Textron Motors MPE 850 OFF-ROAD User manual

TD409135_SHB
Rev A
03.08.2015
MPE 850 OFF-ROAD
– 409135 I2 846 UTV NA-80
This service manual is valid for the following engine models:
Read this service manual thoroughly before operating the engine
for the first time.
SERVICE MANUAL
4-Stroke Engine
en_English

Textron Motors GmbH
Daimlerstraße 5
88677 Markdorf
Germany
www.weber-motor.com
Textron Motors GmbH strives to make continual improvements as part of the ongoing technical development
of its products. All documentation is therefore subject to technical modifications.
Reprints and translations, in whole or in part, require written permission from Textron Motors GmbH.
All rights reserved according to the copyright law.

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Table of contents
Table of contents
1 About this document 6
1.1 Meaning of symbols and signal words........................................... 6
2 Safety 7
2.1 Meaning of safety alert symbol and signal words ..................................7
2.2 Important safety messages ................................................... 8
3 Description 10
3.1 Intended use .............................................................10
3.2 Identification .............................................................10
3.3 Fuel .................................................................... 11
3.4 Engine oil................................................................ 11
3.5 Coolant .................................................................12
3.6 Engine components and information ...........................................13
3.7 Protective functions ........................................................15
3.8 Technical specifications .....................................................17
3.9 Supported vehicle equipment ................................................18
3.9.1 Lights in vehicle .........................................................18
4 Operation 20
4.1 Service intervals ..........................................................20
4.2 Operation during the break-in period...........................................21
4.3 Operating engine ..........................................................22
4.3.1 Checking coolant level .................................................... 22
4.3.2 Put the engine into operation ............................................... 23
4.3.3 Checking oil level ........................................................ 24
4.3.4 Take the engine out of operation ............................................26
4.3.5 Transport and storage of the vehicle .........................................27
5 Special scenarios 28
5.1 Engine storage for more than 90 days .........................................28
6 Malfunctions 29
6.1 Malfunctions table ......................................................... 29
7 Dealer and servicing network 31
7.1 Locating a workshop ....................................................... 31
7.2 Tools and parts ...........................................................31
7.3 Repairs .................................................................31

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Table of contents
8 Service tasks in the workshop 32
8.1 Safety messages workshop.................................................. 32
8.2 Tools and accessories ......................................................33
8.2.1 Service parts............................................................ 33
8.2.2 Diagnostic case .........................................................33
8.2.3 Equipment workshop .....................................................34
8.2.4 Supplies ...............................................................35
8.3 Changing engine oil and oil filter .............................................. 36
8.4 Checking and adjusting valve lash ............................................39
8.4.1 Checking valve lash ...................................................... 39
8.4.2 Adjusting valve lash with valve adjustment kit ..................................43
8.4.3 Adjusting valve lash without special tool....................................... 46
8.5 Replacing spark plugs ......................................................49
8.6 Checking spark plugs ......................................................51
8.7 Changing coolant.......................................................... 54
8.8 Replacing fuel filter ........................................................56
8.9 Preparing the engine for storage ..............................................57
8.10 Disposal................................................................58
9 Confirmation of service tasks 59
Appendix 61
Engine manufacturer ...........................................................61
Index .......................................................................62

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This service manual was designed to help you operating the engine safely and reliably.
Observe the following references:
– Read this service manual thoroughly before operating the engine for the first time.
– Always read the vehicle manufacturer‘s documentation.
– This service manual is for the engine in your vehicle. See the vehicle manufacturer‘s documentation for
vehicle specific information.
– Keep this service manual in a safe place.
– Make sure that all persons using the vehicle have access to this service manual.
– If you sell the vehicle, always pass on this service manual to the new owner.
– The latest version of the servicew manual is available for download in other languages from our web site
www.weber-motor.com.
– Some figures in this service manual are general illustrations and may differ from the actual engine.
1 About this document
1.1 Meaning of symbols and signal words
1About this document
1.1 Meaning of symbols and signal words
Item Meaning
NOTICE The signal word NOTICE indicates potential property damage.
Information The signal word Information indicates specific features and recommendations.

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This engine is state-of-the-art and built according to recognized safety technical and emission regulations.
Ignoring the information in this service manual may result in personal injury or property damage.
Read and observe the following safety messages carefully before operating the engine for the first time.
Observe all generally applicable laws and regulations in addition to the information in this service manual:
– Accident prevention
– Environmental protection
– Handling of hazardous materials
– Personal safety equipment
– Traffic laws
2 Safety
2.1 Meaning of safety alert symbol and signal words
Item Meaning
The safety alert symbol draws your attention to possible dangers.
WARNING
The signal word WARNING indicates a potentially dangerous situation that may
lead to a serious or fatal injury.
CAUTION
The signal word CAUTION indicates a potentially dangerous situation that may
lead to a minor or moderately severe injury.
2Safety
2.1 Meaning of safety alert symbol and signal words

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2.2 Important safety messages
2Safety
2.2 Important safety messages
In order to keep your engine in a safe operating condition, regular
servicing is essential. It is your responsibility to ensure that the engine is
serviced correctly.
►Perform regular inspections and observe the specified service
intervals.
All tasks described in chapter 8 Service tasks in the workshop require
special technical knowledge of this engine.
►Ensure your workshop is qualified to service your engine.
►All Textron Motors authorized workshops are qualified to service
your engine.
Engine malfunctions pose a safety risk to persons.
►Only operate the engine in perfect condition.
►Perform all service tasks according to the service intervals in this
service manual.
►You must immediately address all malfunctions to a qualified
workshop.
All the components in your engine have been carefully tested and fulfill
strict quality and safety requirements.
►Textron Motors offers spare parts to the highest quality. Ensure that
equivalent spare parts corresponds with this quality requirements.
Engine modifications may pose a safety risk to persons.
►Do not install add-on parts or modify the engine.
Engine components become extremely hot during operation.
►Do not touch any engine components during operation.
►Turn off the engine and wait until the components have cooled
before making contact.
Some service tasks require disconnection of the engine from the power
supply. Starting the engine inadvertently may endanger the safety of
persons. Read the vehicle manufacturer‘s documentation for more
information.
►Disconnect the engine from the power supply when requested.
Service tasks
Service tasks in the workshop
Malfunctions
Spare parts
Add-on parts and modifications
Hot engine components
Engine power supply

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2Safety
2.2 Important safety messages
Engine exhaust gases contain carbon monoxide (CO). Inhalation of
carbon monoxide can deprive the body of oxygen and result in organ
damage or death by asphyxiation.
►Never operate the engine in enclosed spaces.
Engine fluids pose a health risk.
►Always read the manufacturer's instructions.
►Always wash your hands prior to eating, smoking and using the
restroom as well as at the end of the working shift when working
with engine fluids.
Engine fluids are hazardous to the environment.
►Never allow engine fluids to escape into the groundwater, water
courses or sewage system. Always dispose of engine fluids
according to applicable regulations.
Danger of slipping on spilled fluids.
►Always use a filler neck or funnel when filling the engine with fluids.
►Always clean up any spilled engine fluids immediately.
Fuel is highly flammable. Vapors may ignite and cause an explosion.
►Do not smoke in the vicinity of the engine and do not allow open
flames or sparks near the engine or the fuel system.
►Always turn off the engine before fueling.
►Never fill with fuel while the engine is running.
►Do not start the engine if you smell fuel or see a fuel leak.
►Fuel on hot surfaces can cause fires.
►In the event of a fire, use foam, dry chemical or carbon dioxide fire
extinguishers. Do not extinguish with water.
Engine oil is flammablew and can emit toxic gases.
►Do not smoke in the vicinity of the engine and do not allow open
flames or sparks near the engine.
►Engine oil on hot surfaces can cause fires.
►In the event of a fire, use foam, dry chemical or carbon dioxide fire
extinguishers. Do not extinguish with water.
This engine und engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
Engine exhaust gases
Fuel, engine oil and coolant
handling
Fuel
Engine oil
California Proposition 65

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1
5
3
2
4
3 Description
3.2 Identification
Each engine will be clearly identified by two
identification numbers. Both numbers are printed
on a label 1affixed to the engine.
The part number “Part No.:” 2is the number of
the engine model.
The serial number “Serial No.:” 3is an unique
number for each individual engine.
Enter the part number and serial number in
chapter 9 Confirmation of service tasks. Both
numbers are important in questions regarding your
engine.
3.1 Intended use
3 Description
3.1 Intended use | 3.2 Identification
Engine model I2 846 UTV NA-80
The label with the part number and the serial
number is located on the valve cover 4.
The serial number is also engraved on the
crankcase 5.
The engine models I2 846 UTV has been designed for powering off-road vehicles. Any other use is not
permissible.
All specifications in this service manual are only valid for the unmodified engine delivered by Textron Motors.
Engine modifications are not permissible and in addition, may void the warranty or violate federal laws.

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3 Description
3.3 Fuel | 3.4 Engine oil
3.3 Fuel
3.4 Engine oil
Engine models I2 846 UTV NA-80
Fuel Unleaded gasoline
Recommended fuel quality 95 ROZ or 85 MOZ
USA ʺPremium 91ʺ
Minimum requirement The minimum requirement is only suitable for using from start of series
production.
The calibration is provided with a knock control, for engine operation
with fuels of lower octane. Observe that using of fuel with minimum
requirements can cause loss of power and/or increased fuel
consumption.
91 ROZ or 82,5 MOZ
USA ʺRegular 87ʺ
Permissible share of ethanol NOTICE! A greater concentration can deteriorate the engine’s fuel
system and starting performance.
Maximum 10 % (E10)
Engine models I2 846 UTV NA-80
Engine oil NOTICE! Engine damage due to incorrect engine oil grade. Always use
the recommended engine oil. Do not mix engine oils of different grades
or viscosity.
0W 40 completely synthetic, at least API SJ, ACEA A3/B3
Fill quantity See the vehicle manufacturer‘s documentation.

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3.5 Coolant
3 Description
3.5 Coolant
Engine models I2 846 UTV NA-80
Coolant additive Coolant additive based on ethylene glycol, silicate- and nitrite- free,
suitable for aluminium engines.
Suggested coolant additives NOTICE! Insufficient cooling due to incompatibilities of coolant.
Combining different coolant additives may trigger a chemical reaction
and they may lose their effectiveness. The suggested coolant additives
are laboratory tested for compatibility. If you use another coolant
additive verify the compatibility previously.
– BASF Glysantin G 30
– Chevron Havoline Extended Life Coolant XLC+B
– Valvoline Zerex G 30
Mixing ratio NOTICE! An incorrect mixing ratio reduces the cooling capacity. When
topping up the coolant, do not change the mixing ratio. Use the same
coolant throughout the year in the mixing ratio specified.
50 % water + 50 % coolant additive
Fill quantity See the vehicle manufacturer‘s documentation.
Coolant additive

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3
2
4
8
1
9
10
6
7
5
3.6 Engine components and information
Engine models
I2 846 UTV NA-80
– 1st cylinder 1
– Sensor camshaft 2/
2nd cylinder
– Fuel supply 3
– Throttle body 4/ Air intake
– Intake Manifold 5/ Intake
side
– Engine oil,
oil tank to engine 6
– Engine oil,
engine to oil tank 7
The intake manifold is not shown
in the figure.
– Oil filter 8
– Coolant circuit to the heat
exchanger 9
– Coolant circuit from the heat
exchanger 10
3 Description
3.6 Engine components and information

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15
13
12
11
14
3 Description
3.6 Engine components and information
– Permanent vent
coolant circuit 11
– Exhaust ports 12 / Exhaust
side
– Engine rotation direction 13
– Stub shaft 14 / Power take off
– Crankcase vent /
Engine oil return 15

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3.7 Protective functions
3 Description
3.7 Protective functions
The engine has an engine diagnostics, which monitors various operating parameters. The protection
functions described in this chapter are intended for your protection and to protect your engine when the
operating parameters exceed defined limits.
Protective function Description
Coolant temperature Temperature variations during engine operation are normal. Therefore
the protective function will be activated in several stages, to protect the
engine from overheating.
Coolant temperature 91 – 110 °C
The temperature range can occur due to operational temperature
variations. The engine output is reduced continuously with increasing
temperature to about 60 %.
No measures are required.
Coolant temperature 111 – 115 °C
The temperature warning light illuminates and the engine power is
reduced to about 30 %. The critical coolant temperature has almost
been reached.
Measures are required. (See chapter 3.9.1 Lights in vehicle.)
Coolant temperature > 115 °C
The temperature warning light and the malfunction indicator light
illuminate at the same time. The engine power is reduced to about 25
% and the engine speed is limited. The critical temperature range is
reached and an engine damage caused by overheating is imminent.
Measures are immediately required. (See chapter 3.9.1 Lights in
vehicle.)
Temperature intake air The protective function is activated when the temperature of the intake
air exceeds 35 °C. The engine output is reduced continuously with
increasing temperature.
Throttle control pedal / Brake
pedal
Observe that the engine power is reduced during vehicle operation
when brake pedal and throttle control pedal are actuated at the same
time.
Roll over detection If your vehicle is equipped with a roll over detection, the roll over
detection will be activated under specific operating conditions. (See the
vehicle manufacturer‘s documentation.)
In this case the ignition, fuel injection and the fuel pump will be
switched off immediately.
For resetting this protective function, turn off the ignition switch and turn
it on again.

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3 Description
3.7 Protective functions
Protective function Description
Engine speed limitations If a speed limitation is active the engine speed cannot be exceeded,
even at full throttle.
In normal operation speed limitations are active for the following
operation conditions:
– 6500 min-1 [rpm] The shift control lever is in neutral position
– 5500 min-1 [rpm] The shift control lever is in reverse gear
– 6000 min-1 [rpm] Overtemperature coolant
Speed limitations are active for the following malfunctions:
– 5000 min-1 [rpm] Synchronization fault of sensors camshaft /
crankshaft
WARNING! Risk of accident. Faults at the pedal value sensor and
electronic throttle system (drive-by-wire) can affect the vehicle
operation substantially. Contact immediately a qualified workshop.
All Textron Motors authorized workshops are qualified to repair
your engine.
– 4500 min-1 [rpm] Fault at the pedal value sensor
– 4000 min-1 [rpm] Fault in the electronic throttle system (drive-by-
wire)

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3 Description
3.8 Technical specifications
3.8 Technical specifications
Engine models I2 846 UTV NA-80
Calibration
Type 4-stroke gasoline engine, parallel twin with balance shaft and single
overhead camshaft (SOHC)
Displacement 846 cm³
Number of cylinders 2
Bore x stroke 89 x 68 mm [3.5 x 2.7 in]w
Compression ratio 11,5 : 1
Engine power SAE J1349 kW @ min-1 [rpm]
Engine speed limit min-1 [rpm]
Idle speed min-1 [rpm]
Fuel system Sequential multipoint manifold injection
Lubrication system Dry sump
Cooling system Closed coolant circuit and open sea water cooling circuit
Engine management system Synerject M3D
Throttle body Electronically controlled, dia. = 44 mm [1.73 in]
Ignition system Electronically controlled distributorless ignition system with individual coils
Starter system Electric starter
Generator, internal > 450 W @ 4000 min-1 [rpm]
Weight without engine oil and
coolant
58 kg [128 lb]
Dimensions L x B x H 444 mm [17 in] x 405 mm [16 in] x 482 mm [19 in]

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3.9.1 Lights in vehicle
3.9 Supported vehicle equipment
3 Description
3.9 Supported vehicle equipment
The lights described in this chapter are controlled by the engine management system. Observe the
information in the vehicle manufacturer‘s documentation.
Light Description
Service light When the service light is illuminating, the next service interval is
reached and service tasks are required.
►The required service tasks must be performed in a qualified
workshop. All Textron Motors authorized workshops are qualified
to service your engine.
Observe that only the regular operating hours intervals will be indicated.
The service light does not indicate the 1st service and the yearly
service intervals. (See chapter 4.1 Service intervals.)
Oil pressure light The oil pressure light illuminates after the engine is started until the
required oil pressure is achieved.
NOTICE! Serious engine damage due to insufficient lubrication. If the
oil pressure light remains on after starting the engine, the required oil
pressure is not built up.
►Turn off the engine immediately.
►Immediately inspect the cause and repair possible faults by a
qualified workshop. All Textron Motors authorized workshops are
qualified to repair your engine.
Malfunction indicator light (MIL) The malfunction indicator light has a self-test function. When you
turn on the ignition or start the engine, the malfunction indicator light
illuminates for a few seconds.If the malfunction indicator light does
not stop illuminating or illuminates during the operation, the engine
diagnostics has detected an fault. If the malfunction indicator light is
flashing, there is an emission-related fault.
►Immediately inspect the cause and repair possible faults by a
qualified workshop. All Textron Motors authorized workshops are
qualified to repair your engine.

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3 Description
3.9 Supported vehicle equipment
Light Description
Temperature warning light If the temperature warning light is illuminating, the coolant temperature
has almost been reached the critical temperature range. Further
information can be found in chapter 3.7 Protective functions.
Depending on equipment of the vehicle observe the chapter 4.3.1
Checking coolant level or the vehicle manufacturer‘s documentation.
CAUTION! Scalding caused by hot steam. Open expansion tank
only with a cold engine.
►Check the coolant level.
NOTICE! Engine damage caused by overheating. An empty expansion
tank may be an indication of a leaking cooling system. Immediately
inspect the cause and repair possible faults by a qualified workshop.
All Textron Motors authorized workshops are qualified to repair your
engine.
►If the expansion tank is empty, turn off the engine immediately.
►If the coolant level is significantly below the MIN-marking, let the
engine cool down and refill coolant.
►If the coolant level is right, adapt the way you operate. Check the
coolant level again after the engine has cooled down.
NOTICE! Engine damage caused by overheating. If the temperature
warning light and the malfunction indicator light illuminate at the same
time, the critical temperature range has been reached.
►Let the engine cool down immediately.
►Immediately inspect the cause and repair possible faults by a
qualified workshop. All Textron Motors authorized workshops are
qualified to repair your engine.

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4 Operation
4.1 Service intervals
4.1 Service intervals
4 Operation
Familiarize yourself with the vehicle before operating the engine. Read the vehicle manufacturer‘s
documentation.
Regular service is essential to keep your engine in a safe operating condition. Perform all engine and vehicle
related service tasks as described in this service manual and the vehicle manufacturer‘s documentation.
Following service tasks you can perform yourself. All activities are described in chapter 4 Operation.
Activity Before every use
Checking coolant level ■
Checking oil level ■
The following service tasks require special technical knowledge of this engine. These service tasks must
be performed in a qualified workshop. All Textron Motors authorized workshops are qualified to service your
engine. All activities are described in chapter 8 Service tasks in the workshop.
Activity
1st service Subsequent service intervals
Preparing for
Storage3 after 12 h1
every 100 h
or at least
once a year
every 200 h
or at least
every 2 years
Changing engine oil and oil
filter ■ ■ ■
Checking and adjusting
valve lash ■ ■2
Replacing spark plugs ■
– Checking spark plugs
– Fuel stabilizer
– Engine internal preservation
■
Changing coolant See the vehicle manufacturer‘s documentation.
Replacing fuel filter See the vehicle manufacturer‘s documentation.
1h = Hours of operation
2These service intervals are only required after the specified hours of operation
3If you do not operate the engine for more than 90 days