slippery ground.
2.
Ensure vehicle shift lever is set to PARK.
3.
Install an hydraulic jack under front skid plate.
4. Lift front of vehicle and install a jack stand on
each side under frame section in front of the lip
for center skid plate.
x

tmr2011-002

1.
Front of vehicle
2.
Hydraulic jack
3.
Jack stand
4.
Lip
for center skid plate
5.
Center skid plate
5. Lower hydraulic lift and ensure vehicle is sup-
ported safely onto both jack stands.
Rear of Vehicle
1. Place vehicle on a flat non slippery ground.
2. Activate 4WD mode.
3. Ensure vehicle shift lever is set to PARK.
4. Install a hydraulic jack under the trailer hitch.
1.
Rear of vehicle
2.
Jack stand
3.
Frame section
6. Lower hydraulic lift and ensure vehicle is sup-
ported safely onto both jack stands.
HOISTING THE VEHICLE
The vehicle may be lifted off the ground by the
cage using a hoist and a lifting strap.
NOTICE
The lifting strap must be wrapped
around the horizontal side tubes at the top of
the cage, NOT fore and aft. Lifting vehicle by
the fore and aft tubes of the cage can cause
damage.
INTRODUCTION
1.
Hydraulic jack
2.
Trailer hitch
5. Lift rear of vehicle and install a jack stand on
each side under frame section in front of rear
wheel.
1.
Lifting strap around horizontal side tubes (top)
2.
Hoist hook
tmr2011-002
XI

A
WARNING
—
Ensure hoist and lifting strap are rated for
lifting the total vehicle weight. Refer to ap-
plicable manufactures instructions.
—
Ensure lifting strap is in good condition be-
fore lifting vehicle.
—
Do not allow anyone in the vehicle or under
any portion of the vehicle while it is sus-
pended by a hoist.
—
Do not perform any work on the vehicle
while it is suspended by a hoist.
INTRODUCTION
TRANSPORTING THE VEHICLE
If the vehicle needs to be transported, it should be
carried inside a full size pick-up box or on a flatbed
trailer of the appropriate size and capacity.
NOTICE
Do not tow this vehicle - towing can
seriously damage the vehicle's drive system.
When contacting a towing or transporting service,
be sure to ask for tie-down straps, a flatbed trailer,
loading ramp or power ramp to safely lift and se-
cure the vehicle. Ensure the vehicle is properly
transported as specified in this section.
NOTICE
Avoid using chains to tie down the
vehicle - they may damage the surface finish
or plastic components.
To load the vehicle for transport, proceed as fol-
lows:
1.
Set gear shift lever to NEUTRAL (N).
2.
Remove the key from the ignition switch.
3.
If the vehicle is equipped with a winch, use the
winch to roll the vehicle onto the transport ve-
hicle.
4.
If the vehicle is not equipped with a winch, pro-
ceed as follows:
4.1 Put a strap around the lower arm of each
front suspension.
4.2 Attach the straps to the winch cable of the
towing vehicle.
4.3 Pull the vehicle on the flatbed trailer with
the winch.
NOTE:
Be sure to leave the gear shift lever in
NEUTRAL (N).
5.
Tie down the front wheels to the front of the
trailer using tire towing straps.
6. Pass a tie-down strap inside each rear wheel.
7.
Firmly attach the rear wheels tie-down straps to
both sides of the rear of the trailer with ratch-
ets.
8.
Ensure that both the front and rear wheels are
firmly secured to the trailer.
ENGINE EMISSIONS
INFORMATION
MANUFACTURER'S
RESPONSIBILITY
Manufacturers of engines must determine the
exhaust emission levels for each engine horse-
power family and certify these engines with
the United States of America Environmental
Protection Agency (EPA). An emissions control
information label, showing emission levels and
engine specifications, must be placed on each
vehicle at the time of manufacture.
DEALER RESPONSIBILITY
When servicing any vehicle that carry an emis-
sions control information label, adjustments must
be kept within published factory specifications.
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.
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 else to modify the engine in any man-
ner that would alter the horsepower or allow emis-
sions levels to exceed their predetermined factory
specifications.
EPA EMISSION REGULATIONS
Vehicles manufactured by BRP are certified to the
EPA standards as conforming to the requirements
of the regulations for the control of air pollution
emitted from new vehicle engines. This certifica-
XII
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A
WARNING
Unless otherwise specified, the engine
should be turned OFF and cold for all main-
tenance and repair procedures.
INTRODUCTION
tion is contingent 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 original 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 more detailed information
on this subject, you may contact the following lo-
cations:
FOR ALL COURIER SERVICES:
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. e pa .gov/otaq/
E-MAIL: [email protected]
MANUAL INFORMATION
MANUAL PROCEDURES
Many of the procedures in this manual are inter-
related. Before undertaking any task, you should
read and thoroughly understand the entire section
or subsection in which the procedure is contained
A number of procedures throughout the book re-
quire the use of special tools. Before starting any
procedure, be sure that you have on hand all re-
quired tools, or their approved equivalents.
The use of RIGHT and LEFT indications in the text
are always referenced to the driving position (sit-
ting on the vehicle).
TYPICAL
1. Left
2. Right
This manual uses technical terms which may be
different from the ones of the PARTS CATALOGS.
When ordering parts always refer to the specific
model PARTS CATALOGS.
NOTICE
Most fasteners are metric, and most
components are built with parts dimensioned
using the metric system. Consult the appropri-
ate
PARTS CATALOGto
obtain and use the cor-
rect parts and fasteners. Mismatched or incor-
rect fasteners could cause damage to the vehi-
cle.
MANUAL LAYOUT
This manual is divided into many major sections as
can be seen in the main table of contents at the
beginning of the manual.
Each section is divided into various subsections,
and again, each subsection has one or more divi-
sions.
Illustrations and photos show the typical construc-
tion of various assemblies and, in all cases, may
not reproduce the full detail or exact shape of the
parts used in a particular model vehicle. However,
they represent parts which have the same or a
similar function.
trnr2011-002
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XIII

INTRODUCTION
TYPICAL PAGE
Section 06 ENGINE I  Page heading
Subsection 01 (MAGNETO)
 indicates section
and subsection.
Subsection title
Indicates applicable
models.
 > MAGNETO

Models
Exploded view assists
you in identifying parts
and their related
positions.
NEW indicates that the
part must be replaced
with a new one.
Illustration number
for publishing process.
Document number for
publishing process.
----)1 ""
r
Specific torque applicable to this installation.
CAUTION: Pay attention to torque specifications.
Some of these are in lbf•in instead of lbf•ft.
Use appropriate torque wrench.
%-it  Page number
Drop represents a
service product
to be applied.
Dotted box contains
parts applicable to a
specific model.
Bold face number
is used to identify
a part referred to
the text.
Tygcaliso_2008_en
XIV
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tmr2011-002

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.
TYPICAL PAGE
Tittle in bold
indicates category ___).
GENERAL
of information to be
carried out. 
NOTE: The 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
. )1 1 .SELLOCA7NG FASTENERS and LOC-
TITE APPLICATION sections at the beginning of
this manual for complete procedure.
PROCEDURES
Indicates component
procedures apply to. ----)MAGNETO FLYWHEEL
Magneto Flywheel Cleaning
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION:
Clean magneto flywheel using only
Indicates specific 
a clean cloth.
procedure to be ---).Magneto
Flywheel Removal
carried out. 
Remove muffler, refer to the EXHAUST SYSTEM
section.
Remove acoustic panel.
Remove rewind starter.
Remove starting pulley no. 2.
A
mmr2008.001
Section 03 ENGINE
Subsection 09 (MAGNETO SYSTEM)
TYP1CA
41(
NOTE: To remove starting pulley bolts, hold mag
veto flywheel with a socket as shown.
TYPICAL
Models
Remove the connecting flange retaining
the
• rewind starter to the engine housing.
57
Reference to a
specific section
or subsection.
"TYPICAL"
indicates a general
view which may
not represent exact
details.
Call-outs pertaining
to above illustration.
Illustration always
follows text to which
it applies.
Italic bold face type-
setting indicates a
procedure applicable
to a specific
model(s).
Bold face number following part
name refers to exploded view
at beginning of subsection.
typical_txt_2008_en
INTRODUCTION
tmr2011 - 002

X
V

A
WARNING
Torque wrench tightening specifications must be strictly adhered to.
Locking devices when removed (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter
pins, etc.) must be replaced.
INTRODUCTION
TIGHTENING TORQUE
Tighten fasteners to the torque specified in the exploded view(s) and/or in the written procedure. When
a torque is not specified, refer to the following table.
In order to avoid a poor assembly, tighten screws, bolts, or nuts in accordance with the following proce-
dure:
1. Manually screw all screws, bolts and/or nuts.
2. Apply half the recommended torque value.
3. Tighten fastener to the recommended torque value.
NOTICE
Be sure to use the recommended tightening torque for the specified fastener used.
NOTE: When possible, always apply torque on the nut.
NOTE:
Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are
used to secure a part (eg. a cylinder head). Some parts must be torqued according to a specific sequence
and torque pattern as detailed in the installation procedure.
Property
class and
head
markings
4.8
-
4.8
8.8
-
8.8
9.8
-
9.8
10.9
-
10.
IMII
-
2.9
12.9
0
iggli 129
14.81
II 8.81  II 9.8.
WI
-
OPT 
UPI MI!
IIIPI

Mil
Property
class and
nut
markings
A00A813S
-
0
5
I°
-
0
-
0
8
:
■ I
-
0
_
-
0
10
MI
•
-
0
-
0
_
12
.
am
an
0
-
FASTENER
SIZE
FASTENER GRADE/TORQUE
5.8 Grade
8.8 Grade
10.9 Grade
12.9 Grade
M4
1.5 - 2 Nom
(13 - 18 lbfoin)
2.5 - 3 Nom
(22 - 27 lbf•in) 3.5 - 4 N•m
(31 - 35 lbf•ft)
4 - 5 Nom
(35 - 441bf•ft)
M5
3 - 3.5 Nom
(27 - 31 lbf•ft)
4.5 - 5.5 Nom
(40 - 47 lbf•ft)
7 - 8.5 Nom
(62 - 75 lbf•ft)
8- 10 Nom
(71 - 89 lbf•ft)
M6
6.5 - 8.5 Nom
(58 - 75 lbf•ft)
8 - 12 Nom
(71 - 106 lbfoft) 10.5 - 15 Nom
(93 - 133 lbfoin)
16 Nom (142 lbf•in)
M8 15 Nom (1331bfoin)
25 N•m (181bf•ft)
32 Nom (24 Ibf•ft) 40 Nom (30 Ibf•ft)
M10
29 Nom (21 lbf•ft)
48 Nom (35 lbf•ft) 61 Nom (45 Ibf•ft)
73 Nom (54 lbfoft)
M12
52 Nom (38 lbfoft)
85 Nom (63 lbfoft)
105 Nom (77 Ibf•ft)
128 Nom (94 lbfoft)
M14
85 Nom (631bf•ft)
135 Nom (1001bf•ft) 170 Nom (1251bf•ft)
200 Nom (1481bf•ft)
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A
■■■
Imr200/ 04C-001 a
INTRODUCTION
FASTENER INFORMATION
NOTICE
Most components in the 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.
SELF-LOCKING FASTENERS
PROCEDURE
TYPICAL — SELF-LOCKING FASTENER
The following describes common procedures
used when working with self-locking fasteners.
Use a metal brush or a tap to properly clean a
threaded hole, then use a solvent. Allow the sol-
vent time to act, approximately 30 minutes, then
wipe off. Solvent utilization is to ensure proper
adhesion of the product used for locking the fas-
tener.
LOCTITE® APPLICATION
PROCEDURE
The following describes common procedures
used when working with Loctite products.
NOTE: Always use proper strength Loctite prod-
uct as recommended in this shop manual.
Threadlocker Application for
Uncovered Holes (Bolts and Nuts)
1. Apply here
2. Do not apply
1.
Clean threads (bolt and nut) with solvent.
2. Apply LOCTITE PRIMER N (P/N 293 800 041)
on
threads and allow to dry.
3. Choose proper strength Loctite threadlocker.
4. Fit bolt in the hole.
5. Apply a few drops of threadlocker at proposed
tightened nut engagement area.
6. Position nut and tighten as required.
Threadlocker Application for Blind
Holes
1. On fastener threads
2. On threads and at the bottom of hole
1.
Clean threads (bolt and hole) with solvent.
2. Apply LOCTITE PRIMER
N (P/N 293 800 041) on
threads (bolt and nut) and allow to dry for 30
seconds.
3. Choose proper strength Loctite threadlocker.
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XVII